power automation PA 8000 EL, PA 8000 LW Series, PA 8000 LW BAS SDI-AN, PA 8000 LW STD SDI-AN, PA 8000 LW PRO SDI-AN Installation Instructions Manual
Installation instructions
PA 8000 EL
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
Option: PA 8000 EL PRO-SDI / PA 8000E EL PRO-SDI
Version 2.0
©2015 Power Automation GmbH
2 24.09.2015
PA 8000 EL 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..................................................................... 10
2 Safety.................................................................................. 11
2.1 Customer's responsibility........................................... 11
2.2 Personnel requirements............................................. 12
2.2.1 Qualifications........................................................... 12
2.2.2 Unauthorized persons............................................. 12
2.3 Intended use.............................................................. 13
2.4 Unintended use.......................................................... 14
2.5 Personal protective gear............................................ 14
2.6 Specific dangers........................................................ 15
2.7 Safety devices........................................................... 17
2.8 Machine safety........................................................... 17
2.8.1 'CNC ready' signal - Emergency stop interlocking.. 18
2.8.2 'Power ok' signal..................................................... 19
2.9 Conduct in a dangerous situation and in case of
accidents.................................................................... 19
2.10 Data safety................................................................. 20
2.10.1 File backup.............................................................. 20
2.10.2 System protection................................................... 20
2.11 Environmental protection........................................... 22
2.12 Labels........................................................................ 23
3 Design and function.......................................................... 27
3.1 Overview.................................................................... 27
3.2 Brief description......................................................... 27
3.3 Module 2416 EL......................................................... 28
3.3.1 Digital inputs............................................................ 29
3.3.1.1 Input interfaces..................................................... 29
3.3.1.2 Input characteristics.............................................. 33
3.3.1.3 Input schematic.................................................... 34
24.09.2015 | 3
PA 8000 EL CNC control unit
Table of contents
3.3.1.4 Handwheel I/O...................................................... 34
3.3.2 Digital outputs......................................................... 37
3.3.2.1 Output interfaces.................................................. 37
3.3.2.2 Output characteristics........................................... 41
3.3.2.3 Output schematic.................................................. 42
3.3.3 Power connection.................................................... 43
3.3.4 Module 2416 EL LEDs............................................ 46
3.4 SDI interface.............................................................. 47
3.5 PC connectors........................................................... 49
3.6 Safety connector........................................................ 55
3.6.1 Safety connector specification................................ 56
3.6.2 Safety connector schematic.................................... 59
3.7 (X20) PA USB software dongle connector................. 59
3.8 PAMIO interface (superbus)...................................... 60
3.8.1 PAMIO boxes and modules.................................... 61
4 Technical data.................................................................... 65
4.1 General specifications............................................... 65
4.2 Connection values..................................................... 65
4.3 Operating conditions.................................................. 66
4.4 Dimension sheet........................................................ 67
4.5 Electromagnetic compatibility.................................... 68
4.6 Installation guidelines................................................ 69
5 Installation.......................................................................... 73
5.1 Prerequisites and preparations.................................. 73
5.1.1 General requirements............................................. 73
5.1.2 Electrical cabinet structural requirements............... 74
5.1.3 Cabinet temperature............................................... 74
5.2 Mounting the control unit in a cabinet........................ 75
5.3 Installing digital I/O.................................................... 80
5.3.1 Wiring example for 2416EL modules...................... 80
5.4 Wiring for machine safety.......................................... 81
5.4.1 Wiring example for 'CNC ready' relay..................... 82
5.4.2 Wiring example for 'Power ok' relay........................ 83
6 Transport, packaging and storage................................... 85
6.1 Transport................................................................... 85
6.2 Packaging.................................................................. 85
6.3 Storage...................................................................... 86
24.09.2015 | 4
PA 8000 EL CNC control unit
Table of contents
7 Maintenance....................................................................... 87
7.1 Safety notes............................................................... 87
7.2 Maintenance schedule............................................... 87
7.3 Measures after maintenance..................................... 88
8 Troubleshooting................................................................. 89
8.1 Safety notes............................................................... 89
8.2 Malfunction indicators................................................ 90
8.2.1 Module 2416 EL LEDs............................................ 91
8.3 Troubleshooting chart................................................ 93
9 Service and return process............................................... 95
9.1 Service....................................................................... 95
9.1.1 Service addresses................................................... 95
9.2 Spare parts................................................................ 97
9.3 Return policy and procedure...................................... 97
9.4 Training.................................................................... 100
10 Dismounting and decommissioning.............................. 101
11 EC Declaration of Conformity......................................... 103
12 Proof of change................................................................ 105
13 Index.................................................................................. 107
24.09.2015 | 5
PA 8000 EL CNC control unit
Table of contents
24.09.2015 | 6
PA 8000 EL CNC control unit
General information
1 General information
1.1 Information on this manual
General Information
Warnings
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.
DANGER!
… indicates an imminently hazardous situation which,
if unavoidable, will result in death or serious injury.
WARNING!
… indicates a potentially hazardous situation which, if
unavoidable, could result in death or serious injury.
CAUTION!
… indicates a potentially hazardous situation which, if
unavoidable, may result in minor or moderate injury.
NOTICE!
… indicates a potentially hazardous situation which, if
unavoidable, may result in property damage.
24.09.2015 | 7
PA 8000 EL CNC control unit
… emphasizes useful hints and recommendations as
well as information for efficient and trouble-free operation.
General information
Special Safety Notes
Additional symbols and highlighting
The following symbols are used in connection with the safety notes
to highlight particular dangers:
DANGER!
… highlights hazards caused by electric current. There
is a danger of serious injury or death if the safety notes
are not complied with.
The following symbols and highlights are used to distinguish
instructions, descriptions of results, cross-references and other 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
ð
an instruction.
n .. Highlights single or unordered instructions and lists.
Ä
“Additional symbols and highlighting” on page 8.. Highlights
cross-references to chapters or sections of this manual.
[Key].. Highlights captions of buttons, fields and other elements of
the software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or
submenu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts
from configuration files.
24.09.2015 | 8
PA 8000 EL CNC control unit
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.
24.09.2015 | 9
PA 8000 EL CNC control unit
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.
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)
24.09.2015 | 10
PA 8000 EL CNC control unit
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
regulations and identify additional dangers which may arise
due to the specific working conditions at the place of use of the
control unit, by means of a risk analysis. These must be 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 func-
tion and completeness.
n The customer must supply his personnel with the necessary
protective equipment.
24.09.2015 | 11
PA 8000 EL CNC control unit
Safety
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Danger of injury in case of insufficient qualifica-
tion!
Improper operation can lead to severe personal injuries and/or material damage.
– Only those persons who have been specified in the
corresponding chapters of this installation manual
should be entrusted with the listed types of work.
– Employ certified experts, if in doubt.
The following qualifications are specified for different areas of
activity listed in the installation manual.
Instructed person
was instructed by the operating company about the duties
assigned to her/him and the possible dangers that may arise from
inappropriate conduct.
Qualified personnel
are able to carry out assigned work and to recognize possible dangers due to professional training, knowledge, and experience as
well as profound knowledge of applicable regulations.
Skilled electrician
A skilled electrician is able to carry out assigned work and to
recognize and avoid possible dangers due to professional training,
knowledge, and experience as well as profound knowledge of
applicable regulations.
The skilled electrician has been trained specially for his working
environment and he has profound knowledge of relevant standards
and regulations.
2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons, who do not meet the requirements described in this installation manual, are not
aware of the dangers in the working area.
– Keep unauthorized persons away from the working
area.
– If in doubt, address such persons and ask them to
leave the working area.
– Interrupt your work as long as unauthorized per-
sons are in the working area.
24.09.2015 | 12
PA 8000 EL CNC control unit
Safety
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.
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
The control unit is exclusively intended and built for the use
described in this installation manual.
The control unit is to be used exclusively to control CNC machines
of a supported number of axes which are in accordance with the
types cleared by Power Automation. Prerequisite for the intended
use of the control unit is proper configuration as described in the
installation manuals provided by Power Automation.
WARNING!
Beware of unintended use!
Any use exceeding the scope of intended use and/or
different application of the control unit can result in
hazardous situations.
– Operate the control unit as intended only.
– Observe all instructions in this installation manual.
– Observe the permissible ambient conditions and
electromagnetic compatibility mentioned in the
technical data.
Claims of any kind for damage resulting from unintended use are
void.
The operator is solely responsible for all damage resulting from
unintended use.
24.09.2015 | 13
Unintended Use
PA 8000 EL CNC control unit
Safety
2.4 Unintended use
WARNING!
Beware of unintended use!
– In particular, avoid using the control unit for the fol-
lowing purposes as these are regarded as not
intended:
– Operation using software not approved by
Power Automation.
– Operation connected to machines/drives not
deemed compatible by Power Automation.
– Operation using wrong number of axes
– Wrong or missing execution of the mainte-
nance intervals
– Operation by not instructed personnel
2.5 Personal protective gear
Wearing of personal protective gear is required to minimize health
hazards and damage when working with the control unit.
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.
24.09.2015 | 14
PA 8000 EL CNC control unit
Safety
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.
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!
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.
DANGER!
Uncontrolled operation due to improper installa-
tion 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.
24.09.2015 | 15
PA 8000 EL CNC control unit
Safety
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 12) 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 manufac-
turers of the CNC machine and the control unit.
WARNING!
Risk of injury due to improper handling of bat-
teries!
Batteries must be handled with special care.
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 irrita-
tion. 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”
CAUTION!
Malfunction due to discharged buffer battery!
The control unit's CMOS settings are buffered by a
battery. If this battery is discharged completely the
CMOS settings are lost. Malfunctions of the control
unit may result.
n For further information, see Ä Chapter 8.3 “Troubleshooting
chart” on page 93.
24.09.2015 | 16
Safety
PA 8000 EL CNC control unit
Safety
2.7 Safety devices
DANGER!
Malfunctioning safety devices may pose a fatal
risk!
Safety devices must be intact and properly integrated
into the control unit's configuration and software in
order to guarantee safety.
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 wiring see Ä Chapter 3.6 “Safety
Ä
connector” on page 55,
safety” on page 17 and Ä Chapter 5.4 “Wiring for
machine safety” on page 81.
Data safety
For information on data safety see Ä Chapter 2.10
“Data safety” on page 20.
Chapter 2.8 “Machine
Additional Information
2.8 Machine safety
For information regarding the safety connector's specification and
Ä
wiring examples see
and Ä Chapter 5.4 “Wiring for machine safety” on page 81.
Chapter 3.6 “Safety connector” on page 55
24.09.2015 | 17
Further Applicable Documents
Personal Injury
PA 8000 EL CNC control unit
Safety
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
DANGER!
Injuries due to uncontrolled operation!
An inactive 'CNC Ready' signal represents a safety
related situation. The "CNC Ready" relay is switched
off when the PA CNC control unit is in a situation
where the axes' movements are not controlled.
As the axes may continue to move in an uncontrolled
manner, the contacts of the "CNC Ready" relay must
be used to disconnect the machine's emergency stop
safety chain. All actions necessary for safety must be
executed in the same way as when the
Emergency Stop button is pushed.
n Properly integrate the 'CNC ready' relay into the machine's
emergency stop chain.
All safety related actions must ensure that at least all axes
movements and spindle rotation (or beam power) are stopped as
quickly as possible.
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
resistors might be necessary.
Unbalanced axes have to execute with the mechanical brake.
The contacts for 'CNC Ready' and 'Power OK' are available on
Ä
connector X19 (see
on page 81).
Chapter 5.4 “Wiring for machine safety”
24.09.2015 | 18
PA 8000 EL CNC control unit
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
Ä
connector X19 (see
on page 81).
– When an external 5V power supply (RMS) is nec-
essary 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 5.4 “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.
24.09.2015 | 19
PA 8000 EL CNC control unit
2.10 Data safety
Safety
General Information
Initial State
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.
CAUTION!
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.
Instructions
Initial State
Personnel:
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 95).
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.
Qualified personnel
n
Instructed person
n
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.
24.09.2015 | 20
PA 8000 EL CNC control unit
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 fire-
wall 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 USBGuardian 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.
24.09.2015 | 21
PA 8000 EL CNC control unit
Safety
Batteries
Fig. 2: Overview FBWF interface
2.11 Environmental protection
CAUTION!
Environmental hazard caused by incorrect han-
dling!
Incorrect handling of environmentally hazardous substances, especially incorrect waste disposal, can
cause considerable damage to the environment.
n Do not release environmentally hazardous substances or com-
ponents 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:
Batteries contain toxic heavy metals. They are considered hazardous waste and must be disposed of by approved specialized
waste disposal companies.
24.09.2015 | 22
PA 8000 EL CNC control unit
Safety
Electronic Components
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 97.
2.12 Labels
The following labels are attached to the control unit.
NOTICE!
Readability Of Labels
Over the course of time labels may become dirty or
nonreadable for any other reason. Improper input voltages applied due to readability of labels can damage
the control unit.
– Keep labels in readable condition at all times.
– Replace damaged labels (not including material
warranty seals).
– Replacements can be obtained from
Power Automation.
Overview
The labels listed hereunder are located on the top side (PC connector side) of the control unit (Fig. 3).
Fig. 3: Control unit top side
24.09.2015 | 23
PA 8000 EL CNC control unit
Safety
Type Plate
Operating System Product Key
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.
CAUTION!
If the label with the operating systems's product key is
not readable or damaged, the particular Windowslicence 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 95).
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.
24.09.2015 | 24
PA 8000 EL 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.
Broken or removed seals void all material warranty
provided by Power Automation.
– Never open the control unit, or you will lose your
material warranty.
– Always contact Power Automation, if extensions,
repairs or modifications are required (see
Ä
Chapter 9 “Service and return process”
on page 95).
24.09.2015 | 25
PA 8000 EL CNC control unit
Safety
24.09.2015 | 26
PA 8000 EL CNC control unit
3 Design and function
3.1 Overview
Design and function
Fig. 6: Overview (Top)
1 Safety connector (X19)
2 PC connectors
3 Superbus connector (X13)
4 SDI connector (X21)
3.2 Brief description
The PA8000 EL is an open architecture CNC control unit providing
numerical interface for the PA-SDI drive. This control unit can be
extended via a superbus interface and external input/output modules (PAMIO) to connect a wide range of machine tools.
Depending on the model, the PA8000 EL provides one or two
internal input/output modules. Thus it is able to control either 24
inputs and 16 outputs, or 48 inputs and 32 outputs.
Machine tool axes are controlled by digital drives of the PA-SDI
range. These drive units are connected via a single digital bus
daisy-chained from the control to the drives. The number of drives
(and thus of axes) depends on the software options. The drives
also ensure the input of various measurement systems, either
incremental or absolute, depending on the velocity of the motors or
the position control loop of the CNC.
Via its Superbus extension board (always included) it is possible to
connect PA modular input/output modules (PAMIO) to extend the
capacity of digital inputs/outputs and/or analog inputs/outputs.
24.09.2015 | 27
PA 8000 EL CNC control unit
Design and function
3.3 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. 7: 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)
24.09.2015 | 28
Overview
PA 8000 EL CNC control unit
Design and function
3.3.1 Digital inputs
3.3.1.1 Input interfaces
Fig. 8: 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).
24.09.2015 | 29
Connection
PA 8000 EL CNC control unit
Design and function
Fig. 9: 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
mm2 (AWG 22 to 15).
n The inputs are always referenced against the 0 V connector of
Ä
the module (X30 pin 3
“Connection” on page 30).
24.09.2015 | 30
Pin Assignment
PA 8000 EL CNC control unit
Design and function
Fig. 10: 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
24.09.2015 | 31
Input Status LEDs
PA 8000 EL CNC control unit
Design and function
Fig. 11: 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.
24.09.2015 | 32
PA 8000 EL CNC control unit
Design and function
3.3.1.2 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
24.09.2015 | 33
PA 8000 EL CNC control unit
Design and function
3.3.1.3 Input schematic
This figure shows how the inputs are realized on each 2416 EL
module.
Fig. 12: Input equivalent schematic
1 Input n+1
2 Logic
3 CNC superbus
4 Input n
3.3.1.4 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.
24.09.2015 | 34
PA 8000 EL 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.
24.09.2015 | 35
Wiring Schematic
PA 8000 EL CNC control unit
Design and function
Fig. 13: Wiring schematic handwheel inputs
1 Handwheel
2 Input byte 3
3 Power supply connector
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).
24.09.2015 | 36
Overview
PA 8000 EL CNC control unit
Design and function
3.3.2 Digital outputs
3.3.2.1 Output interfaces
Fig. 14: Output bytes
2 Output byte 1 (X41)
1 Output byte 2 (X40)
The outputs are grouped in bytes (8 signals).
24.09.2015 | 37
Connection
PA 8000 EL CNC control unit
Design and function
Fig. 15: 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. 15).
The current limitation of each output is 0.7 - 2.5 A per
pin in case of short circuits.
– Consider that the power supply cable for one
output byte has to be chosen accordingly.
Each output has a nominal output capability of 1 A.
Nevertheless each output byte (8 signals) is globally
limited to 4 A.
– Take care of this specification by appropriate
output definition toward the external actuator.
Outputs are monitored for faults. In case of errors, the
output is switched off.
Since every 4 adjacent outputs have a common status
signal, the onboard monitor always switches off 4 outputs in such a case (1 - 4, 5 - 8, 9 - 12, 13 - 16).
24.09.2015 | 38
Pin Assignment
PA 8000 EL CNC control unit
Design and function
Fig. 16: 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
24.09.2015 | 39
Output Status LEDs
PA 8000 EL CNC control unit
Design and function
Fig. 17: 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.
24.09.2015 | 40
PA 8000 EL CNC control unit
Design and function
3.3.2.2 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 out-
All outputs are referenced against 0 V (power supply
connector X30, pin 3).
4 A
0.20 W
0.45 W
puts
24.09.2015 | 41
PA 8000 EL CNC control unit
Design and function
3.3.2.3 Output schematic
This figure shows how the outputs are realized on each 2416 EL
module.
Fig. 18: 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
24.09.2015 | 42
Overview
PA 8000 EL CNC control unit
Design and function
3.3.3 Power connection
Fig. 19: 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).
24.09.2015 | 43
Pin Assignment
PA 8000 EL CNC control unit
Design and function
Fig. 20: Power supply pins
Each module has a 5 pin connector (X30) with the following pin
assignment:
Pin (Fig. 20) 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)
24.09.2015 | 44
PA 8000 EL 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
supplied separately. The two output bytes can be supplied
independently from each other.
This allows, for example, power to be supplied independently
to each byte in case of an emergency stop.
For proper load balancing across pins, connections to
all available pins per output byte are recommended.
– Establish wire connections to both pins 1/2 and 3/4
respectively.
The current limitation of each output is 0.7 - 2.5 A per
pin in case of short circuits.
– Consider that the power supply cable for each
output byte has to be chosen accordingly.
24.09.2015 | 45
Overview
PA 8000 EL CNC control unit
Design and function
3.3.4 Module 2416 EL LEDs
The 2416 EL module has four LEDs for diagnostic purposes.
Fig. 21: Status LEDs
1 Status
2 Access
3 Bustest
4 Monitor
For a detailed assignment of the LEDs' states see Ä Chapter 8.2.1
“Module 2416 EL LEDs” on page 91.
24.09.2015 | 46
Overview
PA 8000 EL CNC control unit
Design and function
3.4 SDI interface
Fig. 22: SDI connector positions
1 Safety connector (X19)
2 PC connectors
3 Superbus connector (X13)
4 SDI connector (X21)
The hardware provides a single RJ 45 connector which is determined at connector X21 (Fig. 22/4, 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.
NOTICE!
Malfunctions and damage to the control unit!
The control unit provides several RJ 45 connectors.
One or two are located on the PC interface panel
(Fig. 22/1) and only intended for Ethernet connections.
The other RJ 45 connector (Fig. 22/4) is located next
to the PAMIO superbus connector. Inadvertent interchanging of the two connectors can cause control unit
malfunctions and damages to the control unit and the
attached drives.
– When setting up the wiring, carefully observe the
connectors' positions given in this installation
manual as well as the labels on the control unit.
24.09.2015 | 47
PA 8000 EL 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. 23: Daisy chain setup
1 PA 8000 EL (control unit)
2
PA SDI Drive MidiTM or Maxi
3
PA SDI Drive MidiTM or Maxi
TM
TM
1. Connect the X21 connector of the control unit with the J1
connector 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.
24.09.2015 | 48
PA 8000 EL CNC control unit
3.5 PC connectors
Design and function
Overview
The control unit provides a number of standard PC interface connectors for various input and output applications.
Fig. 24: Overviews PC connectors
1 Main power supply (X1)
2 VGA connector, Sub-D, 15 pin, male (X4)
3 DVI Connector (X4)
4 4 USB 2.0 connectors
5 Ethernet connector, RJ45
Hardware configuration subject to change
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.
– For information on the applicable number of
interfaces see the specification provided in the
sales records.
24.09.2015 | 49
PA 8000 EL 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. 25: Power supply connector
Power supply properties
Property Value Unit
Voltage 115 - 240 V AC
Tolerances +10 / -15 %
Frequency 50 - 60 Hz
Maximum current (at 115 V) 4 A
Maximum current (at 230 V) 2 A
Maximum power consumption 180 W
NOTICE!
Damage to the control unit!
Supply voltages not supported can cause damage to
the control unit.
24.09.2015 | 50
PA 8000 EL CNC control unit
Design and function
(X4) VGA Connector (2)
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
compatible monitor.
Fig. 26: VGA connector (Sub-D 15)
Property Value
Pins 15
Connector type sub D (high density)
Gender female
Pin
(Ä “(X4)
VGA
Connector
(2)”
on page 51
)
Assignment
1 RED
2 GREEN
3 BLUE
4 not used
5 GND
6 RED GND
7 GREEN GND
8 BLUE GND
9 KEY
10 SYNC GND
11 Monitor ID 1
12 Monitor ID 2
13 HSYNC
14 VSYNC
15 not used
24.09.2015 | 51
PA 8000 EL 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. 27: DVI connector
Pin
(Fig. 27)
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
23 TMDS clock+
24 TMDS clock−
24.09.2015 | 52
PA 8000 EL CNC control unit
Design and function
USB 2.0 Connectors (4)
Pin
(Fig. 27)
C1 RED
C2 GREEN
C3 BLUE
C4 SYNC
C5 GND
The USB ports allow connection of USB peripherals. The control
unit includes 3 standard USB 2.0 type A ports.
Fig. 28: USB connectors (Type A)
Assignment
Property Value
Pins 4
Connector type USB 2.0 Type A
Max length 5 m (16.5 ft)
Pin (Ä “USB 2.0
Connectors (4)”
on page 53)
1 VBUS
2 D-
3 D+
4 GND
Shell Shield
USB assignment
24.09.2015 | 53
PA 8000 EL CNC control unit
Design and function
Ethernet Connector (5)
The Ethernet connector allows connection of the control unit to
local area networks.
Fig. 29: Ethernet connector (RJ 45)
NOTICE!
Malfunctions and damage to the control unit!
The control unit provides one RJ 45 connector. It is
located on the PC interface panel (Ä “Overview”
on page 49/5) and only intended for Ethernet connections. Inadvertent interchanging of the connector 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'
positions given in this installation manual as well as the labels
on the control unit.
Property Value
Pins 8
Connector type RJ 45
Max length 100 m (328 ft)
Pin (Ä “Ethernet
Connector (5)”
on page 54)
1 TX+
2 TX-
3 RX+
4
5
6 RX-
7
8
Ethernet 10/100 BaseT
24.09.2015 | 54
PA 8000 EL CNC control unit
Design and function
(X2) Protective Ground Screw
Overview
The protective ground screw (X2) provides a means to ensure
grounding connection of the control unit.
Fig. 30: Ground screw
n Use the ground screw (M5) provided with the control unit.
n Use a wire of 5 mm2 (11 AWG) cross section at minimum.
n For standard conforming distinction use wire sheathed in
yellow/green.
3.6 Safety connector
All PA 8000 EL models have two relays for safety functions.
The connector provides both a normally closed and a
normally open contact for each relay.
The safety contacts are located on connector X19.
The connector is always located on the PA PCI Interface board.
24.09.2015 | 55
Safety Connector Location
PA 8000 EL CNC control unit
Design and function
Fig. 31: Safety connector location (model "Analog/SDI")
1 Safety connector X19
Purpose / Wiring
Specification
Pin Assignment
For information regarding the safety connector's purpose and
wiring examples see Ä Chapter 2.8 “Machine safety” on page 17
Ä
Chapter 5.4 “Wiring for machine safety” on page 81.
and
3.6.1 Safety connector specification
Property Value
Form factor 6 pin, removable screw plug
Maximum contact load 1A / 24V DC
Fig. 32: Safety connector pins
Pin (Fig. 32) 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
24.09.2015 | 56
PA 8000 EL CNC control unit
Design and function
Relay 1 "Power ok"
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
AND + 12 V OK
AND - 12 V OK
AND T < 60 °C (140 °F)
NOTICE!
Damage to the control unit!
Voltage faults and/or temperatures above the allowed
specification can cause damage to the control unit.
Properly wire the "Power ok" relay to protect the control unit from damaging voltages and temperatures.
active
24.09.2015 | 57
PA 8000 EL CNC control unit
Design and function
Relay 2 "CNC ready"
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
AND Control unit ready
AND T < 55 °C (131 °F)
NOTICE!
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.
active
n Ensure that the "CNC ready" relay is wired properly to the
machine's emergency stop circuit.
24.09.2015 | 58
PA 8000 EL CNC control unit
Design and function
3.6.2 Safety connector schematic
Fig. 33: Safety connector equivalent schematic
3.7 (X20) PA USB software dongle connector
Fig. 34: PA USB software dongle connector
An additional USB port is specially marked as "PA dongle port"
(X20). This USB port 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
software dongle.
24.09.2015 | 59
PA 8000 EL CNC control unit
Design and function
3.8 PAMIO interface (superbus)
Overview
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. 35: Superbus connector
Fig. 36: Location superbus connector
Every PA 8000 EL model has a PAMIO superbus connector
located on the PCI interface board.
Cable Specification
Ä
For further information see
modules” on page 61 or the PA Accessories installation manual.
The interface cable required to connect PAMIO modules can be
ordered from Power Automation.
NOTICE!
All cables connected to the control unit are intended
for stationary use only.
The cable shield is connected to both connector casings.
Chapter 3.8.1 “PAMIO boxes and
24.09.2015 | 60
Basic Description
PA 8000 EL CNC control unit
Design and function
3.8.1 PAMIO boxes and modules
Fig. 37: 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
(internal 2416 EL 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.
24.09.2015 | 61
PAMIO Hardware
PA 8000 EL CNC control unit
Design and function
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 (see Ä Chapter 9
“Service and return process” on page 95).
For further information on the modules' specifications refer to the
PA Accessories installation manual.
Fig. 38: 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)
PAMIO boxes are shipped without connection cables.
Cables of the following lengths can be ordered from
Power Automation: 2 m (6.5 ft), 5 m (16.5 ft),
10 m (33 ft), 20 m (66 ft), 25 m (82 ft) (see
Ä
Chapter 9 “Service and return process” on page 95).
Cable length
– Ensure, that the total cable length between the
control unit and the last PAMIO box does not
exceed 25 m (82 ft).
The PAMIO hardware consists of the following components:
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)
24.09.2015 | 62
PA 8000 EL CNC control unit
Design and function
PAMIO 2416
PAMIO 4ENC4A
PAMIO 2ENC4A
Feature Value Specifications
digital inputs 24 (3 bytes) 24 V DC
digital outputs 16 (2 bytes) 24 V DC
isolation optical
Feature Value Specifications
encoder inputs 4
analog inputs 4 +/- 10 V (12 bit)
analog outputs 4 +/- 10 V (16 bit)
Feature Value Specifications
encoder inputs 2
analog inputs 4 +/- 10 V (10 bit)
analog outputs 4 +/- 10 V (16 bit)
termination plug integrated
PAMIO PWM
Characteristics
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 mod-
Ä
ules (see
Chapter 3.3 “Module 2416 EL” on page 28).
For detailed information about PAMIO modules, their
installation and electric requirements refer to the PA
Accessories installation manual.
24.09.2015 | 63
PA 8000 EL CNC control unit
Design and function
24.09.2015 | 64
PA 8000 EL CNC control unit
4 Technical data
4.1 General specifications
Technical data
General Information
Electrical
Property Value Unit
Dimensions
(WxDxH)
Weight 3.6 kg
123.5 x 300 x 225 mm
4.86 x 11.81 x 8.56 inch
7.94 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
24.09.2015 | 65
PA 8000 EL CNC control unit
4.3 Operating conditions
Technical data
General
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
NOTICE!
Functional defects!
The module casing does not provide sufficient protection against environmental influences. Dust and moisture may cause malfunctions.
– Only operate the control unit inside a cabinet that
complies with the requirements as listed in the
technical data (seeÄ Table on page 74).
10 °C
50 °F
24.09.2015 | 66
PA 8000 EL CNC control unit
4.4 Dimension sheet
Technical data
Fig. 39: dimension sheet
24.09.2015 | 67
PA 8000 EL CNC control unit
Technical data
The dimensions are given in milimeters and in inches
in parentheses.
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
Electrical equipment of machines all met -
Limits [...] of radio disturbance characteristics
for residential, commercial and lightindustrial environments
interference voltage class B
interfering field strength class B
emitted interference class B
24.09.2015 | 68
PA 8000 EL CNC control unit
Technical data
Interference Resistance
Standard Title Requirement Value
IEC / EN 61000-6-2 [...] Immunity standard for industrial
environments
EN 61000-4-2 [...] Electrostatic discharge immunity
[...]
EN 61000-4-3 [...] Radiated, radio-frequency, electro-
magnetic 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
[...]
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
ESD air discharge 8 KV
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
HF power input into the net,
signal/data line
10 V
EN 61000-3-2: 2006 [...] Limits for harmonic current emis-
EN 61000-3-3:2008
sions
4.6 Installation guidelines
Meaning Of EMC
Important Rules For 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.
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 pos-
sible beside ground areas
all met -
24.09.2015 | 69
PA 8000 EL CNC control unit
Technical data
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.
24.09.2015 | 70
PA 8000 EL 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 singlesided grounding in exceptional cases, but if that is done, only
lower frequencies will be absorped.
A single-sided ground connection of the cable shield may be
convenient, if:
– the conduction of a potential compensating line is not pos-
sible
– analog signals (some mV respectively 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.
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.
24.09.2015 | 71
PA 8000 EL CNC control unit
Technical data
24.09.2015 | 72
Safety
PA 8000 EL CNC control unit
Installation
5 Installation
WARNING!
Danger of injury due to improper installation and
commissioning!
Improper installation and commissioning can result in
severe personal injury or material damage.
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 organ-
ized. 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
Prerequisites for installation are influenced by the control unit's required operating conditions and must also
take into account the machine to be controlled.
– Ensure that the control unit's operating condition
requirements are met.
For further information see
Ä
Chapter 4.3 “Operating conditions” on page 66.
– Ensure that the operating conditions requirements
of the machine to be connected to the control unit
are met.
For further information see the CNC machine's
manuals.
Electronic components (e.g. mainboards, power 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.
24.09.2015 | 73
PA 8000 EL 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
IP protection class
(DIN 40050/ IEC 60529)
Mounting hole sizes and
spacing
NOTICE!
Control unit malfunctions
Excessive strain on cables can cause malfunctions
due to disruption of connections.
– Install strain reliefs for all cable holes.
NOTICE!
For shielded cables it is necessary to apply the shieldscreen 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")
Notes
5.1.3 Cabinet temperature
Heat input generated by fitted components
The heat generated by the operator's station influences the operating conditions inside the cabinet.
– When installing the control unit, take the station's
heat dissipation into consideration.
– Ensure an adequate cooling using fans or air con-
ditioning.
24.09.2015 | 74
Mounting Orientation
PA 8000 EL CNC control unit
Installation
5.2 Mounting the control unit in a cabinet
Fig. 40: Mounting orientation
n Always mount the control unit as shown in Fig. 40.
The dimensions are given in milimeters and in inches
in parentheses.
24.09.2015 | 75
PA 8000 EL CNC control unit
Installation
Spacing
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. 41: Front spacing
24.09.2015 | 76
PA 8000 EL CNC control unit
Installation
Top / Bottom Spacing
All PC connectors (PS2, VGA, USB, etc.) and some CNC
connectors (X13/X19) 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 min-
imum 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
control unit.
24.09.2015 | 77
PA 8000 EL CNC control unit
Installation
Fig. 42: Top/bottom spacing
24.09.2015 | 78
PA 8000 EL 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
Fig. 43: Software dongle
The PA software dongle is located on the bottom side
of the control unit (Fig. 43).
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.
transformers, 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.
24.09.2015 | 79
PA 8000 EL CNC control unit
Installation
RF Noise Suppression
General
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.
5.3 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.
n If in doubt, contact the Power Automation's customer support.
Ä
For contact information see
process” on page 95.
Chapter 9 “Service and return
Schematic
5.3.1 Wiring example for 2416EL modules
Fig. 44: Cabling example for 2416EL modules
1 Power supply
2 Fuse (slow)
3 Input signals
4 Inputs
5 Module 2416EL
6 Outputs
7 Output signals
8 Resistive load
9 Inductive load
24.09.2015 | 80
PA 8000 EL CNC control unit
Installation
Safety
Personnel:
1. Set up inputs according to the schematic.
2. Set up outputs according to the schematic.
3. Set up power supply for outputs.
Ensure that the circuit is protected by a fuse of appropriate
ratings.
Inductive loads
Digital outputs switch very quickly. This fact must be
accounted for when inductive loads, like for example
relays, are connected.
n When connecting inductive loads to outputs, ensure that a
recovery diode is connected in parallel as shown in the schematic (pos. 9).
Skilled electrician
n
5.4 Wiring for machine safety
DANGER!
Uncontrolled operation due to improper installa-
tion 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 if the safety relay has been
properly integrated into the machine emergency stop chain.
Ä
n Only let qualified personnel (
on page 12) 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 manufac-
turers of the control unit and the CNC machine.
For information on the safety connector's specifications
and purpose see Ä Chapter 3.6 “Safety connector”
Ä
on page 55 and
on page 17.
Chapter 2.8 “Machine safety”
Chapter 2.2.1 “Qualifications”
24.09.2015 | 81
Emergency Stop Interlocking
PA 8000 EL CNC control unit
Installation
5.4.1 Wiring example for 'CNC ready' relay
DANGER!
Injuries due to uncontrolled operation!
An inactive 'CNC Ready' signal represents a safety
related situation. The "CNC Ready" relay is switched
off when the PA CNC control unit is in a situation
where the axes' movements are not controlled.
As the axes may continue to move in an uncontrolled
manner, the contacts of the "CNC Ready" relay must
be used to disconnect the machine's emergency stop
safety chain. All actions necessary for safety must be
executed in the same way as when the
Emergency Stop button is pushed.
n Properly integrate the 'CNC ready' relay into the machine's
emergency stop chain.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19 (see Fig. 45).
Schematic (Suggested Wiring)
Fig. 45: Wiring example 'CNC ready' relay
4 connector X19 pin 4
6 connector X19 pin 6
24.09.2015 | 82
Power Supply Interlocking
Schematic (Suggested Wiring)
PA 8000 EL CNC control unit
Installation
5.4.2 Wiring example for 'Power ok' relay
The "Power ok" relay is triggered by the hardware monitoring of the
internal supply voltages and the temperature sensor.
The "Power ok" relay is switched off when the supply voltages do
not match the allowed range or the internal temperature is too high.
n Use the contacts of the "Power ok" relay to switch off the main
power supply of the CNC control unit unit to avoid any unexpected damages to the control unit.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19 (see Fig. 46).
Fig. 46: Wiring example 'power ok' relay
1 Connector X19 pin 1
3 Connector X19 pin 3
24.09.2015 | 83
PA 8000 EL CNC control unit
Installation
24.09.2015 | 84
PA 8000 EL CNC control unit
Transport, packaging and storage
6 Transport, packaging and storage
6.1 Transport
Inspection
Improper Transport
Check the delivery immediately on receipt for completeness and
transport damage.
Record the extent of transport damage in the transport documents
or on the delivery note of the forwarding agent.
Complaint periods limited
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within the
applicable complaint periods.
CAUTION!
Improper transport can result in damage!
Improper transport can cause extensive material
damage.
n When unloading the packages upon delivery and during in-
house transport, exercise caution and observe the symbols on
the package.
n Do not remove packaging material until control units are ready
for assembly.
Concerning Packaging
Handling Packaging Materials
6.2 Packaging
The individual packages have been packed to match the transport
conditions that can be expected.
The packaging has the function of protecting the individual components against damage, corrosion, etc. until they are finally fitted.
The packaging material must therefore not be damaged and
should only be removed just before assembly is to take place.
If there is no returns agreement for the packaging, separate materials according to type and size and direct to further use or recycling.
NOTICE!
Environmental damage caused by incorrect waste
disposal!
Packaging materials are valuable raw materials and
can be sensibly reconditioned and recycled in many
cases.
24.09.2015 | 85
PA 8000 EL CNC control unit
Transport, packaging and storage
n Dispose of packaging materials in an environmentally respon-
sible manner.
n Follow the locally valid waste disposal regulations. If necessary
employ a special waste disposal company to dispose of packaging material.
6.3 Storage
Storage Of Packages
Storage Conditions
Store packages under the following conditions:
n Do not store outdoors.
n Store in a dry and dust-free environment.
n Do not subject to aggressive media.
n Protect against direct sunlight.
n Avoid mechanical vibrations.
n For storage periods longer than 3 months check the general
condition of all parts and packaging regularly.
n If necessary renew the packaging.
Property Value Unit
Temperatures -20 - +60 °C
-4 - +140 °F
Humidity (non-condensing) < 80 %
Acceleration < 4.0 G
Additional requirements
Packages may be marked with notes for storage,
which may exceed the requirements mentioned here.
These must be adhered to.
Improper Storage
CAUTION!
Improper storage can result in damage!
Improper storage can cause extensive material
damage.
n Always store the control unit in its original packaging.
n When storing the control units observe the specifications
regarding maximum and minimum storage temperature and
permitted maximum acceleration given in chapter "Technical
Ä
data" (
Chapter 4 “Technical data” on page 65).
24.09.2015 | 86
PA 8000 EL CNC control unit
7 Maintenance
7.1 Safety notes
Maintenance
Personnel
Safety Messages
Some maintenance tasks can only be executed by trained qualified
personnel, or only by Power Automation. In these cases this is
separately indicated in the description of the specific maintenance
tasks. All work on the electrical equipment shall only be executed
by a qualified electrician.
DANGER!
Danger to life caused by electric current!
Touching conductive parts causes a direct danger to
life. Damage to insulations or individual components
can cause danger to life.
NOTICE!
Property damage due to improperly executed
maintenance work!
Improper maintenance can cause property damage.
– Prior to starting work ensure that there is sufficient
assembly space.
– Ensure order and cleanliness at the assembly site!
Loose parts and tools or parts and tools placed on
top of each other are hazard sources.
– If components have been removed, ensure that
they are properly mounted; re-install all mounting
elements and comply with standard screw tightening torque specifications.
7.2 Maintenance schedule
Maintenance tasks that are required for optimum and trouble-free
operation are described in the sections below. If increased dust
pollution is detected at regular inspections do the following:
n Shorten the required maintenance intervals to correspond with
the actual signs of pollution.
n Check, whether the cabinet still adheres to the requirements of
its protection class (IP).
For questions on maintenance work, contact Power Automation
Service (Ä Chapter 9.1 “Service” on page 95).
24.09.2015 | 87
PA 8000 EL CNC control unit
Maintenance
Schedule
Interval Maintenance work Personnel
Once a year Visual check, whether all fan exhausts are clean and the fans are
properly working.
n If required, clean the fan exhausts with a dry cloth or if necessary
use a vacuum cleaner.
Check whether all fans inside the electrical cabinet are operating
accordingly.
n Use a sheet of paper and keep it in front of the fans inside the
electical cabinet to check if it is moving.
Check whether all interface cables are installed properly in their
respective sockets.
n Before re-plugging loose cables, properly shut down the control
unit and machine and secure against inadvertent restart.
n Unplug the respective cables and re-plug them afterwards.
Ä
n Follow instructions in
nance” on page 88.
Make a backup of the data.
n For the exact procedure to make the backups see
Ä
Chapter 2.10 “Data safety” on page 20.
Chapter 7.3 “Measures after mainte-
Instructed person
Instructed person
Instructed person
Skilled electrician
7.3 Measures after maintenance
Perform the following steps after completing maintenance and
before switching on the control unit and the machine:
1. Check all previously loosened screw connections for a tight
fit.
2. Check whether all previously removed protective devices and
covers are properly installed again.
3. Make sure that all tools, materials and other equipment used
were removed again from the cabinet.
4. Clean up work area and remove any substances left over,
such as fluids, cleaning material or the like. Dispose them
according to the current applicable regulations.
5. Make sure that all safety features on the control unit and
relating to the machine are fully functional.
24.09.2015 | 88
PA 8000 EL CNC control unit
8 Troubleshooting
Troubleshooting
General Information
Personnel
The following chapter describes possible causes of faults during
installation and configuration and the steps required to eliminate
them.
n In the event of frequent faults, re-check if the configuration was
set up as described in this installation manual.
n In the event of faults that cannot be eliminated through the fol-
lowing instructions, please contact Power Automation (see
Ä
Chapter 9 “Service and return process” on page 95).
Return procedure
In the event of an error that requires the control unit to
be sent to Power Automation, follow the instructions
given in Ä Chapter 9.3 “Return policy and procedure”
on page 97.
8.1 Safety notes
n The troubleshooting procedures described in this installation
manual can be performed by the operator unless otherwise
marked.
n Some work may be performed only by specially trained per-
sonnel or only by Power Automation, in which case special
notice is given in the description of the individual faults.
n All work on the electrical system must be performed by a quali-
fied electrician.
Authorization
WARNING!
Unauthorized troubleshooting procedures can
result in injury!
Improper troubleshooting procedures can result in
severe personal injury or material damage.
n Observe the personnel requirements for repairs specified in the
troubleshooting chart.
If in doubt, contact Power Automation for help or support by an
authorized service technician.
n Ensure that the power supply has been disconnected.
n Make sure that the assembly location is clean and well organ-
ized.
n Components that are loosely stacked or lying around can
cause accidents.
n If components have been removed, ensure proper assembly,
install all mounting elements and comply with screw tightening
torques.
24.09.2015 | 89
PA 8000 EL CNC control unit
Troubleshooting
In Case Of Faults
The following general rules apply:
Personnel:
Protective equipment:
1. In the event of faults that pose immediate danger to man or
machine, activate the emergency shutoff function immediately.
2. Determine the cause of the fault.
3. Disconnect the control unit from the power supply.
4. Immediately inform the person in charge of the equipment
where the fault is located.
5. Depending on the type of fault, eliminate the fault or have it
eliminated by an authorized specialist.
Qualified personnel
n
Ground strap
n
ESD safety shoes
n
ESD safety pad
n
ESD clothing
n
Protective glasses
n
Ear protection
n
Antistatic gloves
n
Overview
8.2 Malfunction indicators
The following components indicate malfunctions or improper configuration of the control unit.
Module Description
2416 EL LEDs The LEDs of the 2416EL
module indicate operating
states and malfunctions
regarding digital inputs and outputs.
24.09.2015 | 90
Overview
PA 8000 EL CNC control unit
Troubleshooting
8.2.1 Module 2416 EL LEDs
The 2416 EL module has four LEDs for diagnostic purposes.
Fig. 47: Status LEDs
1 Status
2 Access
3 Bustest
4 Monitor
The LEDs' states are assigned the following status messages:
24.09.2015 | 91
PA 8000 EL CNC control unit
Troubleshooting
LED "Monitor" (1)
LED "Bustest" (2)
LED state Module status
Off Error 1: The ambient temperature is above 60 °C
(140 °F) and all outputs are disabled by the
onboard logic
OR Error 2: The watchdog is re-triggered but the 24 V
output supply has been interrupted for more than
60 seconds. In this case the onboard logic switches
off the corresponding 24 V outputs.
Quick flash Warning 1: The ambient temperature is above
55 °C (131 °F)
OR Warning 2: The watchdog is re-triggered but the
24 V output supply has been interrupted for more
than 15 seconds
OR Warning 3: Outputs are overloaded for more than
15s.
On The 24 V output supply is correct
AND There is no temperature error
LED state Module status
LED "Access" (3)
LED "Status" (4)
Off Default
On Bustest between control unit and the last PAMIO
module is active
LED state Module status
Off Default
On Access to this module
LED state Module status
Off No power supply (24 V)
OR Hardware error
Slow flash The module is not configured
Quick flash The module is configured but the outputs are disa-
bled because the watchdog is not re-triggered
On The module is configured and the analog outputs
are enabled
24.09.2015 | 92
Notes
PA 8000 EL CNC control unit
Troubleshooting
8.3 Troubleshooting chart
Malfunctions or errors not listed in this chart require
Power Automation to be contacted (see Ä Chapter 9
“Service and return process” on page 95).
– Do not attempt repairs not described in the
troubleshooting chart or the following chapters.
Attempts at unauthorized repairs void the material
warranty.
– If in doubt regarding listed repairs, contact
Power Automation for help.
Return procedure
In the event of an error that requires the control unit to
be sent to Power Automation, follow the instructions
given in Ä Chapter 9.3 “Return policy and procedure”
on page 97.
General Procedure
Personnel:
1. Properly shut down the control unit and the tooling machine.
Ensure the tooling machine rests in a secured state.
2. Ensure the power supply is deactivated and secured against
inadvertent reactivation.
3. Follow the instructions given in the troubleshooting chart.
4. Restart the control unit and the tooling machine after termina-
tion of the work as described in the respective operating
manuals.
Qualified personnel
n
Skilled electrician
n
24.09.2015 | 93
PA 8000 EL CNC control unit
Troubleshooting
Troubleshooting Chart
No. Error Cause Solution Personnel
001 Unscheduled
shutdown
002 Hardware
failure
003 Malfunction of
the control unit
Overheating
Missing power
supply
Undetermined
Undetermined
n Ensure that all requirements
regarding spacing within the cabinet
Ä
are met (
the control unit in a cabinet”
on page 75).
n Ensure that the ambient tempera-
ture is within the specified limits
Ä
Chapter 4.3 “Operating condi-
(
tions” on page 66).
n Ensure that none of the vents are
blocked.
n Check visually/aurally if the fans are
working.
If not, contact Power Automation
n Check if the power supply wiring is
set up correctly.
n Ensure, that the external main
power supply is working.
n Return the control unit to
Power Automation for repair.
Follow the instructions given in
Ä
Chapter 9.3 “Return policy and
procedure” on page 97.
n Contact Power Automation in case
of malfunctions relating to the control unit's startup and date/time settings.
n Do not open the casing or replace
the battery manually!
n Please contact the Power Automa-
tion service (see
“Service and return process”
on page 95).
Chapter 5.2 “Mounting
Ä
Chapter 9
Skilled electrician
Skilled electrician
Instructed person
Skilled electrician
004 Missing RF
noise suppression
005 Uncontrolled
operation
Undetermined
Inactive 'CNC
Ready' - signal
n Check if the noise suppression com-
ponents are connected directly at
the noise source.
n Check if the power and signal lines
are conducted separately in a distance of at least 10 cm.
n When using mechanical cable
guides, install additional metal
shields.
n Check if the 'CNC ready' relay is
properly integrated into the
machine's emergency stop chain
Ä
(see
example for 'CNC ready' relay”
on page 82).
Chapter 5.4.1 “Wiring
Skilled electrician
Skilled electrician
24.09.2015 | 94
PA 8000 EL CNC control unit
Service and return process
9 Service and return process
9.1 Service
Service At Power Automation
By Phone
PA's well-educated service staff is available to answer your technical questions. Due to the close co-operation with our customers,
our engineers can solve problems often immediately by phone.
If on-site support is necessary, our service staff will diagnose the
problem and will prepare our field service engineer beforehand.
This is to make on-site service as much effective as possible
By Remote Control Software
Every PA CNC is equipped with an Ethernet interface. If you have
a network on-site, you only have to integrate the CNC system to
your network for world-wide-web access.
Power Automation provides a remote control software which allows
our service staff to log into your CNC. This provides all the information available on the machine. They can check all the data like the
PLC program, machine parameters, or the NC programs directly
on the real system under real conditions. This is the fastest and
most cost-effective way to solve problems.
On-Site
If necessary our service engineers will visit you to help you solve
your problems on-site. Our engineers are trained continuously to
be always up to date. Thereby you always can expect the best
support.
Due to our service centers worldwide, our service staff can be on
site normally within 24 hours at the latest.
Service Addresses
9.1.1 Service addresses
Power Automation GmbH (Headquarters)
Gottlieb-Daimler-Strasse 17/2
D-74385 Pleidelsheim
Tel: +49-7144-899-0
Fax: +49-7144-899-299
service@powerautomation.com
24.09.2015 | 95
PA 8000 EL CNC control unit
Service and return process
Power Automation America, Inc.
8601 Jameel Road, Suite 140
Houston, Texas 77040 USA
Tel: +1-713-263-9400
Fax: +1-281-715-2500
sales.america@powerautomation.com
Power Automation Office Turkey
Kustepe Mah. Mecidiyekoy Yolu Cad.
Trump Towers No. 12 Kule: 2 K:18
Daire no: 3211022839 Sisli / Istanbul
Turkey
Tel: +90-212-306-3280
Fax: +90-212-306-3101
sales.turkey@powerautomation.com
Shenzhen Double CNC Tech Co., Ltd
8th Floor,WeiXinDa Building
Bao Min Road 2
Xi Xiang Town
Bao'an District, Shenzhen, Guangdong
PR China
Power Automation France SARL
Cité de la Photonique
Bâtiment Pléione
11 avenue Canteranne
33600 Pessac
France
Tel: +33-559-4010-50
Fax: +33-559-4010-59
pa.france@powerautomation.com
24.09.2015 | 96
PA 8000 EL CNC control unit
Service and return process
ACE Automation
A-721, Twinrex B/D
Deokpungdong-ro 111-10, Hanam-si
Gyeonggi-do, 465-831
South Korea
9.2 Spare parts
Spare Parts
Policy
Due to the high quality of our products we can assure you that you
will not need this service often. Spare parts are often urgent so
Power Automation provides the relevant spare parts at the local
service centers for immediate dispatch.
Our 3 service centers in Europe, North America and Asia allow us
to deliver all needed parts typically within 24 hours.
Only trust PA's original parts - because every part passes our tight
quality checks.
We also offer consulting services to identify the most critical parts
for the machines in your production facilities. We suggest what critical stock may be required to ensure a minimum downtime of your
machines. Our specialists look for common parts to keep your
inventory levels at a minimum.
9.3 Return policy and procedure
Power Automation will only accept control units and
components for replacement or repair, if they have
been returned in adherence to the provisions given
below.
n If material warranty is void or if no error is detected, a testing
flat rate will be charged. If an error is determined, the testing
flat rate will be charged to the repair costs.
n If material warranty is void you will receive a repair offer.
n Before the repair starts we need a repair order from you, if the
material warranty is extinguished.
24.09.2015 | 97
Acquiring RMA Number
PA 8000 EL CNC control unit
Service and return process
1. Contact Power Automation to receive an RMA form in Excel
format.Ä “RMA Form” on page 99
2. Open the 'RMA Process' form provided by Power Automation.
Use one form for each single part you want to ship back to
Power Automation.
3. Fill in the form.
The fields marked with a red star (*) are mandatory fields.
Only fill in the fields next to the yellow bar on the left side of
the form.
Do not fill in the fields next to the blue bar on the left side of
the form. These fields are for internal notes only and blocked.
4. Send the completed form as an Excel file by email to
rma@powerautomation.com to your local support (see
webpage).
We will check the data and send the form back to you as
ð
a PDF file including an RMA number or tell you what
information is missing if necessary.
5. Print the RMA form and add it to the accompanying components and documents.
6. After the check and repair the components will be shipped to
you immediately.
24.09.2015 | 98
RMA Form
PA 8000 EL CNC control unit
Service and return process
Fig. 48: RMA Form
24.09.2015 | 99
Return
PA 8000 EL CNC control unit
Service and return process
1. Pack the goods properly.
Controls must be packed in original or equivalent packaging.
If the packaging is not proper, Power Automation will charge
a packaging flat rate.
NOTICE!
Damages due to inadequate packaging
Inadequate packaging may result in damages to
the control unit. This will void the material warranty. PA does not bear any liabilities for damages in transit.
2. Write the RMA number on the cardboard box clearly readable from outside.
The incoming goods department rejects all deliveries
without a visible, valid RMA number.
3. Ship the goods FREE DOMICILE / DDU. Other deliveries will
be rejected.
Conditions Of Supply
Training Courses
The goods have to arrive within 4 weeks after the date of the
approved RMA form.
9.4 Training
Having the best CNCs is one thing, to bring out the best of it is the
other.
The PA training program comprises of a number of individually
combinable training modules which offer you a well-founded knowledge for using PA CNCs. At our training centers we bring your
employees - beginners and experts- up to scratch in CNC technology. We also offer individual training courses at your site. The
contents of the courses will be customized to your requirements.
For more information see Ä Chapter 9.1.1 “Service addresses”
on page 95.
24.09.2015 | 100
Loading...