Installation guide

H-1000-5247-01-A

SPA2-2 servo power amplifier

© 2007 Renishaw plc. All rights reserved.

This document may not be copied or reproduced in whole or in part, or transferred to any other media or language, by any means, without the prior written permission of Renishaw.

The publication of material within this document does not imply freedom from the patent rights of Renishaw plc.

Disclaimer

Considerable effort has been made to ensure that the contents of this document are free from inaccuracies and omissions. However,

Renishaw makes no warranties with respect to the contents of this document and specifically disclaims any implied warranties.

Renishaw reserves the right to make changes to this document and to the product described herein without obligation to notify any person of such changes.

Trademarks

RENISHAW® and the probe emblem used in the RENISHAW logo are registered trademarks of Renishaw plc in the UK and other countries.

apply innovation is a trademark of Renishaw plc.

All brand names and product names used in this document are trade names, service marks, trademarks, or registered trademarks of their respective owners.

Renishaw part no: H-1000-5247-01-A

Issued: 03 2007

SPA2-2

Installation

2

FCC

FCC

Information to user (FCC section 15.105)

This equipment has been tested and found to comply with the limits for a class A digital device, pursuant to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the installation manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case you will be required to correct the interference at your expense.

Information to user (FCC section 15.21)

The user is cautioned that any changes or modifications not expressly approved by Renishaw PLC or authorised representative could void the user’s authority to operate the equipment.

EC declaration of conformity

EC declaration of conformity

Renishaw plc declare that the product: -

Name Description

SPA2-2

Servo power amplifier has been manufactured in conformity with the following standards: -

BS EN 61326:1998/ inc. amendments

A1:1998/A2:2001/

A3:2003

Electrical equipment for measurement, control and laboratory use - EMC requirements.

Immunity to annex A - industrial locations.

Emissions to class A (non-domestic) limits.

BS EN 61010-1:2001 Safety requirements for electrical equipment for measurement, control and laboratory use.

Part 1: General requirements.

BS EN 60204-1:2006 Safety of machinery - Electrical equipment of machines -

Part 1: General requirements and that it complies with the requirements of directives (as amended): -

89/336/EEC - Electromagnetic compatibility (EMC)

3

The above information is summarised from the full EC declaration of conformity. A copy is available from

Renishaw on request.

4

Care of equipment

Renishaw probes and associated systems are precision tools used for obtaining precise measurements and must therefore be treated with care.

Remove dust from the external surfaces with a clean, dry cloth as the unit is not sealed against fluids / water.

Changes to Renishaw products

Renishaw reserves the right to improve, change or modify its hardware or software without incurring any obligations to make changes to Renishaw equipment previously sold.

Warranty

Renishaw plc warrants its equipment for a limited period (as set out in our Standard Terms and Conditions of Sale) provided that it is installed exactly as defined in associated Renishaw documentation.

Prior consent must be obtained from Renishaw if non-Renishaw equipment (e.g. interfaces and/or cabling) is to be used or substituted. Failure to comply with this will invalidate the Renishaw warranty.

Claims under warranty must be made from authorised service centres only, which may be advised by the supplier or distributor.

Machine safety

!

movement. The user is advised to isolate the machine from the electricity supply, compressed air or other energy sources in accordance with the machine manufacturer's instructions before entering the danger zone or performing any maintenance operations.

If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

References and associated documents

References and associated documents

It is recommended that the following documentation is referred to when installing the SPA2-2.

Renishaw documents

Documentation supplied on Renishaw UCC software CD.

Document number Title

H-1000-5223

H-1000-5057

H-1000-5058

H-1000-5067

H-1000-5109

H-1000-5246

UCC2

controller installation guide

UCC controller programmer’s guide

RENICIS user’s guide

MCU installation and user’s guide

UCClite

installation guide

Digital SPA tuning guide

External documents

National and international standards including the following may be applicable to the finished machine or installation:

BS EN ISO 12100-2:2003 (Safety of machinery - Basic concepts, general principles for design - Part 2:

Technical principles and specifications.

BS EN (IEC) 60204-1:2006 (Safety of machinery - Electrical equipment of machines -

Part 1: General requirements).

5

6

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Contents

7

Contents

1 System description ............................................................................................................................. 9

1.1

Electrical requirements............................................................................................................. 9

1.2

Environmental requirements .................................................................................................. 10

1.3

Output specification................................................................................................................ 11

1.4

SPA2-2 system components.................................................................................................. 11

1.4.1

SPA2-2 DC motor kits...................................................................................................11

1.4.2

SPA2-2 DC motor connector kit....................................................................................12

1.4.3

SPA2-2 4 th

axis interface card kit..................................................................................12

1.4.4

Dual SPA2-2 integration kit...........................................................................................12

1.4.5

SPA2-2 DC connector kit ..............................................................................................12

1.4.6

SPA2-2 and UCC2 system layout.................................................................................13

1.4.7

SPA2-2 and UCClite .....................................................................................................13

2 Front panel description ..................................................................................................................... 14

2.1

Axes status LEDs................................................................................................................... 14

2.1.1

LED positions and axis link 3 axis / 6 axis ....................................................................14

2.2

ESTOP LED ........................................................................................................................... 14

2.3

Air cooling fan inlet................................................................................................................. 14

3 Rear panel description...................................................................................................................... 15

3.1

Rear panel – 3 axis system.................................................................................................... 15

3.2

Rear panel – 6 axis system.................................................................................................... 16

3.3

Connections ........................................................................................................................... 16

3.3.1

Encoder connectors ......................................................................................................16

3.3.2

Motor connector ............................................................................................................17

3.3.3

UCC2 emergency stop connection ...............................................................................17

3.3.4

SPA, -A, -B, -C, -D connections....................................................................................17

3.3.5

External emergency stop connection............................................................................18

3.4

Motor connectors ................................................................................................................... 19

3.4.1

DC motor connection card termination .........................................................................19

3.4.2

Additional axis interface card termination .....................................................................20

3.5

Encoder interface ................................................................................................................... 21

4 Hardware configuration of the SPA2-2............................................................................................. 22

4.1

Fitting a motor connection card.............................................................................................. 22

4.1.1

Recommended procedure to install the motor connection cards..................................22

4.2

Fitting the 4 th

axis option card ................................................................................................ 23

4.2.1

Recommended procedure to install the 4 th

axis interface card .....................................23

4.3

Fitting the REVO™ connector card........................................................................................ 24

4.4

Mounting the SPA2-2 ............................................................................................................. 25

8

Contents

4.4.1

Stand alone mounting .................................................................................................. 25

4.4.2

Mounting in a 19” rack.................................................................................................. 26

5 System installation............................................................................................................................ 27

5.1

General................................................................................................................................... 27

5.2

Testing and verification .......................................................................................................... 27

5.3

Cable preparation................................................................................................................... 27

5.3.1

ESTOP / Reset ............................................................................................................ 28

5.3.2

Axis motors .................................................................................................................. 28

5.4

Replacing an SPA2-2 unit ...................................................................................................... 29

6 Interconnection schemes.................................................................................................................. 31

6.1

UCC2 DC motor and tacho connection .................................................................................. 31

6.2

UCClite DC motor and tacho connection ............................................................................... 32

6.3

Dual SPA2-2 DC motor and tacho configuration.................................................................... 33

6.4

Preparation of integration kits................................................................................................. 34

6.4.1

Motor connectors ......................................................................................................... 34

6.4.2

Emergency stop and reset switch ................................................................................ 35

7 Revision history ................................................................................................................................ 36

System description

9

The SPA2-2 is a digital servo power amplifier solution designed specifically for use with the Renishaw

UCC2

or UCClite controller.

The SPA2-2 is capable of controlling up to seven axes of movement but is customer configurable to the requirements of the installation.

The features offered by the SPA2-2 are:

•

Two base units

•

SPA2-2

3-axis: This is the basic 3-axis configuration suitable for conventional CMMs fitted with brushed dc motors. It can accommodate tacho, tacholess and encoder velocity feedback systems. An additional card can be fitted to extend this unit to a 4-axis system.

•

SPA2-2

6-axis: This configuration is suitable for installations requiring between 5 or 6 axis amplifiers. Like the 3-axis version it can accommodate tacho, tacholess and encoder velocity feedback systems. An additional axis card can be fitted to extend this unit to a 7-axis system.

• Two

units can be combined in a single system permitting a servo power amplifier solution with an overall power rating of 1100 W.

•

Configurable motor voltage

•

• The

motor voltage can be configured by software to support a wide range of motor voltages within the range of 12 V and 60 V. The current limit can also be configured up to a maximum of 5 A continuous, 10 A peak.

•

The voltage setting of each axis is independent and therefore it is possible to have each machine motor driven by a different voltage.

DC analogue tacho, tacholess or encoder compatibility

• The

or UCClite and SPA2-2 control solution has the ability to support different types of velocity control loop based on the feedback to the controller.

•

Three control loop feedback methods are integrated into the standard design of the system, these are analogue tacho based feedback system from the motor, obtaining the feedback from the scales of the CMM or from a motor mounted encoder system.

NOTE:

The UCClite product only permits 3-axis of machine control.

1.1 Electrical requirements

The SPA2-2 is powered from the a.c. mains supply via a connector to IEC 60320/C14. The electrical ratings of the unit are as follows:

100 – 240 V ac +10%, -15% 47 – 63 Hz 750 W maximum

This equipment must be connected to a protective earth conductor via a three core mains (line) cable. The mains plug shall be inserted only into a socket outlet provided with a protective earth contact. The protective earth contact shall not be negated by the use of an extension cable without protective conductor.

10

System description

!

Make sure that the grounding requirements are strictly observed.

NOTE:

An earth stud (M5 thread) is provided to allow bonding of the CMM metal parts to the protective earth. When the SPA2-2 is used with the UCC2 or UCClite controller the CMM frame should be bonded to both the UCC and the SPA2-2 earth studs.

The SPA2-2 is isolated from AC power by disconnecting the IEC mains connector on the rear panel. This should be sited within easy reach of the CMM operator. If any additional means of isolation is required, it must be specified and fitted by the machine manufacturer or the installer of the product. The disconnection device must meet the requirements of IEC 61010-1 and any national wiring regulations applicable in the country of installation.

The use of a suitable RCD (residual current device), for automatic disconnection in the event of an insulation failure, is recommended. The protection device must meet the requirements of IEC 61010-1 and any national wiring regulations applicable in the country of installation.

The installer must ensure that adequate mains over-current protection is provided for the controller equipment (UCC and SPA). See the electrical requirements sections of the appropriate installation guides. This must be in accordance with any national wiring regulations applicable in the country of installation.

1.2 Environmental requirements

Indoor use

IP20 (no protection against water)*

Altitude

up to 2000 m

Operating temperature

0 °C to +50 °C

Storage temperature

-25 °C to +70 °C

Relative humidity

80% maximum (non-condensing) for temperatures up to +31 °C.

Linear decrease to 50% at +40 °C

Transient overvoltages

Installation category II

Pollution degree

2

Maximum weight

9.48Kg (20.9 lb) (7-axis system)

*NOTE:

If a higher IP rating is required an additional external enclosure will be required to house the

SPA2-2

. This enclosure must enable the internal ambient temperature to remain within the SPA2-2 operating temperature range.

System description

11

1.3 Output specification

The SPA2-2 has the following electrical output specification:

Motor output voltage range

Maximum peak current output per channel

(peak current for ≤50 s at a duty cycle of ≤20%)

12 V to 60 V

10 A

Maximum continuous current output per channel

(operating )

5 A

Maximum output wattage of whole SPA2-2

Emergency stop system specification

550 W

Category 2 to EN 954-1:1996

(ISO 13849-1:1999) (refer to section 6.4.2)

1.4 SPA2-2 system components

The SPA2-2 range of products is capable of being configured to enable support of a wide range of motor and tacho feedback giving compatibility with most machine constructions.

Part number Description

Number of axis supported

Refer to

A-5402-8302

SPA2-2

3-axis DC motor kit

A-5402-8622

SPA2-2

6-axis DC motor kit

A-5402-8612

SPA2-2 REVO

™ kit

A-5402-3580

SPA2-2

DC motor connector kit

A-5402-8103

SPA2-2

4 th

axis interface card kit

3 1.4.1

6 1.4.1

3 + REVO™

1.4.1

3 1.4.2

A-5121-0011

A-5121-0028

Dual SPA2-2 integration kit

SPA DC connector kit

1 1.4.3

6 1.4.4

3 1.4.5

1.4.1 SPA2-2 DC motor kits

These kits contain all the necessary components to connect the SPA2-2 to either the Renishaw UCC2 or

UCClite controller and to a CMM fitted with brushed DC motors with a tacho or tacholess velocity feedback system.

These kits contain the following components:

SPA2-2

3-axis DC

3-axis SPA2-2 1

6-axis SPA2-2 -

SPA2-2

6-axis DC

-

1

SPA2-2

3-axis REVO

™

-

1

DC motor connector I/F

REVO™

connector I/F

UCC2

or UCClite to SPA2-2 comms cable

Emergency stop cable

3

-

6

-

3

1

2 3 4

1 1 1

12

System description

1.4.2 SPA2-2 DC motor connector kit

This kit contains the motor output connection cards to permit three DC motors to be connected to the

SPA2-2

unit. Normally these would be supplied with the SPA unit and do not need to be ordered separately, unless you are converting an existing system.

1.4.3 SPA2-2 4

th

axis interface card kit

This kit contains the optional 4 th

axis interface card for the SPA2-2 system. This permits connection of an additional machine axis to the SPA2-2 when using the UCC2 controller.

NOTE:

Each SPA2-2 unit can only support one 4 th

axis interface card.

This kit contains the following components:

•

1 off 4 th

axis interface card

•

1 off internal connection signal loom

•

1 off internal connection power loom

•

4 th

axis hardware mounting kit

•

1 off mating motor connector for machine wiring

This cable kit is designed to permit a high power solution for CMM installations where the power capacity of a single SPA2-2 will not address the requirements for the machine.

This system enables two SPA2-2 units to be combined as a single system and configured to drive the

CMM installation. For example; if required, a single SPA2-2 can power a single axis, or if in a dual drive configuration the two dual axis motors can be supplied from separate SPA2-2 units and the other two axes to be integrated such that each SPA2-2 drives two motors.

This kit contains the following component:

• 1

UCC2

to dual SPA2-2 emergency stop connection cable

1.4.5 SPA2-2 DC connector kit

This kit has been designed to assist in the connection of either a UCC2 or UCClite and SPA2-2 to a machine installation.

This kit contains the following components:

•

3 off 7W2 motor connectors including backshells to permit connection of the motor and analogue tacho signals to the SPA2-2

•

1 off 9-way D connector including backshell to permit the connection of an external emergency stop device to the Renishaw emergency stop chain

1.4.6 SPA2-2 and UCC2 system layout

System description

13

1.4.7 SPA2-2 and UCClite

14

Front panel description

2 Front panel description

The diagram below shows the front panel of the SPA2-2:

Key:

1. Axes status LEDs

3 1 2

3. Air cooling fan inlet

2.1 Axes status LEDs

2.1.1 LED positions and axis link 3 axis / 6 axis

These LEDs indicate the status of the servo engagement within the SPA2-2 unit as shown in the table below:

Axis status LED colour

Off

Orange

Green

Red

System status

The SPA2-2 has no power being applied to the system or these axes are not fitted

The servo system is active but not engaged for this axis

The servo system is engaged for this axis

There is a fault on this axis of the system

Status 1 indicates the status of axis 0 and 1, status 2 indicates the status of axis 2 and 3 (if fitted), status 3 indicates the status of axis 4 and 5 of a 6 axis system and status 4 indicates the status of axis 6.

2.2 ESTOP LED

This red LED indicates if the emergency stop system has been activated.

2.3 Air cooling fan inlet

The SPA2-2 requires air cooling, the inlet being through this fan.

The airflow to the fan must not be obstructed. A minimum of 50 mm clearance in front of the fan is required.

Rear panel description

15

3 Rear panel description

When the SPA2-2 is delivered it will be in a configurable format and it will be necessary for the motor connection cards to be fitted by the installer prior to applying power.

3.1 Rear panel – 3 axis system

10 3

2 4 7 6 5

Key Description

Refer to section

1

2

3

Power input and ON/OFF switch

Axis 0-3 encoder tacho input connectors

Axis 3 motor input connector (optional)

Key

3.3.1 7

3.3.2 8

4

5

UCC2

and UCClite communication link connectors

Axis 2 motor input connector

3.3.4 9

3.3.2 10

9 8

Description

Axis 1 motor input connector

Axis 0 motor input connector

External emergency stop and reset connector

UCC2

and UCClite emergency stop connector

Earth stud

1

Refer to section

3.3.2

3.3.2

3.3.5

3.3.3

1.1

16

Rear panel description

3.2 Rear panel – 6 axis system

1 4

3

2 13 6

7 10 9 8

Key Description

Refer to section

1

Axis 4 - 6 encoder tacho input connector

Key

3.3.1 8

2

Axis 6 motor input connector

3.3.2 9

3

4

5

6

7

Axis 5 motor input connector

Axis 4 motor input connector

Power input and ON / OFF switch

Axis 3 motor input connector (optional)

UCC2

communication link connector

3.3.2 10

3.3.2 11

3.3.2 13

3.3.4

12 11 5

Description

Refer to section

Axis 2 motor input connector

Axis 1 motor input connector

Axis 0 motor input connector

External emergency stop and reset connector

UCC2

emergency stop connector

3.3.2

3.3.2

3.3.2

3.3.5

3.3.3

Earth stud 1.1

3.3 Connections

The encoder interfaces are a machine installer configurable option, they permit the connection of digital encoders to the SPA2-2 and UCC2 or UCClite system to provide motor feedback for inclusion into the machines control loop.

For further details on these connections please refer to section 3.5.

Rear panel description

17

These connections are used for the DC motor connector kit placement.

Axis position 3 is for the additional axis interface card that can be fitted by the machine installer to the

SPA2-2

unit.

For further details on these connections please refer to section 3.4.

3.3.3 UCC2 emergency stop connection

This 9-way D-connector links the emergency stop system between either the SPA2-2 and the UCClite or the SPA2-2 and the MCU1 joystick via the UCC2 controller, the necessary cable for this connection is supplied within the SPA2-2 kit.

3.3.4 SPA, -A, -B, -C, -D connections

These RJ45 connections permit the dedicated servo system communication link between the SPA2-2 and the UCC2 or UCClite controller for an effective control system.

NOTE:

Connections A and B are used for a three or four axis SPA2-2 system, connections C and D are only used when a six or seven axis system is contained within a single box. Refer to section 6 for further details.

18

Rear panel description

3.3.5 External emergency stop connection

This 9-pin D-type connection is designed to permit connection of external emergency stop devices to the

Renishaw controller emergency stop system.

Emergency stop devices must meet the requirements of IEC 60947-5-1 (low-voltage switchgear and controlgear – part 5-1: control circuit devices and switching elements – electromechanical control circuit devices) or UL1054 (standard for special-use switches).

The machine manufacturer or product installer must perform a risk assessment to determine the requirements for emergency stopping and emergency switching off. The SPA2-2 emergency stop safety system is designed to achieve category 2 to standard EN954-1:1996 (ISO 13849-1). The risk assessment should therefore have determined that a category 2 safety function is satisfactory.

There are three connection pins available on this connector. Please refer to the table below for their functions:

Emergency stop switches (push to break)

Pin number Function

Optional reset switch

(momentary push to make)

Any additional emergency stop component that is fitted to this connector must have the following electrical characteristics:

Emergency stop system voltage : 24 V

Emergency stop system current : 1 A

NOTE:

If the emergency stop reset function is not required then it will be necessary to connect pins 5 and

9 so that when an emergency stop is removed from the system, it will automatically reset.

If there are no additional emergency stop devices to be added to a UCC2 controller system, connect pins

6 and 7 to permit the MCU1 emergency stop switch to function. An external ESTOP must be fitted for

UCClite

.

It is strongly recommended that all connections be fitted by a competent technician or engineer and that all wires should be sleeved. See also 6.4.2.

It should not be necessary to switch off the SPA2-2 in an emergency but if a requirement is indicated by the user’s risk assessment, emergency switching off for the complete machine must be implemented externally to the SPA2-2.

Rear panel description

19

If indicated by the user’s risk assessment, a ‘manual reset’ button (refer to EN 954-1:1996 para. 5.4) should be included in the emergency stop system. A reset switch is required when there is limited visibility of the danger zone from the control position. The reset switch must be positioned outside the danger zone and in a safe position from which it may be determined that no person is within the danger zone before resetting the safety system.

3.4 Motor connectors

3.4.1 DC motor connection card termination

Each DC motor connection card presents a 7W2 connector for connection of a CMM motor to the

SPA2-2

, as shown below:

Viewed on face of plug, or rear of socket

There are seven connections available on this connector. Please refer to the table below:

Connector pin Function

A1

A2

1

2

+ve motor connection (default)

-ve motor connection (default)

+ve tacho input (default)

-ve tacho input (default)

4 -ve tacho input (linked to pin 2)

Shell Screen

The table shows the default polarity configurations for all pins

NOTE:

The motor and tacho polarities on this connector are software configured during the SPA2-2 installation process. Please refer to the Renicis user’s guide (Renishaw part number H-1000-5058) for details.

!

that the motor polarities on the dual axes are the same.

20

Rear panel description

3.4.2 Additional axis interface card termination

Viewed on face of plug, or rear of socket

The additional axis interface card presents 1 off 9W4 connector for connection of a CMM motor to the

SPA2-2

, as shown below:

There are seven connections available on this connector. Please refer to the table below:

Connector pin Function

A1

A2

+ve motor connection (default)

Reserved for future expansion

A3

A4

1

2

-ve motor connection (default)

Reserved for future expansion

+ve tacho input (default)

-ve tacho input (default)

4 -ve tacho input (linked to pin 2)

Shell Screen

The table shows the default polarity configurations for all pins

NOTE:

The motor and tacho polarities on this connector are software configured during the SPA2-2 installation process. Please refer to the Renicis user’s guide (Renishaw part number H-1000-5058) for details.

!

: Pins with the function reserved for future expansion must not be connected to any other system component

!

that the motor polarities on the dual axes are the same.

Rear panel description

21

3.5 Encoder interface

The encoder interface offers four axes of encoder input to the SPA2-2 system, each being a 15-way highdensity D-type connector, designed for digital tacho (encoder) input.

The encoder interface is designed to accept signals from an RS422 compliant encoder (maximum input frequency 20 MHz).

NOTE:

Connection to single ended encoders is not recommended.

The 5 V supply from the encoder interface has the ability to supply a maximum of 1 A per axis pair.

For connection details please refer to the table below:

Connector pin Function

2 0 V (from SPA2-2)

7

8

9

+5 V supply from SPA2-2

+5 V supply from SPA2-2

0 V (from SPA2-2)

15 0 V (from SPA2-2)

Shell Screen

22

Hardware configuration of the SPA2-2

4 Hardware configuration of the SPA2-2

!

machine to the protective ground (earthing) is the responsibility of the manufacturer or equipment installer.

Isolation: is isolated by removing the mains connector. It is the responsibility of the equipment installer or user to fit additional means of isolation if indicated by risk assessment.

Earth fault/residual current protection: It is the responsibility of the machine manufacturer or product installer to ensure an adequate level of protection for the complete machine installation.

4.1 Fitting a motor connection card

When the SPA2-2 kit is ordered, the appropriate quantity and type of motor connector cards for that kit will be supplied with the SPA2-2. The following section details the installation procedure for these cards.

4.1.1 Recommended procedure to install the motor connection cards

NOTE:

It is assumed that this is the first installation process and that no mains supply is connected to the unit.

the from its transit packaging. the on a firm flat surface, with the front of the unit placed on the surface and the rear of the unit in the upward direction.

3. Remove only the necessary connector protection covers from the rear of the SPA2-2. These are retained by spring clips and can be simply pulled out using the hole in the centre.

4. Remove a motor connection card from its packaging.

5. Align the motor connection card with the necessary axis connection position on the rear of the SPA2-2 and press the connector firmly into position (see following diagram).

!

CAUTION:

It is essential that each axis connector location should have either a connector blanking plate or a motor connector in place before the SPA2-2 is powered up.

NOTE:

The motor connection card must be inserted into the SPA2-2 until its mounting plate is in contact with the rear panel of the SPA2-2.

Hardware configuration of the SPA2-2

23

6. Using the screws provided with the kit, fix the motor connection card to the SPA2-2 rear panel.

7. Repeat steps 3 through 6 until all required motor connections are fitted to the SPA2-2.

8. If a 4th axis interface card is to be fitted please proceed to section 4.2, or if a REVO™ interface card is to be fitted then proceed to section 4.3. Otherwise the unit can now be installed.

4.2 Fitting the 4

th

axis option card

If the 4 th

axis interface card has been purchased with the SPA2-2 the recommended procedure for installation of this card follows.

4.2.1 Recommended procedure to install the 4

th

axis interface card

the on a firm flat surface, with the base of the unit placed on the surface and the rear of the unit facing towards you.

2. Remove the four plastic bungs from the front of the side panels.

3. Remove the top panel of the SPA2-2 enclosure by removing the three lid screws at the top of the rear panel and then lever the rear of the top panel upwards by inserting a screwdriver into the semi-circular cut out in the top of the rear panel. When the top panel is clear of the rear panel pull the top panel towards you to release the front clips. The top panel can now be lifted off. Retain the fixings.

4. Remove the necessary connector protection cover from the rear of the SPA2-2, this is retained by a spring and can simply be pushed out.

5. Remove the 4th axis option card from its packaging.

6. Attach the communication and power cables that are supplied with the 4th axis option card to the motherboard, see diagram below.

NOTE:

If this interface card is being fitted to a 6-axis SPA2-2 then the communication and power cables will have already been installed on the lower motherboard. In this instance the cables supplied with the kit can be discarded.

7. Position the 4th axis interface card into the location, as shown in diagram below.

24

Hardware configuration of the SPA2-2

8. Locate the 4 th

axis interface card onto the pillar mounts using the M3 screws supplied with the kit. Do not tighten these screws yet.

9. Using the jackscrews supplied in the kit, locate the 4 th

axis interface connector through the location hole in the rear panel of the SPA2-2. Tighten these jackscrews (taking care not to overtighten) and then tighten the screws inserted in step 7.

10. Fit the communication cable attached to the SPA2-2 motherboard control electronics to the 4th axis interface card.

11. Fit the voltage supply cable loom from the SPA2-2 control electronics to the 4th axis option card, as shown in diagram below.

12. Refit the top panel by reversing the procedure given in step 3 and replacing the plastic bungs.

4.3 Fitting the REVO™ connector card

To fit the REVO™ connector card into the SPA2-2 the procedure is the same as for the motor connector card (see section 4.1) with the following exception:

The REVO™ connection is via a single connector but this takes the output of three axis channels. To avoid any misconnection the REVO™ connector card is mounted on a bracket which is fitted across all three output ports, so all three blanking plates have to be removed and the REVO™ connector card secured with the six screws provided.

Hardware configuration of the SPA2-2

25

4.4 Mounting the SPA2-2

The SPA2-2 can be installed into either a 19” rack mount system or as a stand alone unit.

The dimensions of the units are:

4.4.1 Stand alone mounting

Four self-adhesive rubber feet are supplied with the unit for stand-alone use.

26

Hardware configuration of the SPA2-2

4.4.2 Mounting in a 19” rack

To permit the SPA2-2 to be fitted into a 19” enclosure, a 3U rack mounting kit (A-1333-0029) is required.

NOTE:

The screws supplied with this kit are M5 × 6 mm countersink type. DO NOT replace with longer screws as damage could occur.

The following procedure is recommended to fit the rack mounting brackets to the SPA2-2: the on a firm flat surface, with either the left or right hand side of the unit placed on the surface and the front of the unit facing towards you.

2. Remove the blanking plugs from the side of the unit, there are two of these located about 15mm from the front lip on the enclosure and about 15 mm from the top and bottom of the enclosure.

3. Remove the 3U rack mounting kit from its packaging and place one of the countersunk screws supplied in the kit through one of the rack mounting brackets supplied.

4. Align this screw and mounting bracket assembly to the fixing holes in the side of the SPA2-2 enclosure and engage the screw into the mating thread. Do not tighten at this point

5. Align the other fixing location in the rack mounting bracket with the fixing hole in the side of the

SPA2-2

, and engage the other countersunk screw into the mating thread.

6. Tighten both countersunk screws to ensure a secure fixing. to 6. the such that the other side of the enclosure can be accessed and then repeat steps 2

Hardware configuration of the SPA2-2

27

5.1 General

The SPA2-2 system is configured by software settings stored within the unit and on the host PC. The setting of these configuration parameters is performed by the Renicis commissioning software via the

UCC2

or UCClite communication protocol.

The Renicis software contains a structured installation process to assist in the commissioning of the

SPA2-2

, please refer to the Renicis installation guide (Renishaw part number H-1000-5058) for further information.

5.2 Testing and verification

The manufacturer of the finished machine, or the installer of the SPA2-2, is responsible for ensuring that the following test and verification procedures are performed to the appropriate standards on the complete installation:

•

Verification that the electrical equipment is in compliance with the technical documentation

•

Continuity of the protective bonding circuit

•

Insulation resistance tests

•

Protection against residual voltages

•

Functional tests, particularly those related to safety

It is strongly recommended that the CMM manufacturer or retrofitter includes a periodic test of the emergency stop and, if fitted, the associated reset switch, in their maintenance instructions.

5.3 Cable preparation

The cables for connecting the UCC controller to the host PC and to a Renishaw SPA are provided with the controller and SPA kits. The OEM or retrofitter is responsible for the provision of the following cables:

•

ESTOP / Reset

•

Motor encoder (if appropriate)

NOTE:

We strongly recommend that all cables are screened with a braided screen with a minimum of

70% coverage and that the screen is connected to the connector body. Connector backshells should be metal and connected to the screen.

The following sections cover Renishaw’s recommendations.

28

System installation

5.3.1 ESTOP / Reset

The external ESTOP connector is provided to allow connection of external ESTOP switches and a reset switch (see section 3.3.5 for connection details). For the circuit the maximum voltage is 24 V dc and the maximum current is 1 Amp. The cable size will depend on its length (see the table below for our recommendations).

The current taken by the ESTOP can be up to 1A.

Maximum current

(Amps)

Maximum permitted

Volt drop

Maximum length

(metre)

Minimum

CSA (mm

2

)

Minimum diameter

(mm)

Nearest

AWG size

1 2 10 0.09 0.33 27

1 2 20 0.17 0.47 24

1 2 40 0.34 0.66 21

The axis motor connectors provide the power to the axis motors and, if appropriate, the motor tacho connections. For the SPA2-2 the maximum voltage is 60Vdc and the peak current is 10 amps. The actual peak current will be dependant on the size of motor fitted and how hard it needs to be driven, so cable sizes for 2 A, 5 A and 10 A are given in the table below.

The 3 motor connections can provide 5A continuous and 10A peak.

Maximum motor current

(Amps)

Maximum permitted

Volt drop *

Max length

(metre)

Minimum

CSA (mm

2

)

Minimum diameter

(mm)

Nearest

AWG size

2 2 10 0.17 0.47 24

2 2 20 0.34 0.66 21

2 2 40 0.69 0.94 18

5 2 10 0.43 0.74 20

5 2 20 0.86 1.05 17

5 2 40 1.72 1.48 14

10 2 10 0.86 1.05 17

10 2 20 1.72 1.48 14

10 2 40 3.44 2.09 11

*

This is just a suggested value. The machine design will determine the actual value.

Hardware configuration of the SPA2-2

29

If the axis drive motors are fitted with rotary encoders as a method of speed control then these encoders will need to be connected to the SPA2-2 Motor encoder connectors. The encoders are sensitive to supply voltage so the recommended maximum volt drop is only 0.25V.

The encoder can typically take up to 500mA.

Maximum current

(Amps)

Maximum permitted

Volt drop

Maximum length

(metre)

Minimum

CSA (mm

2

)

Minimum diameter

(mm)

Nearest

AWG size

0.5 0.25 10 0.34 0.66 21

0.5 0.25 20 0.69 0.94 18

0.5 0.25 40 1.38 1.32 15

5.4 Replacing an SPA2-2 unit

All the digital SPA units (SPA2-2, SPA2 and SPAlite) have their section of the machine .ini set up file, stored in internal memory. When changing a SPA unit on a CMM that has already been set up and tuned, it is important that the SPA configuration is uploaded to the new SPA unit using the following procedure.

•

Start the Renicis utility program.

•

Boot the UCC controller.

•

Click on the “edit configuration files” icon.

•

In the Master Configuration Dialog window, click on the “SPA Configuration” tab.

•

At the bottom of the screen (see below) click on the “update SPA2” button.

•

Click on the Exit button.

•

After exiting Renicis the controller should be reset.

30

System installation

Other differences to be aware of when changing between SPA types are:-

• The

axis card for the SPA2-2 is different from the one for the SPA2 and cannot be interchanged, i.e. the 4 th

axis card must be correct one for the SPA type (the motor connections are the same on both so there is no problems on changing between SPA2 and SPA2-2 on an installation).

•

The axis motor connectors are in a different order on the SPA2 than they are on the SPA2-2 and

SPAlite

. Looking on the back panel and reading from left to right, the axes are 0, 1, 2 on the SPA2-2 and SPAlite units, but 2, 1, 0 on the SPA2.

6.1 UCC2 DC motor and tacho connection

31

32

Interconnection schemes

6.2 UCClite DC motor and tacho connection

6.3 Dual SPA2-2 DC motor and tacho configuration

33

34

Interconnection schemes

6.4 Preparation of integration kits

The SPA2-2 integration kit will contain the necessary components required connect the SPA2-2 and either the UCC2 or UCClite controller system to a CMM installation.

NOTE:

All connectors used in the integration of the SPA2-2 to a CMM installation are widely commercially available, the connector kits are designed to ease the system integration by permitting the connectors to be purchased at the same time as the SPA2-2.

Each connector kit will contain three motor connectors which are appropriate for DC motor output from the

SPA2-2

.

NOTE:

This connector is of the solder bucket variety, it is recommended that they are fitted to the CMM wiring by a competent technician or engineer, and that sleeving is used for all connections to reduce the possibility of short circuits.

Each of the three connector assemblies consist of the following:

•

1 off metal backshell

•

1 off 7W2 power and signal D-type connector

•

2 off power pins

35

6.4.2 Emergency stop and reset switch

The SPA2-2 and UCC2 control system is capable of providing category 2 * emergency stop system safety level. The SPA2-2 and UCClite is capable of providing a category B emergency stop. However, this is subject to the machine manufacturers / installers method of integration and their risk assessment.

Each machine integration kit contains one 9-way D-type connector that permits the installer to add additional emergency stop devices to the emergency stop system integrated within the SPA2-2.

NOTE:

Emergency stop switches (where required by the manufacturer or installer's risk assessment) must comply with the requirements of standards UL1054/EN60947.

This connector is of the solder bucket variety. It is recommended that they are fitted to the CMM wiring by a competent technician or engineer, and that sleeving is used for all connections to reduce the possibility of short circuits.

* Category 2 to EN954-1:1996 (ISO13849-1:1999).

36

Revision history

Issue 01-A

First issue.

Renishaw plc

New Mills, Wotton-under-Edge,

Gloucestershire, GL12 8JR

United Kingdom

T

+44 (0)1453 524524

F

+44 (0)1453 524901

E

[email protected]

www.renishaw.com

For worldwide contact details, please visit our main website at www.renishaw.com/contact

*H-1000-5247-01*