Installation instructions
PA 8000 LW
CNC control unit
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 PRO SDI-AN / PA 8000E LW PRO SDI-AN
Version 2.0
©2015 Power Automation GmbH
2 25.09.2015
PA 8000 LW CNC control unit
Table of contents
Table of contents
1 General information................................................................... 7
1.1 Information on this manual................................................ 7
1.2 Explanation of symbols...................................................... 7
1.3 Limitation of liability............................................................ 9
1.4 Copyright........................................................................... 9
1.5 Warranty terms.................................................................. 9
1.6 Customer service............................................................. 10
1.7 Glossary........................................................................... 11
2 Safety........................................................................................ 13
2.1 Customer's responsibility................................................. 13
2.2 Personnel requirements................................................... 14
2.2.1 Qualifications................................................................. 14
2.2.2 Unauthorized persons................................................... 14
2.3 Intended use.................................................................... 15
2.4 Unintended use................................................................ 15
2.5 Personal protective gear.................................................. 16
2.6 Specific dangers.............................................................. 16
2.7 Safety devices................................................................. 18
2.8 Machine safety................................................................. 19
2.8.1 'CNC ready' signal - Emergency stop interlocking........ 19
2.8.2 'Power ok' signal........................................................... 20
2.9 Conduct in a dangerous situation and in case of acci-
dents................................................................................ 20
2.10 Data safety....................................................................... 21
2.10.1 File backup.................................................................... 21
2.10.2 System protection......................................................... 21
2.11 Environmental protection................................................. 23
2.12 Labels.............................................................................. 24
3 Design and function................................................................ 27
3.1 Overview.......................................................................... 27
3.2 Brief description............................................................... 29
3.3 Module 4AXLX................................................................. 30
3.3.1 Digital Inputs................................................................. 31
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Table of contents
3.3.1.1 Input interfaces........................................................... 31
3.3.1.2 Input characteristics.................................................... 32
3.3.1.3 Input schematic.......................................................... 33
3.3.1.4 RMS encoder wiring example..................................... 34
3.3.2 Analog Outputs............................................................. 35
3.3.2.1 Output interfaces........................................................ 35
3.3.2.2 Output characteristics................................................. 36
3.3.2.3 Output schematic........................................................ 37
3.3.2.4 Output Monitor............................................................ 38
3.3.2.5 Analog axes wiring example....................................... 38
3.3.3 RMS power supply........................................................ 40
3.3.4 Module 4AXLX LEDs.................................................... 42
3.4 Module 2416 EL............................................................... 43
3.4.1 Digital inputs.................................................................. 44
3.4.1.1 Input interfaces........................................................... 44
3.4.1.2 Input characteristics.................................................... 48
3.4.1.3 Input schematic.......................................................... 49
3.4.1.4 Handwheel I/O............................................................ 49
3.4.2 Digital outputs............................................................... 52
3.4.2.1 Output interfaces........................................................ 52
3.4.2.2 Output characteristics................................................. 56
3.4.2.3 Output schematic........................................................ 57
3.4.3 Power connection.......................................................... 58
3.4.4 Module 2416 EL LEDs.................................................. 61
3.5 SDI interface.................................................................... 62
3.6 PC connectors................................................................. 64
3.7 Safety connector.............................................................. 75
3.7.1 Safety connector specification...................................... 75
3.7.2 Safety connector schematic.......................................... 78
3.8 (X20) PA USB software dongle connector....................... 78
3.9 PAMIO interface (superbus)............................................ 79
3.9.1 PAMIO boxes and modules.......................................... 80
4 Technical data.......................................................................... 83
4.1 General specifications..................................................... 83
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4.2 Connection values........................................................... 83
4.3 Operating conditions........................................................ 84
4.4 Dimension sheet.............................................................. 85
4.5 Electromagnetic compatibility.......................................... 87
4.6 Installation guidelines...................................................... 88
5 Installation................................................................................ 91
5.1 Prerequisites and preparations........................................ 91
5.1.1 General requirements................................................... 91
5.1.2 Electrical cabinet structural requirements..................... 92
5.1.3 Cabinet temperature..................................................... 92
5.2 Mounting the control unit in a cabinet.............................. 93
5.3 Installing analog axes...................................................... 95
5.3.1 Analog axes wiring example......................................... 96
5.3.2 RMS encoder wiring example....................................... 97
5.3.3 Setting up RMS supply voltage drop compensation..... 98
5.4 Installing digital I/O........................................................ 100
5.4.1 Wiring example for 2416EL modules.......................... 101
5.5 Wiring for machine safety.............................................. 102
5.5.1 Wiring example for 'CNC ready' relay......................... 102
5.5.2 Wiring example for 'Power ok' relay............................ 103
6 Transport, packaging and storage....................................... 105
6.1 Transport....................................................................... 105
6.2 Packaging...................................................................... 105
6.3 Storage.......................................................................... 106
7 Maintenance........................................................................... 107
7.1 Safety notes................................................................... 107
7.2 Maintenance schedule................................................... 107
7.3 Measures after maintenance......................................... 108
8 Troubleshooting..................................................................... 109
8.1 Safety notes................................................................... 109
8.2 Malfunction indicators.................................................... 110
8.2.1 Module 4AXLX LEDs.................................................. 111
8.2.2 Module 2416 EL LEDs................................................ 115
8.3 Troubleshooting chart.................................................... 117
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9 Service and return process................................................... 119
9.1 Service........................................................................... 119
9.1.1 Service addresses....................................................... 119
9.2 Spare parts.................................................................... 121
9.3 Return policy and procedure.......................................... 121
9.4 Training.......................................................................... 124
10 Dismounting and decommissioning.................................... 125
11 EC Declaration of Conformity............................................... 127
12 Proof of change...................................................................... 129
13 Index........................................................................................ 131
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1 General information
1.1 Information on this manual
General information
General Information
Warnings
L DANGER
This installation manual provides important information on how to work
with the control unit safely and efficiently.
The installation manual is part of the control unit, must always be kept
in the control unit's direct proximity and should be available for the 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 specified 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.
… indicates an imminently hazardous situation which, if unavoidable, will result in death or serious injury.
L WARNING
L CAUTION
Special Safety Notes
NOTICE
… indicates a potentially hazardous situation which, if unavoidable, could result in death or serious injury.
… indicates a potentially hazardous situation which, if unavoidable, may result in minor or moderate injury.
… indicates a potentially hazardous situation which, if unavoidable, may result in property damage.
… emphasizes useful hints and recommendations as well as information for efficient and trouble-free operation.
The following symbols are used in connection with the safety notes to
highlight particular dangers:
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General information
L DANGER
Additional symbols and highlighting
… 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 elements inside this manual.
.. Highlights a step as part of a procedure of instructions.
.. Highlights a state or an automatic process as a result of an
ð
instruction.
n .. Highlights single or unordered instructions and lists.
Ä
“Additional symbols and highlighting” on page 8.. Highlights cross-
references to chapters or sections of this manual.
[Key].. Highlights captions of buttons, fields and other elements of the
software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or submenu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts from
configuration files.
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1.3 Limitation of liability
General information
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:
n disregarding this installation manual
n unintended use
n employment of untrained personnel
n unauthorized conversions
n unauthorized modifications to the software
n technical modifications
n use of unapproved spare parts
n 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 contract,
the general terms and conditions, and the delivery conditions of Power
Automation and the legal regulations valid at the time of contract apply.
We reserve the right to make technical modifications in order to
improve usability.
Copyright
Material Warranty
1.4 Copyright
This installation manual is protected by copyright law.
Passing this installation manual on to third parties, duplication of any
kind – even in form of excerpts – as well as the use and/or disclosure
of the contents without the written consent of Power Automation is not
permitted.
Violations oblige to compensation. The right for further claims remains
reserved.
1.5 Warranty terms
The material warranty terms are provided in Power Automation's terms
and conditions as well as inside the sales documents.
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1.6 Customer service
General information
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 improvements.
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General information
1.7 Glossary
CMOS - Complementary metal-oxide-semiconductor
CNC - Computerized Numerical Control
DDU - Delivered Duty Unpaid
HMI - Human Machine Interface
The graphical user interface provided by the PA software.
IPC - Insulating Piercing Connector
MDI - Manual Data Input
MTBP - Machine Tool Builder's Panel
Panel including the basic requirements for a machine tool
operator: emergency stop push button, cycle start and stop
push buttons, jog plus and minus push buttons, feed rate
and spindle speed override pots and a number of auxiliary
push buttons.
NC-Start - Numerical Control Start Button
NC-Stop - Numerical Control Stop Button
PA - Power Automation
PAMIO - Power Automation Modular Input Output
Extendable Superbus based interface allowing connection
of additional I/O modules.
PASIO - Power Automation Slot Input Output
Extendable EtherCATâ based interface allowing
connection of additional I/O modules.
PC - Personal Computer
PCI - Peripheral Component Interconnect
Personal computer extension for periphery devices 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)
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General information
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Safety
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 industrial
safety.
The safety, accident prevention and environmental protection regulations 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:
n The customer must become familiar with the industrial safety regu-
lations and identify additional dangers which may arise due to the
specific working conditions at the place of use of the control unit,
by means of a risk analysis. These must be converted into operating instructions for operation of the control unit.
n Throughout the time of use of the control unit the customer must
check whether the operating instructions created by him correspond to the current status of regulations and standards. Whenever changes in regulations and standards occur, instructions must
be adapted accordingly.
n The customer must clearly specify the responsibilities for
installation, operation, maintenance, and cleaning.
n 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:
n The customer must make sure that the maintenance intervals
specified in these operating instructions are complied with.
n The customer must regularly check all safety features for function
and completeness.
n The customer must supply his personnel with the necessary pro-
tective equipment.
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L WARNING
PA 8000 LW CNC control unit
Safety
2.2 Personnel requirements
2.2.1 Qualifications
Danger of injury in case of insufficient qualification!
– Only those persons who have been specified in the corre-
sponding chapters of this installation manual should be
entrusted with the listed types of work.
– Employ certified experts, if in doubt.
Improper operation can lead to severe personal injuries and/or
material damage.
The following qualifications are specified for different areas of activity
listed in the installation manual.
Instructed person
was instructed by the operating company about the duties assigned to
her/him and the possible dangers that may arise from inappropriate
conduct.
Qualified personnel
are able to carry out assigned work and to recognize possible dangers
due to professional training, knowledge, and experience as well as
profound knowledge of applicable regulations.
L WARNING
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
Danger for unauthorized persons!
– Keep unauthorized persons away from the working area.
– If in doubt, address such persons and ask them to leave the
working area.
– Interrupt your work as long as unauthorized persons are in
the working area.
Unauthorized persons, who do not meet the requirements
described in this installation manual, are not aware of the dangers in the working area.
Only persons who are expected to perform their tasks reliably are permitted as personnel. Persons whose reaction capability is impaired,
e.g. through drugs, alcohol or medication are not permitted.
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Safety
n When selecting personnel, ensure that the personnel can work
with the control unit in terms of technical and content aspects.
2.3 Intended use
Intended Use
Dangers
L WARNING
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.
Beware of unintended use!
– Operate the control unit as intended only.
– Observe all instructions in this installation manual.
– Observe the permissible ambient conditions and electromag-
netic compatibility mentioned in the technical data.
Any use exceeding the scope of intended use and/or different
application of the control unit can result in hazardous situations.
Claims of any kind for damage resulting from unintended use are void.
The operator is solely responsible for all damage resulting from
unintended use.
Unintended Use
L WARNING
2.4 Unintended use
Beware of unintended use!
– In particular, avoid using the control unit for the following pur-
poses as these are regarded as not intended:
– Operation using software not approved by
Power Automation.
– Operation connected to machines/drives not deemed com-
patible by Power Automation.
– Operation using wrong number of axes
– Wrong or missing execution of the maintenance intervals
– Operation by not instructed personnel
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Safety
2.5 Personal protective gear
Wearing of personal protective gear is required to minimize health hazards and damage when working with the control unit.
n Always wear the protective equipment that is necessary for the
respective task when working.
n Follow the instructions on personal protective equipment that are
listed in this installation manual and other installation manuals provided by Power Automation.
n 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 components.
ESD safety pad
for protection of components susceptible to electrostatic discharge. Put
the ESD safety pad on the floor before starting to work.
ESD safety shoes
for protection of components susceptible to electrostatic discharge.
Wear the ESD safety shoes to protect electrostatic-discharge-sensitive
devices due to inadequate derivative electrostatic energy.
Ear protection
for protection of the ears during the work. Wear the ear protection
always until the work is finished.
Ground strap
for protection of components susceptible to electrostatic discharge.
Wear the ground strap on your wrist and connect it to a suitable
equipotential bonding.
Protective glasses
for protection of the eyes during the work. Always wear the protective
glasses until the work is finished.
2.6 Specific dangers
The following section lists the residual risks.
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L DANGER
PA 8000 LW CNC control unit
Safety
n 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 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.
n In the event of damage to insulation, switch off the power supply
immediately and have the defective parts repaired.
n Work on the electric system must be carried out only by skilled
electricians.
n Before maintenance, cleaning or repair work, switch off the power
supply and secure it against being switched on again.
n Do not bridge fuses or make them ineffective. When changing
fuses make sure you use the correct amperage.
n Keep moisture away from conductive parts. This can cause short-
circuits.
n De-energize the machine for all work on the electrical system.
L DANGER
L WARNING
Uncontrolled operation due to improper installation and configuration!
The control unit's safety relay must be properly integrated into
the CNC machine emergency stop chain. Improper wiring and
configuration of the safety relay may result in uncontrolled operation of the CNC machine and in consequence may lead to irreversible personal injuries or death.
n Only operate the CNC machine when the safety relay has been
properly integrated into the machine emergency stop chain.
Ä
n Only let qualified personnel (
on page 14) set up the emergency stop chain.
n For information on safety devices integrated into the machine see
the manual supplied by the machine's manufacturer.
n If in doubt regarding the configuration, contact the manufacturers
of the CNC machine and the control unit.
Risk of injury due to improper handling of batteries!
Batteries must be handled with special care.
n Do not throw batteries into fire or expose to high temperature.
Explosion hazard!
n Do not charge batteries. Explosion hazard!
n Battery fluid leaking due to wrong usage may cause skin irritation.
Avoid contact with the battery fluid. In case of contact, flush the
battery fluid with large amounts of water. If the battery fluid enters
the eyes, flush immediately with water for 10 min. and consult a
physician without delay.
Chapter 2.2.1 “Qualifications”
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Safety
Safety
L CAUTION
L DANGER
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.
n For further information, see Ä Chapter 8.3 “Troubleshooting chart”
on page 117.
2.7 Safety devices
Malfunctioning safety devices may pose a fatal risk!
Safety devices must be intact and properly integrated into the
control unit's configuration and software in order to guarantee
safety.
n Before initial commissioning of the machine, ensure that all safety
devices are fully functional and correctly installed.
n Ensure that safety related inputs/outputs of the PAMIO compo-
nents and the CNC control unit are fully functional and perform as
intended.
n Never disable safety devices.
n Heed regulations concerning hardwiring of safety circuits.
Superior Control Units
Safety Connector
Software
Superior CNC Control unit or PLC
For information on required connections between the PA control unit
and safety devices integrated into the CNC machine see the documentation provided by the machine's manufacturer.
Safety connector
For information on the safety connector's purpose, specification and
Ä
wiring see
Ä
Chapter 2.8 “Machine safety” on page 19 and Ä Chapter 5.5 “Wiring
for machine safety” on page 102.
Data safety
For information on data safety see
on page 21.
Chapter 3.7 “Safety connector” on page 75,
Ä
Chapter 2.10 “Data safety”
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2.8 Machine safety
Safety
Additional Information
Further Applicable Documents
Personal Injury
L DANGER
For information regarding the safety connector's specification and
wiring examples see Ä Chapter 3.7 “Safety connector” on page 75 and
Ä
Chapter 5.5 “Wiring for machine safety” on page 102.
For information on the machine's safety devices and emergency stop
chain see the manual provided by the CNC machine's manufacturer.
The manufacturer of the CNC machine is responsible for the proper
installation of the emergency stop.
2.8.1 'CNC ready' signal - Emergency stop interlocking
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 executed in the same way
as when the Emergency Stop button is pushed.
n Properly integrate the 'CNC ready' relay into the machine's emer-
gency stop chain.
All safety related actions must ensure that at least all axes movements
and spindle rotation (or beam power) are stopped as quickly as possible.
n Refer to the drive manufacturer manual, to determine the best way
of stopping movements and other dangerous power on the
machine.
n If drive capability does not exist, the use of external braking resis-
tors might be necessary.
Unbalanced axes have to execute with the mechanical brake.
The contacts for 'CNC Ready' and 'Power OK' are available on con-
Ä
nector X19 (see
on page 102).
Chapter 5.5 “Wiring for machine safety”
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Safety
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.
n Use the contacts of the "Power ok" relay to switch off the main
power supply of the control unit to avoid any unexpected damages
to the control unit.
The contacts for 'CNC Ready' and 'Power OK' are available on con-
Ä
nector X19 (see
on page 102).
– When an external 5V power supply (RMS) is necessary to supply
incremental measuring systems, use the corresponding entry in
the control unit's drive configuration file (DriveCfg.ini) to activate 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.
Chapter 5.5 “Wiring for machine safety”
Preventive Measures
In Case Of Accidents
2.9 Conduct in a dangerous situation and in case of accidents
n Stay informed about locations of first aid equipment (first aid kit,
covers, etc.) and fire extinguishers at the site of installation.
n Instruct personnel about accident reporting, first aid and rescue
facilities at the site of installation.
n Disconnect power supply immediately.
n Initiate first aid measures.
n Inform responsible persons at the site.
n Call for rescue service if applicable.
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2.10 Data safety
Safety
General Information
L CAUTION
Initial State
Instructions
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 created
regularly and kept in a secure environment.
To minimize the chance of data loss, it is recommended to protect the
system patition (C:) with the File Based Write Filter (FBWF) and use a
second partition for user data.
Extended system outage in case of data loss!
If backup copies of critical control unit data are not created regularly and kept securely, the control unit configuration would have
to be set up from scratch in case of data loss.
n 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:
Qualified personnel
n
Instructed person
n
Initial State
1.
Follow the instructions to properly configure the control unit for
use with the intended machine.
2.
Ensure that the configuration is functioning as intended.
3.
Ensure that the machine data is saved regularly (see
Ä
Chapter 9 “Service and return process” on page 119).
4.
Keep a record of all modifications to the configuration done by
the operator.
5.
Ensure that backups are updated manually in case of modifications to the configuration.
2.10.2 System protection
Automated regular anti-virus scanning and manual scanning of files
copied to the control unit are advised by Power Automation as needed.
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Safety
To protect the system against virus attacs or other system failures, it is
recommended to take the following measures:
n Either work without the CNC without Internet connection or assure
it is connected via a managed firewall.
n Be sure that there is no virus software already behind the firewall
in your intranet. Only then, it is save to use the internal ethernet
connection for data transfer.
n Use only virus free and verified USB memory sticks for data
transfer to the CNC control. Don't allow users to transfer data with
unverified USB memory sticks. If you are not sure whether you can
guarantee this, please consider the usage of a USB-Guardian software (see http://www.trinit-soft.de/usb-waechter/).
Filebased Write Filter (FBWF)
In Windows 7, the FBWF is already part of the system. There is no
special graphical user interface (GUI) necessary. The FBWF interface
can be started in the taskbar, see Fig. 1.
Fig. 1: Start of the FBWF interface
Click on the little lock and the FBWF interface shows up the folling
window (Fig. 2).
After delivery, the FBWF is in state "enabled". You must put it into the
state "disabled" if you want to install further software on the system
partition, or if you need to do other modifications there.
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Safety
Fig. 2: Overview FBWF interface
2.11 Environmental protection
L CAUTION
Environmental hazard caused by incorrect handling!
Incorrect handling of environmentally hazardous substances,
especially incorrect waste disposal, can cause considerable
damage to the environment.
n Do not release environmentally hazardous substances or compo-
nents into the environment.
n Always properly dispose of environmentally hazardous compo-
nents/substances in accordance with local law and regulations.
The following environmentally hazardous components or substances
are contained in the control unit:
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PA 8000 LW CNC control unit
Safety
Batteries
Electronic Components
NOTICE
Batteries contain toxic heavy metals. They are considered hazardous
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.
n Follow the standard return procedure, as described in
Ä
Chapter 9.3 “Return policy and procedure” on page 121.
2.12 Labels
The following labels are attached to the control unit.
Readability Of Labels
– Keep labels in readable condition at all times.
– Replace damaged labels (not including material warranty
seals).
– Replacements can be obtained from Power Automation.
Over the course of time labels may become dirty or nonreadable
for any other reason. Improper input voltages applied due to readability of labels can damage the control unit.
Overview
The labels listed hereunder are located at the positions shown in
Fig. 3.
Fig. 3: Label positions
1 Material Warranty seal
2 Type Plate
3 License Operating system
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PA 8000 LW CNC control unit
Safety
Type Plate
Operating System Product Key
L CAUTION
The type plate includes the following information:
n Manufacturer address
n 'CE'-sign
n Control unit model
n Serial number
n Article number
n Connection values
Fig. 4: Type Plate (Example)
The label affixed to the side of the control unit next to the type plate
provides the operating system's product key.
If the label with the operating systems's product key is not readable or damaged, the particular Windows-licence will be void and
can not be renewed. For this reason, the label has to be treated
carefully. A new operating system's licence can be ordered at
Power Automation (see Ä Chapter 9 “Service and return process”
on page 119).
Fig. 5: Windows 7 for Embedded Systems operating system license
The first CNC Software version, which runs under Windows 7 is version 3.5.0.0. For compatibility reasons, the folders remain unchanged
for Windows XP systems.
25.09.2015 | 25
PA 8000 LW CNC control unit
Safety
New CNC Installation Folder
Compatibility To CNC Versions
Before 3.5.x
The CNC installation folder has been changed. Formerly, everything
had been installed in c:\program files\power automation.
In Windows 7 (W7) it is installed under c:\pacnc. This is also true for
the files, which are written from the CNC software on d:\ partition.
So there is also a folder called d:\pacnc for the files, which are written
from the CNC during runtime. Everything below c:\pacnc and
d:\pacnc is the same as before below
c:\program files\power automation and
d:\program files\power automation. For compatibility reasons, the
folders remain c:\program files\powerautomation and
d:\program files\power automation for Windows XP systems.
The PA standard HMI is fully compatible. Also every User-HMI, which
is based on HTML will run without problems. User-HMIs, based on
own code (scripts, C, Java or ActiveX) must be tested by the customer
itself.
The usage of compile cycles is the same as before.
Old CNC/HMI Backups cannot be used in the current version of 3.5.x,
because of the changed installation path. There will be a future version, which will allow to restore old backups to the new installation
paths.
Material Warranty Seals
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.
– Never open the control unit, or you will lose your material warranty.
– Always contact Power Automation, if extensions, repairs or modifi-
cations are required (see Ä Chapter 9 “Service and return
process” on page 119).
Broken or removed seals void all material warranty provided by
Power Automation.
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Top View
PA 8000 LW CNC control unit
Design and function
3 Design and function
3.1 Overview
25.09.2015 | 27
PA 8000 LW CNC control unit
Design and function
Fig. 6: Modules
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]
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PA 8000 LW CNC control unit
Design and function
Model Configurations
Model Description PC connec-
PA 8000 LW
BAS SDI-AN
PA 8000 LW
STD SDI-AN
PA 8000 LW
PRO SDI-AN
SDI and analog
axes
SDI and analog
axes
SDI and analog
axes
The PA 8000 LW is shipped in three different models containing the
following modules and interfaces.
tors
included included 2 included included
included 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 control unit upon delivery
are listed in the following chapters.
SDI Module 2416EL Module 4AXLX
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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 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.
Fig. 7: 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
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Connectors
PA 8000 LW CNC control unit
Design and function
Pos. Label No. Function
6 X33 Measurement input 3. axis
7 Status LEDs
3.3.1 Digital Inputs
3.3.1.1 Input interfaces
Fig. 8: Input interfaces
Pos. Label
No.
1 X31 Connector 1st axis 15 pin, sub-D, female
2 X32 Connector 2nd axis 15 pin, sub-D, female
4 X35 RMS supply 2 pole connector
5 X33 Connector 3rd axis 15 pin, sub-D, female
6 X34 Connector 4th axis 15 pin, sub-D, female
Function Connector
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Pin Assignment
PA 8000 LW CNC control unit
Design and function
Fig. 9: Encoder input connector (X31/X32/X33/X34)
Pins (Fig. 9) RMS Input Function
Pin 1 Track A+
Pin 2 Track A-
Pin 3 Track B+
Pin 4 Track B-
Pin 5 Track R+
Pin 6 Track R-
RMS Inputs
Pin 7 Probe input
Pin 8 Probe ground
Pin 9/11/13/15 Ground RMS
Pin 10/12/14 +5 V RMS
3.3.1.2 Input characteristics
Property Value Unit
Interface type RS 422
Track common mode range -7 - +7 V
Max. track input voltage -11 - +14 V
Min. track input voltage +/- 500 mV
Track input impedance 150
Max. track frequency (no filter) 5 MHz
Max. count frequency (no filter) 20 MHz
External connector 15 pin Sub-D female / axis
Ω
All signals on the RMS inputs are referenced against RMS ground.
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PA 8000 LW CNC control unit
Design and function
Probe Inputs
Property Value Unit
Max. measurement input voltage 27 V
Measurement input current (at 24 V) 7 mA
Measurement input impedance 2200
Measurement operating voltage
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 application, each input of all used
axes must be wired in parallel.
Ω
5 V DC max.
RMS Input Equivalent Schematic
3.3.1.3 Input schematic
Fig. 10: RMS input equivalent schematic
25.09.2015 | 33
RMS Encoder Wiring Example
PA 8000 LW CNC control unit
Design and function
3.3.1.4 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).
Fig. 11: RMS encoder wiring example
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Connection
PA 8000 LW CNC control unit
Design and function
3.3.2 Analog Outputs
3.3.2.1 Output interfaces
Fig. 12: Analog axes output connector
The signals of the four analog output channels are connected via a 9pin connector (Fig. 12).
Each output channel has its own reference connection.
NOTICE
Potential malfunctions of the control unit!
– Always connect reference wiring separately. Never tie refer-
ence wiring together.
Different references of the channels have different voltage potential. Contact between the reference wiring may cause control unit
malfunctions.
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PA 8000 LW CNC control unit
Design and function
Pin Assignment
Axes Output
Pins (Fig. 12) RMS Input Function
Pin 1 +/- output channel 1
Pin 2 ground for channel 1
Pin 3 +/- output channel 2
Pin 4 ground for channel 2
Pin 5 +/- output channel 3
Pin 6 ground for channel 3
Pin 7 +/- output channel 4
Pin 8 ground for channel 4
Pin 9 analog ground (ACOM)
3.3.2.2 Output characteristics
Property Value Unit
Number of analog output channels
4
Output signal range (max.) +/- 10 V
Output current load (max.) +/- 15 mA
Output capacitive load (max.) 350 pF
Bipolar zero error (max.) +/- 40 mV
Full scale error (max.) +/- 1 %
Channel to channel mismatch
(max.)
Linearity error (max.) +/- 2.44 mV
Resolution 305 μV
Conversion time (max.) 10
Output slew rate 0.4 μV/s
Watchdog (max.) 64 ms
External connector 1 terminal block
+/- 1 %
μ
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PA 8000 LW CNC control unit
Design and function
3.3.2.3 Output schematic
Fig. 13: Module 4AXLX analog output schematic
Analog output wiring
– During drive installation check whether the drive analog inputs are
grounded.
– If the analog inputs are grounded connect the drives according to
the schematic for non differential inputs.
– If the analog inputs are not grounded connect the drives according
to the schematic for differential inputs.
The wiring of the analog output to the drive depends on the type of
drive analog inputs.
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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 digital/analog
converter, the system can react and avoid machine damages.
Fig. 14: 4AXLX output monitor
Analog output monitor
– Deactivates the safety relay "CNC Ready" (refer &)
– Outputs an error message:
CNC 75 D/A output __ defective or missing
where "__" indicates the number of the defective axis
In case of errors, the system:
L CAUTION
– Check carefully the analog wiring between CNC and drive
(refer &)!
– 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
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:
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.
25.09.2015 | 38
Drives With Non-Differential Inputs
(Unipolar)
Drives With Differential Inputs
PA 8000 LW CNC control unit
Design and function
Fig. 15: Schematic non-differential inputs (unipolar)
Fig. 16: Schematic differential inputs
25.09.2015 | 39
PA 8000 LW CNC control unit
3.3.3 RMS power supply
Design and function
Pin Assignment
Fig. 17: RMS power supply connector (X35)
If required, the rotating measurement systems (RMS) can get their
power from the module. The supply voltage, however, is not generated
on the module but must be externally supplied via a 2 pole connector
(X35 Fig. 17) on the 4AXLX module.
Pin
(Fig. 17)
1 +5 V RMS supply
2 0 V RMS ground
Voltage Assignment
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PA 8000 LW CNC control unit
Design and function
Technical Data
Property Value Unit
Operating
Voltage
Tolerance -0 - +20 %
For further reference see Ä Chapter 5.3.3 “Setting up RMS supply
voltage drop compensation” on page 98.
5 V dc
25.09.2015 | 41
Overview
PA 8000 LW CNC control unit
Design and function
3.3.4 Module 4AXLX LEDs
The 4AXLX module has ten LEDs for diagnostic purposes.
Fig. 18: Status LEDs
1 Status
2 Access
3 Bustest
4 Monitor
5 Axis 1
6 Axis 2
7 Axis 3
8 Axis 4
9 Power OK
10 CNC Ready
For a detailed assignment of the LEDs' states see Ä Chapter 8.2.1
“Module 4AXLX LEDs” on page 111.
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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 system. The module status is displayed via 4 LEDs.
Fig. 19: Overview: connectors module 2416 EL
1 Output byte 2 (X41)
2 Output byte 1 (X40)
3 Status LEDs output byte 2
4 Status LEDs output byte 1
5 Power connector +24 V (X30)
6 Module status LEDs
7 Status LEDs input byte 2
8 Status LEDs input byte 1
9 Status LEDs input byte 3
10 Input byte 2 (X46)
11 Input byte 1 (X45)
12 Input byte 3 (X47)
25.09.2015 | 43
Overview
PA 8000 LW CNC control unit
Design and function
3.4.1 Digital inputs
3.4.1.1 Input interfaces
Fig. 20: 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).
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Connection
PA 8000 LW CNC control unit
Design and function
Fig. 21: Reference pin power connector
n Each byte is connected with an 8 pole terminal block.
n The conductor cross-section of the wire must be 0.3 to 1.75 mm
2
(AWG 22 to 15).
n The inputs are always referenced against the 0 V connector of the
Ä
module (X30 pin 3
“Connection” on page 45).
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Pin Assignment
PA 8000 LW CNC control unit
Design and function
Fig. 22: Pin assignment
Byte 1 +24 V input Byte 2 +24 V input Byte 3 +24 V input
pin 1 1. input bit pin 1 9. input bit pin 1 17. input bit
pin 2 2. input bit pin 2 10. input bit pin 2 18. input bit
pin 3 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
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
pin 8 8. input bit pin 8 16. input bit pin 8 24. input bit
25.09.2015 | 46
Input Status LEDs
PA 8000 LW CNC control unit
Design and function
Fig. 23: 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.
n A HIGH input signal causes the corresponding LED to turn ON.
n A LOW input signal causes the corresponding LED to turn OFF.
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PA 8000 LW CNC control unit
Design and function
3.4.1.2 Input characteristics
Property Value Unit
Number of inputs 24
Maximum input DC voltage 27 V
Input current at 24 V / 5 V (typical) < 3 mA
Power dissipation at 24 V / 5 V per
input
Input impedance (24 V input) 10.5 kΩ
Input impedance (5 V input) 8.6 kΩ
operating DC voltage OFF (24 V input) 6 V max.
operating DC voltage ON (24 V input) 18 V min.
operating DC voltage OFF (5 V input) 1.2 V max.
operating DC voltage ON (5 V input) 2.5 V min.
Input ON delay 25 μs
Input OFF delay 65 μs
Isolation by opto coupler
Input ON display LED
External connection 1 terminal block
< 70 mW
for 8 inputs
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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.
Fig. 24: Input equivalent schematic
1 Input n+1
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 handwheel 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 specifications.
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.
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PA 8000 LW CNC control unit
Design and function
Required Handwheel Specifications
Behavior
Property Value Unit
Supply level 24 V DC
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 supported.
When these particular inputs are used for a handwheel, the software 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:
n control unit software revision above 2.3.8
n special machine parameter settings
For further information refer to the machine parameter manual or
machine parameter tool (MPTOOL) online help.
25.09.2015 | 50
Wiring Schematic
PA 8000 LW CNC control unit
Design and function
Fig. 25: Wiring schematic handwheel inputs
1 Handwheel
2 Input byte 3
The ground of the power supply used for the handwheel must be connected to the one of the power supplies of the 2416 EL module
(connector X30, pin 3).
3 Power supply connector
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Overview
PA 8000 LW CNC control unit
Design and function
3.4.2 Digital outputs
3.4.2.1 Output interfaces
Fig. 26: Output bytes
2 Output byte 1 (X41)
1 Output byte 2 (X40)
The outputs are grouped in bytes (8 signals).
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Connection
PA 8000 LW CNC control unit
Design and function
Fig. 27: Reference pin power connector
n Each byte is connected with an 8 pole terminal block.
n Each output byte has its own power supply connection.
This feature can be used to turn off a whole byte using an external
switch.
n The outputs are always referenced against 0 V, located in the
power connector (X30 pin 3 Fig. 27).
– Consider that the power supply cable for one output byte has to be
chosen accordingly.
The current limitation of each output is 0.7 - 2.5 A per pin in case of
short circuits.
– Take care of this specification by appropriate output definition
toward the external actuator.
Each output has a nominal output capability of 1 A. Nevertheless each
output byte (8 signals) is globally limited to 4 A.
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 outputs in such a
case (1 - 4, 5 - 8, 9 - 12, 13 - 16).
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Pin Assignment
PA 8000 LW CNC control unit
Design and function
Fig. 28: Pin assignment
Byte 1 +24 V output Byte 2 +24 V output
pin 1 1. output bit pin 1 9. output bit
pin 2 2. output bit pin 2 10. output bit
pin 3 3. output bit pin 3 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
25.09.2015 | 54
Output Status LEDs
PA 8000 LW CNC control unit
Design and function
Fig. 29: Output status LEDs
The output LEDs are located directly in the output path and therefore
show the real state of the 24 V outputs.
n If the outputs are ON, the corresponding LEDs are ON.
n If the outputs are OFF, the corresponding LEDs are OFF.
n In case of a short circuit, the output LED is OFF, even if the output
is active.
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PA 8000 LW CNC control unit
Design and function
3.4.2.2 Output characteristics
Property Value Unit
Number of outputs 16
Max. continuous output DC per pin 1 A
Max. total continuous
output current per byte
Power dissipation
per pin at 24 V for 0.5 A
Power dissipation
per pin at 24 V for 1.5 A
Output ON delay (typical) 100 μs
Output OFF delay (typical) 200 μs
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 outputs
All outputs are referenced against 0 V (power supply connector X30,
pin 3).
4 A
0.20 W
0.45 W
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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.
Fig. 30: Module 2416 EL output schematic
1 Supplied from PCI Superbus board
2 Output supply input (-15 % - +12.5 %)
3 Output n + 1
4 Output n
5 Logic
6 Internal serial bus
25.09.2015 | 57
Overview
PA 8000 LW CNC control unit
Design and function
3.4.3 Power connection
Fig. 31: Power supply connector + 24 V DC
Each of the 2416 EL modules needs a separate + 24 V DC power
supply for its DC outputs (connector X30).
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Pin Assignment
PA 8000 LW CNC control unit
Design and function
Fig. 32: Power supply pins
Each module has a 5 pin connector (X30) with the following pin assignment:
Pin (Fig. 32) Assignment
Pin 1 + 24 V power supply for output byte 1
Pin 2 + 24 V power supply for output byte 1
Technical Data
Pin 3 0 V
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 V DC
Tolerance -15.0/+12.5 %
Effective range 10.4 - 27.0 V
Current limitation 0.7 - 2.5 A
Reference Pin 3 (0 V)
25.09.2015 | 59
PA 8000 LW CNC control unit
Design and function
Notes
n Pin 1 and 2 are connected internally.
n Pin 4 and 5 are connected internally.
n Reference for all is pin 3 (0 V).
n With pins 1 and/or 2 and pins 4 and/or 5 the output bytes are sup-
plied 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.
– Establish wire connections to both pins 1/2 and 3/4 respectively.
For proper load balancing across pins, connections to all available pins
per output byte are recommended.
– Consider that the power supply cable for each output byte has to
be chosen accordingly.
The current limitation of each output is 0.7 - 2.5 A per pin in case of
short circuits.
25.09.2015 | 60
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.
Fig. 33: Status LEDs
1 Status
2 Access
3 Bustest
4 Monitor
For a detailed assignment of the LEDs' states see Ä Chapter 8.2.2
“Module 2416 EL LEDs” on page 115.
25.09.2015 | 61
Overview
PA 8000 LW CNC control unit
Design and function
3.5 SDI interface
Not included in all models
The SDI interface is only included in models with SDI axes.
NOTICE
Fig. 34: SDI connector positions
The hardware provides a single RJ 45 connector which is determined
at connector X21 (Fig. 34 pos. 8, X21). This connector communicates
with the SDI-drives. The SDI bus is a serial bus for full capturing of the
axes position inputs and velocity command outputs.
Malfunctions and damage to the control unit!
– When setting up the wiring, carefully observe the connectors'
positions given in this installation manual as well as the labels
on the control unit.
The control unit provides two RJ 45 connectors. One is located
on the PC interface panel (Fig. 34/13) and only intended for
Ethernet connections. The other RJ 45 connector (Fig. 34/8) 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.
25.09.2015 | 62
PA 8000 LW CNC control unit
Design and function
Connection Requirements
SDI drives must be wired toward the control unit's SDI connector in a
daisy chain setup.
Fig. 35: Daisy chain setup
1 PA 8000 LW (control unit)
2
PA SDI Drive Midi
3
PA SDI Drive Maxi
1.
Connect the X21 connector of the control unit with the J1 con-
TM
TM
nector of the first SDI drive.
2.
Connect additional SDI drives via the J1 and J2 connectors to
each other and to the J2 connector of the first SDI drive as
shown in the schematic.
Further drives have to be connected via connector 'J2' of the previous
drive to the connector 'J1' of the next drive.
25.09.2015 | 63
PA 8000 LW CNC control unit
3.6 PC connectors
Design and function
Overview
Fig. 36: Overview PC connectors
1 Main power supply (X1)
2 Operator's panel keyboard cable
3 PS2, 6 pin mini DIN, connector for mouse, female
4 Connector CNC operator's keyboard (X3)
5 USB 2.0 connectors (optional)
6 USB 2.0 connectors (optional)
7 Serial port connector, COM1, Sub-D 9 pin male
(X5c)
8 Serial port connector, COM1, Sub-D 9 pin male
(X5b)
9 PA SDI-Interface (X21)
The control unit provides a number of standard PC interface connectors for various input and output applications (see Fig. 36).
10 Protective earth, ground screw (X2)
11 PAMIO Connector (X13)
12 Safety Connector (X19)
13 Ethernet connector RJ 45
14 USB 2.0 connectors
15 DVI Connector (X4)
16 VGA connector, Sub D 15 pin female (X4)
17 Serial port connector, COM1, Sub-D 9 pin male
(X5a)
18 PS2, 6 pin mini DIN, connector for keyboard,
female
Hardware configuration subject to change
– For information on the applicable number of interfaces see the
specification provided in the sales records.
Due to varying configurations of the mainboards produced by the suppliers, the number and positions of USB, serial and parallel ports may
differ from the example provided in this installation manual.
25.09.2015 | 64
PA 8000 LW CNC control unit
Design and function
(X1) Main Power Supply (1)
n Always use the line cable delivered with the control unit.
n Ensure, that the line cable is only connected to either 115 V AC or
230 V AC.
n 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. 37: Power supply connector
Power supply properties
Property Value Unit
Voltage 115 - 240 V AC
Tolerances +10 / -15 %
NOTICE
Frequency 50 - 60 Hz
Maximum current (at 115 V) 4 A
Maximum current (at 230 V) 2 A
Maximum power consumption 180 W
Damage to the control unit!
Supply voltages not supported can cause damage to the control
unit.
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PA 8000 LW CNC control unit
Design and function
(X3) CNC Operator's keyboard (4)
(Optional)
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:
n CP 121
n CP 121 T
Fig. 38: Connector CNC operator's keyboard
Keyboard power supply
The listed operator's panels include their own keyboard 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
connector an additional 12 V is supplied, unlike on standard keyboard
connectors.
n Note that the connector is only compatible with the listed panels.
Pin (Fig. 36) Assignment
1 keyboard clock
2 keyboard data
3 + 12 V
4 GND
5 + 5 V
25.09.2015 | 66
PA 8000 LW CNC control unit
Design and function
Ethernet Connector (13)
NOTICE
The Ethernet connector allows connection of the control unit to local
area networks.
Fig. 39: Ethernet connector (RJ 45)
Malfunctions and damage to the control unit!
The control unit provides two RJ 45 connectors. One is located
on the PC interface panel (Fig. 36/13) and only intended for
Ethernet connections. The other RJ 45 connector (Fig. 36/9) 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.
n When setting up the wiring, carefully observe the connectors' posi-
tions 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. 36) Ethernet 10/100 BaseT
1 TX+
2 TX-
3 RX+
4
5
6 RX-
7
8
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PA 8000 LW CNC control unit
Design and function
(X2) Protective Earth, Ground
Screw (10)
USB 2.0 Connectors (5, 6, 14)
The protective ground screw (X2) provides a means to ensure
grounding connection of the control unit.
Fig. 40: Ground screw
n Use the ground screw (M6) provided with the control unit.
n Use a wire of 6 mm2 (10 AWG) cross section at minimum.
n 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.
Fig. 41: USB connectors (Type A)
Property Value
Pins 4
Connector type USB 2.0 Type A
Max length 5 m (16.5 ft)
Pin (Fig. 36) Assignment USB
1 VBUS
2 D-
3 D+
4 GND
Shell Shield
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PA 8000 LW CNC control unit
Design and function
(X4) VGA Connector (16)
The control unit is equipped with a VGA connector to connect graphic
displays.
n Only use either with PA operator's panels or a standard VGA com-
patible monitor.
Fig. 42: VGA connector (Sub-D 15)
Property Value
Pins 15
Connector type sub D (high density)
Gender female
Pin
(Fig. 36)
1 RED
Assignment
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
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PA 8000 LW CNC control unit
Design and function
(X4) DVI Connector (15)
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.
Fig. 43: DVI connector
Pin
(Fig. 43)
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
Assignment
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 TMDS data 0+
19 TMDS data 0/5 shield
20 TMDS data 5−
21 TMDS data 5+
22 TMDS clock shield
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PA 8000 LW CNC control unit
Design and function
Pin
(Fig. 43)
23 TMDS clock+
24 TMDS clock−
C1 RED
C2 GREEN
C3 BLUE
C4 SYNC
C5 GND
Assignment
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(X5) Serial Port Connector (7,8,17)
PA 8000 LW CNC control unit
Design and function
Fig. 44: 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
(Fig. 44)
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 COM3 (X5c) have the same layout and
the same characteristics as serial port COM1 (X5).
Assignment
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PA 8000 LW CNC control unit
Design and function
(X3) PS2 Connector For Keyboard
(4)
The control unit is equipped with a PS2 connector that can be used for
a standard keyboard connection.
Fig. 45: Keyboard connector (PS2 mini)
Keyboard installation
This connector must be used when no operator's panel is installed.
This connector can be used to connect an additional secondary keyboard.
Connection of PA operator's panel
– Ensure, that the panel's keyboard is connected to the CNC opera-
tor's keyboard connector (Fig. 36 pos. 4).
– Ensure, that the built-in PA keyboard cable (Fig. 36 pos. 2) is con-
nected to this PS2 connector (Fig. 36 pos. 18).
When connecting a PA operator's panel with keyboard, the following
requirements have to be met:
Supported panels
n CP 121
n CP 121 T
Property Value
Pins 6
Connector type PS2 mini DIN
Gender female
Pin
(Fig. 36)
1 data
2
3 GND
4 power supply +5V
Assignment
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PA 8000 LW CNC control unit
Design and function
PS2 Connector For Mouse (3)
Pin
(Fig. 36)
5 clock
6
The control unit is equipped with a PS2 connector that can be used for
a standard mouse connection.
Fig. 46: Mouse connector (PS2 mini)
Property Value
Assignment
Pins 6
Connector type PS2 mini DIN
Gender female
Pin
(Fig. 36)
1 data
2
3 GND
4 power supply + 5V
5 clock
6
Assignment
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Overview
PA 8000 LW CNC control unit
Design and function
3.7 Safety connector
Fig. 47: X19 Safety Connector
All PA 8000 LW models have two relays for safety functions (connector
X19) (seeÄ “Overview” on page 64 pos. 12).
The connector provides both a normally closed and a normally open
contact for each relay.
Purpose / Wiring
Specification
For information regarding the safety connector's purpose and wiring
examples see Ä Chapter 2.8 “Machine safety” on page 19 and
Ä
Chapter 5.5 “Wiring for machine safety” on page 102.
3.7.1 Safety connector specification
Property Value
Form factor 6 pin, removable screw plug
Maximum contact load 1A / 24V DC
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Pin Assignment
PA 8000 LW CNC control unit
Design and function
Fig. 48: Safety connector pins
Pin (Fig. 48) Assignment
1 Power ok, common
2 Power ok, normally closed
3 Power ok, normally open
4 CNC ready, common
5 CNC ready, normally closed
6 CNC ready, normally open
Relay 1 "Power ok"
NOTICE
The first relay is called "Power ok" and switches when the following
conditions are met:
n The power supply voltages are in operating range.
n The operating temperature is below +60 °C (+140 °F)
Logic Condition Result
+ 5 V OK Ready relay active
AND + 12 V OK
AND - 12 V OK
AND T < 60 °C (140 °F)
Damage to the control unit!
Properly wire the "Power ok" relay to protect the control unit from
damaging voltages and temperatures.
Voltage faults and/or temperatures above the allowed specification can cause damage to the control unit.
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PA 8000 LW CNC control unit
Design and function
Relay 2 "CNC ready"
NOTICE
The second relay is called "CNC ready" and switches when the following conditions are met:
n The control unit is ready when:
– The watchdog is re-triggered.
The software is monitored and works properly.
– All encoder signals of the axes are correct.
– All axes position loops are under control.
n The RMS power supply voltage is within operation range.
n The operating temperature is below +55°C (+131°F).
Logic Condition Result
+ 5 V RMS OK Ready relay active
AND Control unit ready
AND T < 55 °C (131 °F)
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.
n Ensure that the "CNC ready" relay is wired properly to the
machine's emergency stop circuit.
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PA 8000 LW CNC control unit
3.7.2 Safety connector schematic
Design and function
Fig. 49: Safety connector equivalent schematic
3.8 (X20) PA USB software dongle connector
Fig. 50: 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 recognize the dongle
and in consequence will not start.
n Always use the specially marked port to connect the PA USB soft-
ware dongle.
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PA 8000 LW CNC control unit
3.9 PAMIO interface (superbus)
Design and function
Overview
Cable Specification
NOTICE
The control unit's interfaces are extendable via the Superbus interface.
A variety of I/O and axes extension modules (PAMIO) can be connected to the connector.
Fig. 51: Superbus Connector
For further information see Ä Chapter 3.9.1 “PAMIO boxes and modules” on page 80 or the PA Accessories installation manual.
The interface cable required to connect PAMIO modules can be
ordered from Power Automation.
All cables connected to the control unit are intended for stationary use only.
The cable shield is connected to both connector casings.
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Basic Description
PA 8000 LW CNC control unit
Design and function
3.9.1 PAMIO boxes and modules
Fig. 52: PAMIO superbus schematic
1 control unit
2 PA superbus connection
3 PAMIO box with two analog axes modules
4 PA superbus connection
5 termination plug
6 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 well as two plug-in-slots for I/O 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.
Limited cable length
The limits for the I/O system are 31 I/O modules (1 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.
I/O 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 corresponding LED displays on the front side.
Scope of delivery (control unit)
The PAMIO modules listed below are not included in the control unit's
basic scope of delivery. They can be ordered from Power Automation
Ä
(see
Chapter 9 “Service and return process” on page 119).
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PAMIO Hardware
PA 8000 LW CNC control unit
Design and function
For further information on the modules' specifications refer to the PA
Accessories installation manual.
Fig. 53: PAMIO hardware
1 connection cable (30 m / 98 ft max.)
2 lateral rail stoppers
3 module box
4 stopping bracket
5 termination plug
Scope of delivery (PAMIO hardware)
Cable length
– Ensure, that the total cable length between the control unit and the
last PAMIO box does not exceed 25 m (82 ft).
PAMIO boxes are shipped without connection cables. Cables of the
following lengths can be ordered from Power Automation: 2 m (6.5 ft),
Ä
5 m (16.5 ft), 10 m (33 ft), 20 m (66 ft), 25 m (82 ft) (see
“Service and return process” on page 119).
The PAMIO hardware consists of the following components:
Chapter 9
PAMIO 2416
n PAMIO boxes
n PAMIO modules (2 per box, options listed below)
n cable between control unit and PAMIO box
n termination plug
(always required)
n lateral rail stoppers
(required if more than one module box is used on the same rail)
n slot cover
(required when a module slot is not occupied by a PAMIO module)
Feature Value Specifications
digital inputs 24 (3 bytes) 24 V DC
digital outputs 16 (2 bytes) 24 V DC
isolation optical
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PA 8000 LW CNC control unit
Design and function
PAMIO 4ENC4A
PAMIO 2ENC4A
PAMIO PWM
Characteristics
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 inputs and outputs of the
PAMIO 2416 are similar to the ones of the integrated 2416EL modules
(see Ä Chapter 3.4 “Module 2416 EL” on page 43).
Likewise the characteristics of the measuring systems inputs and of
the analog outputs of the PAMIO 4ENC4A are similar to the ones of
Ä
the integrated 4AXLX modules (see
on page 30).
For detailed information about PAMIO modules, their installation and
electric requirements refer to the PA Accessories installation manual.
Chapter 3.3 “Module 4AXLX”
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PA 8000 LW CNC control unit
4 Technical data
4.1 General specifications
Technical data
General Information
Electrical
Property Value Unit
Dimensions (WxDxH) 332.2 x 125 x 257 mm
13.12 x 4.92 x 10.12 inch
Weight 6.2 kg
13.7 lb
4.2 Connection values
Property Value Unit
Input voltage 115 - 240 V AC
Tolerance +10 / -15 %
Frequency 50 - 60 Hz
Maximum current (at 115 V) 4 A
Maximum current (at 240 V) 2 A
Maximum power consumption 180 W
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PA 8000 LW CNC control unit
4.3 Operating conditions
Technical data
General
NOTICE
Property Value Unit
Operating temperature +5 - +45 °C
+41 - +113 °F
Storage temperature -20 - +60 °C
-4 - +140 °F
Temperature gradient (within 10
minutes)
Relative humidity (non-condensing) 80 %
Maximum acceleration (non-operating) 4.0 G
Maximum acceleration (operating) 3.5 G
Protection class (EN 60529) IP20
Functional defects!
– Only operate the control unit inside a cabinet that complies
with the requirements as listed in the technical data
(seeÄ Table on page 92).
The module casing does not provide sufficient protection against
environmental influences. Dust and moisture may cause malfunctions.
10 °C
50 °F
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PA 8000 LW CNC control unit
4.4 Dimension sheet
Technical data
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PA 8000 LW CNC control unit
Technical data
Fig. 54: dimension sheet
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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
(VDE 0113-1)
Emitted Interference
Standard Title Requirement Value
EN 55011:2009 + A1:
2010
EN 55022:2006 + A1:
2007
EN 61000-6-3:2011 Generic standards - Emission standard for
Electrical equipment of machines all met -
Limits [...] of radio disturbance characteristics
residential, commercial and light-industrial
environments
interference voltage class B
interfering field strength class B
emitted interference class B
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PA 8000 LW CNC control unit
Technical data
Interference Resistance
Standard Title Requirement Value
IEC / EN 61000-6-2 [...] Immunity standard for industrial envi-
ronments
EN 61000-4-2 [...] Electrostatic discharge immunity [...] ESD air discharge 8 KV
EN 61000-4-3 [...] Radiated, radio-frequency, electromag-
netic field immunity [...]
EN 61000-4-4 [...] Electrical fast transient/burst immunity
[...]
EN 61000-4-5 [...] Surge immunity [...] symmetric 1 KV
EN 61000-4-6 [...] Conducted disturbances immunity [...] HF power input into the net,
EN 61000-4-8 [...] Magnetic field immunity [...] magnetic field 50 Hz 30 A/m
EN 61000-4-11 [...] Voltage variations [...] voltage drops and interrupts
Net Overtones
Standard Title Requirement Value
contact discharge 4 KV
HF irradiation 80..1000 MHz 10 V/m
power line burst 2 KV
signal data line burst 1 KV
asymmetric 2 KV
10 V
signal/data line
EN 61000-3-2: 2006 [...] Limits for harmonic current emissions all met -
EN 61000-3-3:2008
4.6 Installation guidelines
Meaning Of EMC
Electromagnetic compatibility (EMC) refers to the ability of an electrical
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.
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PA 8000 LW CNC control unit
Technical data
Important Rules For EMC
Cabling
n The cabling must be in line groups (high voltage, current supply,
signal and data lines)
n High voltage lines and signal respectively data lines must be laid in
separate channels or bundles
n The signal and data lines have to be routed as near as possible
beside ground areas
Reference potential and ground of all electrical operating supplies
n 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.
n 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
n A central connection between the ground and the protected ground
conductor system have to be installed.
n All inactive metals have to be connected extensively and impe-
dance-low.
Fixing of the cable shield
n Data cables and analog cables must be laid separately from each
other.
n The cable shield has to be laid extensively on a protected ground
conductor rail directly after the cabinet entry and the fixation of the
shield with cable clamps.
n The isolation / protected ground rail has to be connected impe-
dance-low with the cabinet.
n The metallic or metallized plug cases for shielded cables must be
used.
n When transmitting signals with small amplitudes the one sided
grounding of the cable shield may be favorable.
Possible Interferences
Electromagnetic interferences may interfere with the control unit:
n Electromagnetic fields (RF coupling)
n Magnetic fields with power frequency
n Power supply
n Protected ground conductor
n Superbus system
Depending on the spreading medium and the distance to the interference cause, interferences to the control unit occur by means of capacitive, galvanic, inductive or radiant coupling mechanisms.
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PA 8000 LW CNC control unit
Technical data
Shielding Of Conductors
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:
n The screen cover should be higher than 80%
n The cables have a copper braid (shield / screen)
n 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 frequency
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 possible
– analog signals (some mV respectively μA) are transferred
– foil screens (static screens) are used instead of screens made
of copper braid.
n 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.
n It is convenient to strip the insulated cable interruption free and lay
it on the isolation/protected ground conductor line (stationary operation).
n Metal cable clamps to fix the cable shield have to be used. The
clamps must clasp the copper braid extensively and have good
contact.
n 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.
L CAUTION
Please observe at installation!
At potential differences between the grounding points, there may
be a compensation current via the cable shield grounded at both
sides.
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Safety
L WARNING
PA 8000 LW CNC control unit
Installation
5 Installation
Danger of injury due to improper installation and commissioning!
Improper installation and commissioning can result in severe personal injury or material damage.
n Prior to beginning installation, ensure that there is sufficient space
to work.
n Handle open sharp-edged components with care.
n Make sure that the assembly location is clean and well organized.
Components that are loosely stacked or lying around can cause
accidents.
n Assemble components properly.
n Secure components so that they cannot fall or tip over.
5.1 Prerequisites and preparations
5.1.1 General requirements
– Ensure that the control unit's operating condition requirements are
met.
For further information see
Ä
Chapter 4.3 “Operating conditions” on page 84.
– 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.
Prerequisites for installation are influenced by the control unit's
required operating conditions and must also take into account the
machine to be controlled.
Electronic components (e.g. mainboards, power supplies, hard disks)
have to be adjusted to the ambient air temperature before using. The
components must not put to power until their temperature is the same
as the ambient temperature.
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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 Value
Fixed Values
Notes
NOTICE
NOTICE
IP protection class
(DIN 40050/ IEC 60529)
Mounting hole sizes and
spacing
Control unit malfunctions
– Install strain reliefs for all cable holes.
Excessive strain on cables can cause malfunctions due to disruption of connections.
For shielded cables it is necessary to apply the shield-screen at
the cable inlet into the electrical cabinet.
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")
5.1.3 Cabinet temperature
Heat input generated by fitted components
– When installing the control unit, take the station's heat dissipation
into consideration.
– Ensure an adequate cooling using fans or air conditioning.
The heat generated by the operator's station influences the operating
conditions inside the cabinet.
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Mounting Orientation
PA 8000 LW CNC control unit
Installation
5.2 Mounting the control unit in a cabinet
Spacing
Fig. 55: Mounting orientation
n 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.
n Ensure that there is clearance of at least 50 mm (2 inches) to allow
accessibility to the connectors.
Fig. 56: Front spacing
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PA 8000 LW CNC control unit
Installation
Top / Bottom Spacing
All PC connectors (PS2, VGA, USB, etc.) and some CNC connectors
(X13/X19 and the grounding screw) are located on the top side.
n 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.
n Ensure, that there is clearance of 40 mm (1.6 inches) at minimum
for air circulation.
The cabinet fan provides internal air circulation for the control unit. Its
proper operation is a prerequisite for safe operation of the control unit.
n Ensure that there is clearance of at least 30 mm (1.2 inches) next
to the fan's exhaust.
n Install an additional fan inside the cabinet, directed toward the con-
trol unit.
Fig. 57: Top/bottom spacing
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PA 8000 LW CNC control unit
Installation
Service access
For service or maintenance purposes access to the control unit may be
necessary.
n Install the control unit and adjacent components in a way that
allows for access to all mounting points, cables etc. by service personnel.
EMC Shield
RF Noise Suppression
Electrical noise may influence the control unit's operation.
n 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. trans-
formers, coils, drive amplifiers or relays.
n To decrease the influence of electrical noise, mount
1.5 mm (0.06 inch) metal shields between the control unit and the
external electrical devices causing the noise. Connect the shields
to a PE rail.
n Install noise suppression components for all coils, relays, valves,
switching units, motor windings, other operator display panels and
other RF noise producing devices.
n 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.
n Make sure, that noise suppressing capacitors have a low
inductance and a good high frequency conductance.
n Conduct power and signal lines separately in a distance of at least
10 cm.
n When using mechanical cable guides, install additional metal
shields.
n For all electrical installations, follow the rules of VDE 0113.
General
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.
n If in doubt, contact Power Automation's customer support.
Ä
For contact information see
process” on page 119.
Chapter 9 “Service and return
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Drives With Non-Differential Inputs
(Unipolar)
PA 8000 LW CNC control unit
Installation
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.
Drives With Differential Inputs
Fig. 58: Schematic non-differential inputs (unipolar)
Fig. 59: Schematic differential inputs
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RMS Encoder Wiring Example
PA 8000 LW CNC control unit
Installation
5.3.2 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).
Fig. 60: RMS encoder wiring example
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Precondition
PA 8000 LW CNC control unit
Installation
5.3.3 Setting up RMS supply voltage drop compensation
The distance between the measuring systems and the power supply
can be relatively long. The ohmic resistance of the power supply cable
and the RMS' current consumption generate a voltage drop.
Fig. 61: Schematic encoder power supply voltage drop
1 Power supply
2 Rotating measurement system (RMS)
UASupply output voltage
U1Voltage drop
U2Voltage at the RMS
U3Voltage drop
As shown in the figure, the voltage U2 equals the difference between
the output voltage UA and the voltage drop U1+U3.
Adjusted voltage U2 = UA - (U1 + U3)
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PA 8000 LW CNC control unit
Installation
Examples
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.
n For proper compensation, calculate the actual values as shown in
the following section.
Conductor
cross section
[mm2]/[AWG]
0.08 / AWG 28 0.235 10 0.47
0.14 / AWG 25 0.131 10 0.26
0.25 / AWG 23 0.075 10 0.15
Specific
resistance
[Ω/m]
Cable length
[m]
20 0.94
35 1.65
20 0.52
35 0.92
20 0.30
Voltage drop
at 100 mA [V]
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
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PA 8000 LW CNC control unit
Installation
Calculation
Compensation
n Use the actual data obtained from the cable's technical
specifications.
n 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).
n Calculate the voltage drop as follows:
Voltage drop [V] = 2 x L x CR x P
C
L - Cable length [m]
C - CR Specific resistance per meter [Ω/m]
P - PC Power consumption [A]
Personnel:
1.
Install a power supply with adjustable output voltage to supply
Skilled electrician
n
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.
General
– 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.
A measurement system contains integrated electronic components.
Relating to the current consumption Power Automation only indicates
mean values. Current peaks of a multiple of the mean value may occur
for several microseconds during operation. These steps guarantee that
the RMS' supply voltage does not drop below the required minimum.
5.4 Installing digital I/O
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.
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