Installaon instrucons
PA 9000
Micro CNC control
Power Automation GmbH
CNC-Automatisierungstechnik
Gottlieb-Daimler-Str. 17/2
74385 Pleidelsheim
Germany
Telephone: +49-7144-899-0
Fax: +49-7144-899-299
E-mail: info@powerautomation.com
Internet: www.powerautomation.com
Original installation instructions
Variante: PA 9000 MC2 BAS / PA 9000E MC2 BAS
Version 2.0
© 2018 Power Automation GmbH
2 12.06.2018
PA 9000 Micro CNC control
Table of contents
Table of contents
1 General information............................................................. 5
1.1 Information on this manual.......................................... 5
1.2 Explanation of symbols................................................ 5
1.3 EtherCAT trademark.................................................... 7
1.4 Limitation of liability...................................................... 7
1.5 Copyright..................................................................... 7
1.6 Warranty terms............................................................ 8
1.7 Customer service......................................................... 8
2 Safety.................................................................................... 9
2.1 Customer's responsibility............................................. 9
2.2 Personnel requirements............................................. 10
2.2.1 Qualifications........................................................... 10
2.2.2 Unauthorized persons............................................. 11
2.3 Intended use.............................................................. 11
2.4 Unintended use.......................................................... 12
2.5 Personal protective gear............................................ 12
2.6 Specific dangers........................................................ 13
2.7 Safety devices........................................................... 15
2.8 Machine safety........................................................... 15
2.9 Conduct in a dangerous situation and in case of
accidents.................................................................... 15
2.10 Data safety................................................................. 16
2.10.1 File backup.............................................................. 16
2.10.2 System protection................................................... 17
2.10.3 PA Recovery Stick................................................... 18
2.11 Environmental protection........................................... 19
2.12 Labels........................................................................ 19
3 Design and function.......................................................... 23
3.1 Overview.................................................................... 23
3.2 Brief description......................................................... 23
3.3 EtherCATâ interface.................................................. 24
3.4 PC connectors........................................................... 26
3.5 (X20) PA USB software dongle connector................. 34
3.6 EtherCATâ-interface (PASIO).................................... 35
4 Technical data.................................................................... 37
4.1 General specifications............................................... 37
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Table of contents
4.2 Connection values..................................................... 37
4.3 Operating conditions.................................................. 38
4.4 Dimension sheet........................................................ 39
4.5 Electromagnetic compatibility.................................... 39
4.6 Installation guidelines................................................ 40
5 Installation.......................................................................... 43
5.1 Prerequisites and preparations.................................. 43
5.1.1 General requirements............................................. 43
5.1.2 Electrical cabinet structural requirements............... 44
5.1.3 Cabinet temperature............................................... 44
5.2 Mounting the control unit in a cabinet........................ 45
6 Transport, packaging and storage................................... 49
6.1 Transport................................................................... 49
6.2 Packaging.................................................................. 49
6.3 Storage...................................................................... 51
7 Maintenance....................................................................... 53
7.1 Safety notes............................................................... 53
7.2 Maintenance schedule............................................... 53
7.3 Measures after maintenance..................................... 54
8 Troubleshooting................................................................. 55
8.1 Safety notes............................................................... 55
8.2 Troubleshooting chart................................................ 56
9 Service and return process............................................... 59
9.1 Service....................................................................... 59
9.1.1 Service addresses................................................... 60
9.2 Spare parts................................................................ 61
9.3 Return policy and procedure...................................... 62
9.4 Training...................................................................... 64
10 Dismounting and decommissioning................................ 65
11 EC Declaration of Conformity........................................... 67
12 Proof of change.................................................................. 69
13 Glossary.............................................................................. 71
14 Index.................................................................................... 73
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PA 9000 Micro CNC control
General informaon
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.
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PA 9000 Micro CNC control
NOTICE!
… indicates a potentially hazardous situation
which, if unavoidable, may result in property
damage.
… emphasizes useful hints and recommendations
as well as information for efficient and trouble-free
operation.
General informaon
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 6.. Highlights
cross-references to chapters or sections of this manual.
[Key].. Highlights captions of buttons, fields and other elements of
the software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or
submenu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts
from configuration files.
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PA 9000 Micro CNC control
General informaon
1.3 EtherCAT trademark
EtherCATâ is a registered trademark and patented technology,
lisensed by Beckhoff Automation GmbH, Germany.
Liability
Fig. 1: EtherCAT
â
Branding logo
1.4 Limitation of liability
All information and notes in this installation manual were compiled
under due consideration of valid standards and regulations, the
present status of technology and our years of knowledge and
experience.
Power Automation can not be held liable for damage resulting
from:
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
1.5 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.
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PA 9000 Micro CNC control
General informaon
Violations oblige to compensation. The right for further claims
remains reserved.
1.6 Warranty terms
Material Warranty
Service
The material warranty terms are provided in Power Automation's
terms and conditions as well as inside the sales documents.
1.7 Customer service
Our Customer Service is always available for technical information.
For information on whom to contact by phone, fax, e-mail or via the
internet, see Power Automation's address on page 2.
Additionally, Power Automation staff is always interested in
receiving new information and experiences resulting from the use
of our products, which could be of great value for future improvements.
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PA 9000 Micro CNC control
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.
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PA 9000 Micro CNC control
Safety
2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Danger of injury in case of insufficient qualifi-
cation!
Improper operation can lead to severe personal
injuries and/or material damage.
– Only those persons who have been specified in
the corresponding chapters of this installation
manual should be entrusted with the listed
types of work.
– Employ certified experts, if in doubt.
The following qualifications are specified for different areas of
activity listed in the installation manual.
Instructed person
was instructed by the operating company about the duties
assigned to her/him and the possible dangers that may arise from
inappropriate conduct.
Qualified personnel
are able to carry out assigned work and to recognize possible 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.
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PA 9000 Micro CNC control
Safety
2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons, who do not meet the
requirements described in this installation manual,
are not aware of the dangers in the working area.
– Keep unauthorized persons away from the
working area.
– If in doubt, address such persons and ask
them to leave the working area.
– Interrupt your work as long as unauthorized
persons are in the working area.
Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is
impaired, e.g. through drugs, alcohol or medication are not permitted.
Intended Use
Dangers
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
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.
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Unintended Use
PA 9000 Micro CNC control
Safety
The operator is solely responsible for all damage resulting from
unintended use.
2.4 Unintended use
WARNING!
Beware of unintended use!
– In particular, avoid using the control unit for the
following 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.
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PA 9000 Micro CNC control
Safety
ESD safety shoes
for protection of components susceptible to electrostatic discharge.
Wear the ESD safety shoes to protect electrostatic-discharge-sensitive devices due to inadequate derivative electrostatic energy.
Ear protection
for protection of the ears during the work. Wear the ear protection
always until the work is finished.
Ground strap
for protection of components susceptible to electrostatic discharge.
Wear the ground strap on your wrist and connect it to a suitable
equipotential bonding.
Protective glasses
for protection of the eyes during the work. Always wear the protective glasses until the work is finished.
2.6 Specific dangers
The following section lists the residual risks.
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.
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PA 9000 Micro CNC control
Safety
DANGER!
Uncontrolled operation due to improper instal-
lation and configuration!
The control unit's safety relay must be properly
integrated into the CNC machine emergency stop
chain. Improper wiring and configuration of the
safety relay may result in uncontrolled operation of
the CNC machine and in consequence may lead to
irreversible personal injuries or death.
n Only operate the CNC machine when the safety relay has been
properly integrated into the machine emergency stop chain.
Ä
n Only let qualified personnel (
on page 10) 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.
Chapter 2.2.1 “Qualifications”
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.
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 8.2 “Troubleshooting
chart” on page 56.
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Safety
Superior Control Units
PA 9000 Micro CNC control
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 CNC control
unit are fully functional and perform as intended.
n Never disable safety devices.
n Heed regulations concerning hardwiring of safety circuits.
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.
Software
Further Applicable Documents
Preventive Measures
Data safety
For information on data safety see Ä Chapter 2.10
“Data safety” on page 16.
2.8 Machine 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.
2.9 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.
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PA 9000 Micro CNC control
Safety
In Case Of Accidents
General Information
n Disconnect power supply immediately.
n Initiate first aid measures.
n Inform responsible persons at the site.
n Call for rescue service if applicable.
2.10 Data safety
To ensure the ability to restore critical data in case of control unit or
storage malfunctions, internal and external (off-site) backup copies
of all files that are critical to proper machine function must be 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.
Initial State
Instructions
n Pay attention to all instructions regarding data safety as given
in this and the other installation manuals provided by Power
Automation.
2.10.1 File backup
A backup solution is preinstalled and configured.
It is neccessary to select and activate the backup-function inside
the CNC.
Personnel:
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 59).
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
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Initial State
PA 9000 Micro CNC control
Safety
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.
To protect the system against virus attacs or other system failures,
it is recommended to take the following measures:
n Either don't connect the CNC to the Internet or assure it is con-
nected 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. 2.
Fig. 2: Start of the FBWF interface
Click on the little lock and the FBWF interface shows up the folling
window (Fig. 3).
After delivery, the FBWF is in state "enabled". You must put it into
the state "disabled" if you want to install further software on the
system partition, or if you need to do other modifications there.
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PA 9000 Micro CNC control
Safety
Fig. 3: Overview FBWF interface
2.10.3 PA Recovery Stick
For various reasons it may become necessary to re-install or to
repair the operating system (Windows 7 Embedded) of the control
unit. Power Automation offers a Recovery Stick which is necessary
for re-installation or repair. for more information about this
Recovery Stick please look into the PA Accessories Manual.
The PA Recovery Stick is an All-in-One Solution for checking,
testing and most of all recovering and restoring the PA 8000 / PA
9000 control. The main feature of the PA Recovery Stick is to give
the user the ability to recover and restore the complete HDD of his
PA 8000 / 9000 control if somehow a data loss or a system crash
has occurred. It also gives the user the opportunity to perform an
Antivirus scan if an infection is suspected. Also located on the PA
Recovery Stick are other helpful tools like a RAM test. The following manual will show what the various possibilities of the PA
Recovery Stick are.
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PA 9000 Micro CNC control
Safety
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
Electronic Components
Batteries contain toxic heavy metals. They are considered hazardous waste and must be disposed of by approved specialized
waste disposal companies.
Electronic components are considered special waste. They must
be properly disposed of.
Power Automation will accept the control unit to properly dispose of
its components upon decommissioning.
n Follow the standard return procedure, as described in
Ä
Chapter 9.3 “Return policy and procedure” on page 62.
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 mate-
rial warranty seals).
– Replacements can be obtained from
Power Automation.
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PA 9000 Micro CNC control
Safety
Overview
The labels listed hereunder are located at the positions shown in
Fig. 4.
Fig. 4: Label Positions
1 Material Warranty seal
2 Type Plate
3 License Operating system
Type Plate
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. 5: Type Plate (Example)
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PA 9000 Micro CNC control
Safety
Operating System Product Key
Material Warranty Seals
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
Windows-licence will be void and can not be
renewed. For this reason, the label has to be
treated carefully.
A new operating system's licence can be ordered
at Power Automation (see Ä Chapter 9 “Service
and return process” on page 59).
Fig. 6: Windows 7 for Embedded Systems operating system
license
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 exten-
sions, repairs or modifications are required
(see Ä Chapter 9 “Service and return process”
on page 59).
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PA 9000 Micro CNC control
Safety
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Top/Bottom View
PA 9000 Micro CNC control
Design and funcon
3 Design and function
3.1 Overview
Fig. 7: Top view
Model Configurations
Fig. 8: Bottom view
The PA 9000 MC2 is shipped in one model containing the following
modules and interfaces.
Model Description PC interfaces
PA 9000 MC2 BAS EtherCAT
axes only
Max. number of digital inputs with PASIO (24V) 1024
Max. number of digital outputs with PASIO (24V) 1024
Max. number of analog inputs with PASIO (0 - 10V) 64
Max. number of analog outputs with PASIO (0 - 10V) 64
â
included
3.2 Brief description
The PA9000 MC2 is an open architecture CNC control unit providing a variety of interfaces to connect machine tools. This control
unit can be extended via an EtherCATâ interface and external
input/output modules (PASIO) to connect a wide range of machine
tools.
The interfaces and modules included in this control unit upon
delivery are listed in the following chapters.
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Overview
PA 9000 Micro CNC control
Design and funcon
3.3 EtherCATâ interface
Fig. 9: EtherCAT connector position
The hardware provides a single EtherCATâ connector. This connector provides the EtherCATâ interface for communication with
EtherCATâ devices approved by Power Automation. The
EtherCATâ bus is a serial bus for full capturing of the axes position
inputs and axis command outputs.
NOTICE!
Malfunctions and damage to the control unit!
The control unit provides one EtherCATâ connector. It is located on the bottom of the control
unit and only intended for EtherCATâ connections.
Inadvertent interchanging of the connector 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.
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PA 9000 Micro CNC control
Design and funcon
Connection Requirements
EtherCATâ drives must be wired toward the control unit's
EtherCATâ connector in a daisy chain setup.
Fig. 10: Daisy chain setup
1 PA 9000 MC2 (control unit)
2 e.g. PA ETC Drive Micro
3 e.g. PASIO module
1. Connect the X23 connector of the control unit with the 'IN'
connector of the first ETC drive or PASIO module.
2. Connect additional ETC drives or PASIO modules via the 'IN'
and 'OUT' connectors to each other and to the 'OUT' connector of the first ETC drive or PASIO module as shown in
the schematic.
Further drives or I/O modules have to be connected via connector
'OUT' of the previous drive or I/O module to the connector 'IN' of
the next drive or I/O module.
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PA 9000 Micro CNC control
3.4 PC connectors
Design and funcon
Overview
The control unit provides a number of standard PC interface connectors for various input and output applications (see Fig. 11).
Fig. 11: Overview PC connectors
1 Ground (protective earth, PE)
2 Terminal block for 24 V DC power supply, 3 pin (X1)
3 DVI Connector (X4)
4 Serial COM1 port, Sub D 9 pin male (X5)
5 Serial COM2 port, Sub D 9 pin male (X6)
6 Terminal block for Power ON switch, 2 pin (Remote power on/
off)
7 Ethernet connector RJ 45
8 EtherCAT connector RJ 45 (X23)
9 USB 2.0 connector (3x)
10 USB 3.0 connector (1x)
11 Power on switch button
12 AT/ATX switch
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(X1) Terminal block for 24 V DC
power supply, 3 pin (2)
PA 9000 Micro CNC control
Design and funcon
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.
Fig. 12: Terminal block
PA 9000 MC2 BAS features a pluggable terminal block for direct
DC wiring. The 3-pin pluggable terminal block on the back panel is
fit for field usage where DC power is usually provided. It accepts a
wide range of DC power input from 9 to 48V. The screw clamping
connection of terminal block gives a very reliable way for wiring the
DC power. The following table ( Ä Table on page 27) describes the
pin definition of the pluggable terminal block.
Pin
(Fig. 12)
1 +9 - 48V IN
2 Chassis GND
3 GND
Assignment
NOTICE!
Damage to the control unit!
Supply voltages not supported can cause damage
to the control unit.
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PA 9000 Micro CNC control
Design and funcon
(X4) DVI Connector (3)
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. 13: DVI connector
Pin
(Fig. 13)
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−
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PA 9000 Micro CNC control
Design and funcon
(X5) / (X6) Serial Port Connector (4,
5)
Pin
(Fig. 13)
C1 RED
C2 GREEN
C3 BLUE
C4 SYNC
C5 GND
Fig. 14: Serial port connector (Sub-D 9)
Property Value
Pins 9
Connector type sub-D
Assignment
Gender male
Signal type RS232
Maximum cable length 15 m (49 ")
Pin
(Fig. 14)
1 DCD (input)
2 RXD (input)
3 TXD (output)
4 DTR (output)
5 GND
6 DSR (input)
7 RTS (output)
8 CTS (input)
9 RI
Assignment
12.06.2018 | 29
Terminal block for Power ON
switch, 2 pin (Remote power on/off)
(6)
PA 9000 Micro CNC control
Design and funcon
Fig. 15: Terminal block
PA 9000 MC2 BAS features a pluggable terminal block for wiring of
an external "Power ON" switch. This function is the same as with
the built-in Power ON button (Fig. 11/11). The following table
Ä
Table on page 30) describes the pin definition of the pluggable
(
terminal block.
Pin
(Fig. 15)
1 GND (could be also 0V DC of your electric cabinet)
2 PWR_ON
Assignment
NOTICE!
Damage to the control unit!
Do not apply supply voltages to this connector.
There may be only a switch connected to this connector.
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PA 9000 Micro CNC control
Design and funcon
Ethernet Connector / EtherCAT
connector (7, 8)
The Ethernet connector allow connection of the control unit to local
area networks.
Fig. 16: Ethernet connector (RJ 45)
NOTICE!
Malfunctions and damage to the control unit!
The control unit provides two RJ 45 connectors.
Both are located on the PC interface panel. The
first connector (X23) is only intended for
EtherCATâ connections. The other RJ 45 con-
nector is only intended for Ethernet connections.
Inadvertent interchanging of the two connectors
can cause control unit malfunctions and damages
to the control unit and the attached drives.
n When setting up the wiring, carefully observe the connectors'
positions given in this installation manual as well as the labels
on the control unit.
Property Value
Pins 8
Connector type RJ 45
Max length 100 m (328 ft)
Pin (Fig. 16) Ethernet 10/100 BaseT
1 TX+
2 TX-
3 RX+
4
5
6 RX-
7
8
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PA 9000 Micro CNC control
Design and funcon
USB 2.0 Connectors (9)
The USB port allows connection of USB peripherals. The control
unit includes 3 standard USB 2.0 type A ports.
Fig. 17: USB connector 2.0 (Type A)
Property Value
Pins 4
Connector type USB 2.0 Type A
Max length 5 m (16.5 ft)
Pin (Fig. 17) Assignment USB
1 VBUS
2 D-
3 D+
4 GND
Shell Shield
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PA 9000 Micro CNC control
Design and funcon
USB 3.0 Connectors (10)
The USB ports allow connection of USB peripherals. The control
unit includes 1 standard USB 3.0 type A port.
Fig. 18: USB connector 3.0 (Type A)
Property Value
Pins 4
Connector type USB 3.0 Type A
Max length 5 m (16.5 ft)
Pin (Fig. 18) Assignment USB
1 VBUS
2 D-
3 D+
4 GND
5 SSRX−
6 SSRX+
7 GND_DRAIN
8 SSTX−
9 SSTX+
Shell Shield
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AT/ATX switch (12)
PA 9000 Micro CNC control
Design and funcon
Fig. 19: AT/ATX switch
The following table ( Ä Table on page 34) describes the pin definition of the switch.
Pin
(Fig. 19)
Left ATX Power Mode (Default)
Right AT Power Mode
Assignment
The control starts after pressing the built-in Power
ON Button or an external Power ON switch applied
to the according connector.
The control starts always after the specified DC
power is applied.
3.5 (X20) PA USB software dongle connector
Fig. 20: PA USB software dongle connector
n Always use the specially marked port to connect the PA USB
software dongle.
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PA 9000 Micro CNC control
Design and funcon
3.6 EtherCATâ-interface (PASIO)
Overview
Cable Specification
The control unit's interfaces are extendable via the EtherCAT
interface. A variety of I/O and axes extension modules (PASIO)
can be connected to the connector.
Fig. 21: EtherCATÓ connector
For further information see the PA Accessories installation manual.
The interface cable required to connect PASIO modules can be
ordered from Power Automation.
NOTICE!
All cables connected to the control unit are
intended for stationary use only.
â
The cable shield is connected to both connector
casings.
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PA 9000 Micro CNC control
Design and funcon
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PA 9000 Micro CNC control
4 Technical data
4.1 General specifications
Technical data
General Information
Electrical
Property Value Unit
Dimensions
(WxDxH)
Weight 0.86 kg
179 x 105 x 56.02 mm
7.05 x 4.13 x 2.21 inch
1.896 lb
4.2 Connection values
Property Value Unit
Input voltage 9 - 48 V DC
Maximum current 1.7 A
Maximum power consumption 15 W
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PA 9000 Micro CNC control
4.3 Operating conditions
Technical data
General
Property Value Unit
Operating temperature 0 - +45 °C
+32 - +113 °F
Storage temperature -40 - +80 °C
+25 - +176 °F
Temperature gradient (within 10
minutes)
Relative humidity (non-condensing) 10 - 95 %
Maximum acceleration (non-operating) 5.0 G
Maximum acceleration (operating) 5.0 G
Protection class (EN 60529) IP20
EMC (EN 55022) / (EN 55024) A
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 44).
10 °C
50 °F
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PA 9000 Micro CNC control
4.4 Dimension sheet
Technical data
Fig. 22: dimension sheet
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 55022:2010 Limits [...] of radio disturbance charac-
EN 61000-6-3:2006 +
A1:2009 + A2:2009
Electrical equipment of machines all met -
interfering field strength class B
teristics
Generic standards - Emission standard
for residential, commercial and lightindustrial environments
emitted interference class B
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PA 9000 Micro CNC control
Technical data
Interference Resistance
Standard Title Requirement Value
EN 61000-4-2 [...] Electrostatic discharge immunity
[...]
EN 61000-4-3 + A1 +A2[...] 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
EN 61000-3-2: 2006 +
A1:2009 + A2:2009
[...] Limits for harmonic current emissions
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
all met -
10 V
EN 61000-3-3:2008
Measurement
Standard Title Requirement Value
EN 55024:2010 [...] Limits and methods of measure-
ment
all met -
4.6 Installation guidelines
Meaning Of EMC
Electromagnetic compatibility (EMC) refers to the ability of an electrical device to work flawlessly in an electromagnetic environment
without generating or being susceptible to disturbances. All PA
Control units are designed for use in industrial environments and
meet high EMC specifications.
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PA 9000 Micro CNC control
Technical data
Important Rules For EMC
Cabling
n The cabling must be in line groups (high voltage, current
supply, signal and data lines)
n High voltage lines and signal respectively data lines must be
laid in separate channels or bundles
n The signal and data lines have to be routed as near as pos-
sible beside ground areas
Reference potential and ground of all electrical operating supplies
n Installation parts and cabinets with your CNC control unit have
to be connected in star topology with the isolation/protected
ground conductor system to avoid ground loops.
n Sufficiently dimensioned potential compensation lines have to
be laid if there are potential differences between installation
parts and cabinets
Area-wide grounding of the inactive metal parts
n A central connection between the ground and the protected
ground conductor system have to be installed.
n All inactive metals have to be connected extensively and impe-
dance-low.
Fixing of the cable shield
n Data cables and analog cables must be laid separately from
each other.
n The cable shield has to be laid extensively on a protected
ground conductor rail directly after the cabinet entry and the fixation of the shield with cable clamps.
n The isolation / protected ground rail has to be connected impe-
dance-low with the cabinet.
n The metallic or metallized plug cases for shielded cables must
be used.
n When transmitting signals with small amplitudes the one sided
grounding of the cable shield may be favorable.
Possible Interference
Electromagnetic interferences may interfere with the control unit:
n Electromagnetic fields (RF coupling)
n Magnetic fields with power frequency
n Power supply
n Protected ground conductor
n Superbus system
Depending on the spreading medium and the distance to the interference cause, interferences to the control unit occur by means of
capacitive, galvanic, inductive or radiant coupling mechanisms.
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PA 9000 Micro CNC control
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 fre-
quency range. The cable shield can be connected to single-
sided grounding in exceptional cases, but if that is done, only
lower frequencies will be absorped.
A single-sided ground connection of the cable shield may be
convenient, if:
– the conduction of a potential compensating line is not pos-
sible
– analog signals (some mV respectively 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 / PASIO 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.
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Safety
PA 9000 Micro CNC control
Installaon
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 condi-
tion requirements are met.
For further information see
Ä
Chapter 4.3 “Operating conditions”
on page 38.
– Ensure that the operating conditions require-
ments 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.
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PA 9000 Micro CNC control
Installaon
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
shield-screen at the cable inlet into the electrical
cabinet.
IP 54
Standards defined in DIN 41494
("Equipment practices for electronic
equipment; mechanical structures of
the 482.6 mm (19 inch) series;
dimensions of electrical cabinets
and suites of racks")
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 sta-
tion's heat dissipation into consideration.
– Ensure an adequate cooling using fans or air
conditioning.
12.06.2018 | 44
Mounting Orientation
PA 9000 Micro CNC control
Installaon
5.2 Mounting the control unit in a cabinet
Fig. 23: Mounting orientation
n Always mount the control unit as shown in Fig. 23.
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PA 9000 Micro CNC control
Installaon
Spacing
n Ensure that there is clearance of at least 20 mm (0.8 inches) to
allow adequate air circulation.
Fig. 24: Front spacing
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PA 9000 Micro CNC control
Installaon
Top / Bottom Spacing
All PC connectors (PS2, VGA, USB, etc.) are located on the top
and bottom side.
n Ensure that there is clearance of at least 80 mm (3.15 inches)
to allow accessibility to the connectors.
The PC connectors are shown as examples, and can vary from
case to case.
n Ensure, that there is clearance of 80 mm (3.15 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.
Fig. 25: Top/bottom spacing
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PA 9000 Micro CNC control
Installaon
Service access
For service or maintenance purposes access to
the control unit may be necessary.
n Install the control unit and adjacent components in a way that
allows for access to all mounting points, cables etc. by service
personnel.
EMC Shield
RF Noise Suppression
Electrical noise may influence the control unit's operation.
n Locate the control unit at least 300 mm (12 inches) from areas
which may transmit electrical noise.
Electrical noise may be caused by components such as e.g.
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.
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.
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PA 9000 Micro CNC control
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.
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PA 9000 Micro CNC control
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.
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PA 9000 Micro CNC control
6.3 Storage
Transport, packaging and 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 37).
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PA 9000 Micro CNC control
Transport, packaging and storage
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PA 9000 Micro CNC control
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 suffi-
cient 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 59).
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PA 9000 Micro CNC control
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 54.
Make a backup of the data.
n For the exact procedure to make the backups see Ä Chapter
2.10 “Data safety” on page 16.
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.
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PA 9000 Micro CNC control
8 Troubleshooting
Troubleshoong
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 59).
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 62.
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.
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PA 9000 Micro CNC control
Troubleshoong
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
Notes
8.2 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 59).
– 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 62.
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General Procedure
PA 9000 Micro CNC control
Troubleshoong
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
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PA 9000 Micro CNC control
Troubleshoong
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 45).
n Ensure that the ambient tempera-
ture is within the specified limits
Ä
Chapter 4.3 “Operating condi-
(
tions” on page 38).
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 62.
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 59).
Chapter 5.2 “Mounting
Ä
Chapter 9
Skilled electrician
Skilled electrician
Instructed person
Skilled electrician
004 Missing RF
noise suppression
Undetermined
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.
Skilled electrician
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PA 9000 Micro CNC control
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.
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Service Addresses
PA 9000 Micro CNC control
Service and return process
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
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
http://www.powerautomation.info
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
9th-10th Floor, Zhongkenuo Industry Park
No. 7 Seventh Road, Tongguan Blvd
Guangming New Area
518132 ShenZhen, Guangdong
PR China
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PA 9000 Micro CNC control
Service and return process
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
ACE Automation
A-721, Twinrex B/D
Deokpungdong-ro 111-10, Hanam-si
Gyeonggi-do, 465-831
South Korea
Spare Parts
9.2 Spare parts
Due to the high quality of our products we can assure you that you
will not need this service often. Spare parts are often urgent so
Power Automation provides the relevant spare parts at the local
service centers for immediate dispatch.
Our 3 service centers in Europe, North America and Asia allow us
to deliver all needed parts typically within 24 hours.
Only trust PA's original parts - because every part passes our tight
quality checks.
We also offer consulting services to identify the most critical parts
for the machines in your production facilities. We suggest what 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.
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Policy
Acquiring RMA Number
PA 9000 Micro CNC control
Service and return process
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.
1. Contact Power Automation to receive an RMA form in Excel
format. Ä “RMA Form” on page 63
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.
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RMA Form
PA 9000 Micro CNC control
Service and return process
Fig. 26: RMA Form
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Return
PA 9000 Micro CNC control
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.
12.06.2018 | 64
Dismounting
PA 9000 Micro CNC control
Dismounng and decommissioning
10 Dismounting and decommissioning
When the control unit has reached the end of its service life it must
be dismounted and disposed of in an environmentally responsible
manner.
Personnel:
1. Ensure that the machine connected to the control unit rests in
a safe state.
2. Disable the external power supply.
3. Disconnect the power supply cable.
4. Disconnect all input, output and interface wiring.
5. Secure the control unit against unwanted movement.
6. Loosen the screws that fix the control unit inside the cabinet.
7. Dismount the control unit.
Qualified personnel
n
Decommissioning
Electronic components are considered special waste. They must
be properly disposed of.
Power Automation will accept the control unit to properly dispose of
its components upon decommissioning.
To return the control unit follow the instructions
given in Ä Chapter 9.3 “Return policy and procedure” on page 62.
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.
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PA 9000 Micro CNC control
Dismounng and decommissioning
12.06.2018 | 66
PA 9000 Micro CNC control
EC Declaraon of Conformity
11 EC Declaration of Conformity
Fig. 27: EC-Declaration of Conformity
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PA 9000 Micro CNC control
EC Declaraon of Conformity
12.06.2018 | 68
PA 9000 Micro CNC control
12 Proof of change
Proof of change
Proof Of Change
Version Change Date
1 Original version 02/08/2018
2
Chapter 1.3 "EtherCATâ trademark" included
06/12/2018
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PA 9000 Micro CNC control
Proof of change
12.06.2018 | 70
PA 9000 Micro CNC control
Glossary
13 Glossary
CNC Computerized Numerical Control
DDU Delivered Duty Unpaid
EDI EtherCAT field bus Device Interface
HMI Human Machine Interface
The graphical user interface provided by the PA software.
IPC Insulating Piercing Connector
MCP Machine Control Panel
MDI Manual Data Input
MPG Manual Pulse Generator
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
PASIO Power Automation Slot Input Output
Extendable EtherCATâ based interface allowing connection
of additional I/O modules.
PC Personal Computer
PDO Process Data Object
PLC Programmable Logic Controller
POU Program Organization Unit PLC functions, function blocks
and programs are POUs
RMS Rotating Measuring Systems (Encoder)
RXPDO Receive Process Data Object
TXPDO Transmit Process Data Object
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PA 9000 Micro CNC control
Glossary
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14 Index
PA 9000 Micro CNC control
Index
A
Acceleration ............................ 38
Air circulation ........................... 46
AT/ATX switch ........................... 34
B
Backup ................................ 16
Batteries ............................... 19
C
CNC machine ........................... 15
Connection values ........................37
Connectors
EtherCAT ......................... 24, 35
PC interfaces ......................... 26
Customer's responsibility ................... 9
D
Data safety ............................. 16
Files ................................ 16
Viruses ..............................17
Decomissioning ..........................65
Dimension sheet ......................... 39
Dismounting ............................ 65
Drive setup
EtherCAT ............................ 25
DVI ................................... 28
E
EC Declaration of Conformity ............... 67
Electrical Cabinet ........................ 44
Electrical connection ...................... 37
Electrician .............................. 10
Electronic components ................. 19, 65
EMC shield ............................. 48
Environmental hazard ..................... 19
Error .................................. 56
EtherCAT .............................. 24
EtherCAT connector ...................... 31
Ethernet ............................... 31
F
Fans .................................. 46
Filebased Write Filter (FBWF) ............... 17
Files .................................. 16
G
General specifications .....................37
H
Humidity ............................... 38
I
Installation ..............................43
Installation Guidelines ..................... 40
Instructed person ........................ 10
Intended use ............................ 11
IP protection class ........................44
L
Labels ................................. 19
Limitation of liability ........................ 7
M
Maintenance ............................ 53
Personnel ............................53
Schedule ............................ 53
Malfunction ............................. 56
Material Warranty seals ....................21
Mounting orientation ...................... 45
O
Operating conditions ...................... 38
Operating system ........................ 21
Orientation ............................. 45
P
PA Recovery Stick ........................18
PASIO ................................. 35
PC connectors .......................... 26
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PA 9000 Micro CNC control
Index
Personal protective gear ................... 12
Personnel .............................. 10
Maintenance ......................... 53
Pictures
in the manual .......................... 5
Power supply .........................27, 30
Product key (Operating System) ............. 21
Proof of change ..........................69
Q
Qualification
electrician ............................10
requirements ......................... 10
technician ............................10
Unauthorized person ................... 11
Qualified personnel ....................... 10
R
RF noise ............................... 48
RMA form .............................. 63
RMA-number ............................62
U
Unintended use ..........................12
USB ............................... 32, 33
W
Waste disposal .......................... 19
S
Safety devices ...........................15
Serial port .............................. 29
Service ................................ 59
Service access .......................... 48
Service Addresses ....................... 60
Shield ................................. 48
Spacing ................................46
Spare Parts ............................. 61
Structural requirements .................... 44
System protection ........................ 17
T
Technician .............................. 10
Temperature ......................... 38, 44
Training ................................64
Troubleshooting ......................... 56
Type Plate ..............................20
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