Pa 8000

Installation instructions
PA 8000
PAMIO
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
Version 2.0
© 2015 Power Automation GmbH
2 12.01.2017
PA 8000 PAMIO
Table of contents
Table of contents
1 General information............................................................. 7
1.1 Information on this manual.......................................... 7
1.2 Explanation of symbols................................................ 7
1.3 Limitation of liability...................................................... 9
1.4 Copyright..................................................................... 9
1.5 Warranty terms............................................................ 9
1.6 Customer service....................................................... 10
1.7 Glossary..................................................................... 10
2 Safety.................................................................................. 11
2.1 Customer's responsibility........................................... 11
2.2 Personnel requirements............................................. 12
2.2.1 Qualifications........................................................... 12
2.2.2 Unauthorized persons............................................. 12
2.3 Intended use.............................................................. 13
2.4 Unintended use.......................................................... 14
2.5 Personal protective gear............................................ 14
2.6 Specific dangers........................................................ 15
2.7 PAMIO safety devices ............................................... 16
2.8 Machine Safety.......................................................... 17
2.8.1 'CNC ready' signal - Emergency stop interlocking.. 17
2.8.2 'Power ok' signal..................................................... 18
2.8.3 Control Units and associated PAMIO 4ENC4A....... 18
2.9 Conduct in a dangerous situation and in case of
accidents.................................................................... 19
2.10 Environmental protection........................................... 19
2.11 Labels........................................................................ 20
3 Overview............................................................................. 23
4 PAMIO Components.......................................................... 25
4.1 Generality.................................................................. 25
4.1.1 General specifications............................................. 25
4.1.2 Maximum Number of PAMIO Modules.................... 25
4.1.3 PAMIO Boxes and PAMIO Modules........................ 27
4.1.4 Connection to the control unit and interconnection. 29
4.1.5 Bus termination....................................................... 30
4.2 Mechanical Installation.............................................. 30
4.2.1 Dimensions............................................................. 30
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Table of contents
4.2.1.1 PAMIO models 2416 / 4ENC4A / PWM................ 30

4.2.1.2 PAMIO Modell 2ENC4A........................................ 32
4.2.2 DIN rail installation.................................................. 33
4.2.3 Mechanical assembly.............................................. 35
4.2.4 Stopping brackets................................................... 36
4.2.5 Ventilation................................................................ 38
4.2.6 Termination plug...................................................... 39
4.2.7 Superbus cables..................................................... 41
4.2.8 Changing PAMIO modules...................................... 45
4.3 Electrical Installation.................................................. 46
4.3.1 Connection to the CNC........................................... 46
4.3.2 PAMIO On-Board Logic Power Supply................... 47
4.3.3 Protective Grounding.............................................. 50
4.3.4 Ambient Conditions................................................. 51
4.4 PAMIO 2416.............................................................. 52
4.4.1 Technical Data......................................................... 52
4.4.2 Design and Functions............................................. 53
4.4.2.1 Digital Inputs......................................................... 54
4.4.2.2 Digital Outputs...................................................... 57
4.4.2.3 Power Supply....................................................... 62
4.4.2.4 Status LEDs.......................................................... 64
4.5 PAMIO 4ENC4A........................................................ 64
4.5.1 Technical Data......................................................... 64
4.5.3 Axis Measurement Inputs (RMS)............................ 66
4.5.4 RMS Power Supply................................................. 72
4.5.5 Axes Analog Outputs.............................................. 73
4.5.6 Analog Inputs.......................................................... 77
4.5.7 Power Supply.......................................................... 79
4.5.8 Safety Function....................................................... 81
4.5.9 Status LEDs............................................................ 85
4.6 PAMIO PWM.............................................................. 85
4.6.1 Technical Data......................................................... 85
4.6.2.1 Digital Outputs...................................................... 87
4.6.2.2 5V to 24V signal converter................................... 90
4.6.2.3 Power Supply....................................................... 94
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Table of contents
4.6.2.4 Wiring Example.................................................... 96

4.6.2.5 Status LEDs.......................................................... 96
4.7 PAMIO 2ENC4A........................................................ 97
4.7.1 Technical Data......................................................... 97
4.7.3 Axis Measurement Inputs (RMS)............................ 99
4.7.4 RMS Power Supply............................................... 106
4.7.5 Axes Analog Outputs............................................ 107
4.7.6 Analog Inputs........................................................ 110
4.7.7 Power Supply........................................................ 113
4.7.8 Status LEDs.......................................................... 115
5 Troubleshooting............................................................... 117
5.1 Safety notes............................................................. 117
5.2 Malfunction indicators.............................................. 118
5.2.1 PAMIO 2416 LEDs................................................ 119
5.2.2 PAMIO 4ENC4A LEDs.......................................... 121
5.2.3 PAMIO PWM LEDs............................................... 124
5.2.4 PAMIO 2ENC4A LEDs.......................................... 126
6 Service and return process............................................. 129
6.1 Service..................................................................... 129
6.1.1 Service addresses................................................. 130
6.2 Spare parts.............................................................. 131
6.3 Return policy and procedure.................................... 132
6.4 Training.................................................................... 134
7 Proof of Change............................................................... 135
8 Index.................................................................................. 137
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Table of contents
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PA 8000 PAMIO
General information
1 General information
1.1 Information on this manual
General Information 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 speci-
fied safety notes and instructions is a basic requirement for safety
at work.
Moreover, the accident prevention guidelines and general safety
regulations applicable at the place of use of the control unit must
also be complied with.
Illustrations in this installation manual are intended to facilitate
basic understanding, and may differ from the actual design of the
control unit.
The enclosed manuals for the installed components apply together
with this installation manual.
1.2 Explanation of symbols

Warnings 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!
which, if unavoidable, may result in minor or mod-
erate injury.
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General information
NOTICE!
which, if unavoidable, may result in property
damage.
… emphasizes useful hints and recommendations

as well as information for efficient and trouble-free
operation.
Special Safety Notes 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.
Additional symbols and high- The following symbols and highlights are used to distinguish
lighting instructions, descriptions of results, cross-references and other ele-
ments inside this manual.
.. Highlights a step as part of a procedure of instructions.
ð .. Highlights a state or an automatic process as a result of
an instruction.
n .. Highlights single or unordered instructions and lists.

Ä “Additional symbols and highlighting” on page 8.. Highlights
cross-references to chapters or sections of this manual.
[Key].. Highlights captions of buttons, fields and other elements of
the software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or
submenu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts
from configuration files.
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PA 8000 PAMIO
General information
1.3 Limitation of liability

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 con-
tract, the general terms and conditions, and the delivery conditions
of Power Automation and the legal regulations valid at the time of
contract apply.
We reserve the right to make technical modifications in order to
improve usability.
1.4 Copyright
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 dis-
closure of the contents without the written consent of Power Auto-
mation is not permitted.
Violations oblige to compensation. The right for further claims
remains reserved.
1.5 Warranty terms

Material Warranty The material warranty terms are provided in Power Automation's
terms and conditions as well as inside the sales documents.
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General information
1.6 Customer service

Service Our Customer Service is always available for technical information.
For information on whom to contact by phone, fax, e-mail or via the
internet, see Power Automation's address on page 2.
Additionally, Power Automation staff is always interested in
receiving new information and experiences resulting from the use
of our products, which could be of great value for future improve-
ments.
1.7 Glossary
CMOS - Complementary metal-oxide-semiconductor
CNC - Computerized Numerical Control
DDU - Delivered Duty Unpaid
HMI - Human Machine Interface
The graphical user interface provided by the PA soft-
ware.
IPC - Insulating Piercing Connector
MDI - Manual Data Input
MTBP - Machine Tool Builder's Panel
Panel including the basic requirements for a machine
tool operator: emergency stop push button, cycle start
and stop push buttons, jog plus and minus push but-
tons, feed rate and spindle speed override pots and a
number of auxiliary push buttons.
NC-Start - Numerical Control Start Button
NC-Stop - Numerical Control Stop Button
PA - Power Automation
PAMIO - Power Automation Modular Input Output
Extendable Superbus based interface allowing
connection of additional I/O modules.
PASIO - Power Automation Slot Input Output
Extendable EtherCATâ based interface allowing
connection of additional I/O modules.
PC - Personal Computer
PCI - Peripheral Component Interconnect
Personal computer extension for periphery devices
connected to the motherboard.
PLC - Programmable Logic Controller
POU - Program Organization Unit PLC functions, function
blocks and programs are POUs
RMS - Rotating Measuring Systems (Encoder)
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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 indus-
trial safety.
The safety, accident prevention and environmental protection regu-
lations applicable for the area of application of the machine must
be complied with, along with the safety notes specified in this
installation manual. The following applies in particular:
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 con-
verted 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, instruc-
tions 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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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.
Qualified personnel
are able to carry out assigned work and to recognize possible dan-
gers due to professional training, knowledge, and experience as
well as profound knowledge of applicable regulations.
Skilled electrician
A skilled electrician is able to carry out assigned work and to
recognize and avoid possible dangers due to professional training,
knowledge, and experience as well as profound knowledge of
applicable regulations.
The skilled electrician has been trained specially for his working
environment and he has profound knowledge of relevant standards
and regulations.
2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons, who do not meet the
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 per-
mitted.
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Safety
n When selecting personnel, ensure that the personnel can work

with the control unit in terms of technical and content aspects.
2.3 Intended use

Intended Use 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.
Dangers
WARNING!
Beware of unintended use!
Any use exceeding the scope of intended use
and/or different application of the control unit can
result in hazardous situations.
– Operate the control unit as intended only.
– Observe all instructions in this installation
manual.
– Observe the permissible ambient conditions
and electromagnetic compatibility mentioned in
the technical data.
Claims of any kind for damage resulting from unintended use are
void.
The operator is solely responsible for all damage resulting from
unintended use.
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Safety
2.4 Unintended use

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 man-
uals 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 compo-
nents.
ESD safety pad

Put the ESD safety pad on the floor before starting to work.
ESD safety shoes

Wear the ESD safety shoes to protect electrostatic-discharge-sen-
sitive devices due to inadequate derivative electrostatic energy.
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PA 8000 PAMIO
Safety
Ear protection
for protection of the ears during the work. Wear the ear protection
always until the work is finished.
Ground strap
Wear the ground strap on your wrist and connect it to a suitable
equipotential bonding.
Protective glasses
for protection of the eyes during the work. Always wear the protec-
tive glasses until the work is finished.
2.6 Specific dangers

The following section lists the residual risks.
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 compo-
nents 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.
WARNING!
Risk of injury due to improper handling of bat-
teries!
Batteries must be handled with special care.
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Safety
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.
2.7 PAMIO safety devices

Safety
DANGER!
Malfunctioning safety devices may pose a fatal
risk!
Safety devices must be intact and properly inte-
grated into the control unit and the PAMIO compo-
nents configuration in order to guarantee safety.
n Before initial commissioning of the machine, ensure that all

safety devices are fully functional and correctly installed.
n Ensure that safety related inputs/outputs of the PAMIO compo-
nents and the CNC control unit are fully functional and perform
as intended.
n Never disable safety devices.
n Heed regulations concerning hardwiring of safety circuits.
Hardware
External CNC machine
For information on required connections between
the PA PAMIO components and safety devices
integrated into the CNC machine see the docu-
mentation provided by the machine's manufacturer.
Safety connector
For information on the safety connector's purpose,
specification and wiring see Ä Chapter 4.5.8
“Safety Function” on page 81.
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PA 8000 PAMIO
Safety
2.8 Machine Safety

The PAMIO module type 4ENC4A (and only this one) provides
specific safety connectors. The following instructions apply only
when these modules are part of the PAMIO components configura-
tion.
Further Applicable Documents

For information on the machine's safety devices
and emergency stop chain see the manual pro-
vided by the CNC machine's manufacturer. The
manufacturer of the CNC machine is responsible
for the proper installation of the emergency stop.
2.8.1 'CNC ready' signal - Emergency stop inter-

locking
Personal Injury
DANGER!
Injuries due to uncontrolled operation!
An inactive 'CNC Ready' signal represents a safety
related situation. The "CNC Ready" relay is
switched off when the PA CNC control unit is in a
situation where the axes' movements are not con-
trolled.
As the axes may continue to move in an uncon-
trolled manner, the contacts of the "CNC Ready"
relay must be used to disconnect the machine's
emergency stop safety chain. All actions neces-
sary for safety must be executed in the same way
as when the Emergency Stop button is pushed.
n Properly integrate the 'CNC ready' relay into the machine's

emergency stop chain.
All safety related actions must ensure that at least all axes
movements and spindle rotation (or beam power) are stopped as
quickly as possible.
n Refer to the drive manufacturer manual, to determine the best
way of stopping movements and other dangerous power on the
machine.
n If drive capability does not exist, the use of external braking
resistors might be necessary.
Unbalanced axes have to execute with the mechanical brake.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19.
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PA 8000 PAMIO
Safety
2.8.2 'Power ok' signal

The "Power ok" relay is triggered by the hardware monitoring of the
internal supply voltages and the temperature sensor.
The "Power ok" relay is switched off when the power supplies do
not match the allowed range or the internal temperature is too high.
n Use the contacts of the "Power ok" relay to switch off the main
power supply of the control unit to avoid any unexpected dam-
ages to the control unit.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19.
– When an external 5V power supply (RMS) is

necessary to supply incremental measuring
systems, use the corresponding entry in the
control unit's drive configuration file
(DriveCfg.ini) to activate the monitoring of
the correct range of these 5 V.
When the monitoring is activated, an error on
this power supply will cause the "Power ok"
relay to drop.
2.8.3 Control Units and associated PAMIO 4ENC4A
DANGER!
Use all CNC Ready contacts!
When a Power Automation control unit is used in
association with PAMIO components of type
4ENC4A it is necessary to use both the CNC
Ready contacts of the control unit and those of
these PAMIO components in the Emergency Stop
Chain.
DANGER!
Use all Power OK contacts!
When a Power Automation control unit is used in
association with PAMIO components of type
4ENC4A it is necessary to use both the Power OK
contacts of the control unit and those of these
PAMIO components in the Emergency Stop Chain.
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PA 8000 PAMIO
Safety
2.9 Conduct in a dangerous situation and in

case of accidents
Preventive Measures 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.
In Case Of Accidents 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 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 environ-
ment.
The following environmentally hazardous components or sub-

stances are contained in the control unit:
Electronic Components Electronic components are considered special waste. They must
be properly disposed of.
Power Automation will accept the control unit to properly dispose of
its components upon decommissioning.
n Follow the standard return procedure, as described in
Ä Chapter 6.3 “Return policy and procedure” on page 132.
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Safety
2.11 Labels
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.
Label - Overview
Fig. 1: PAMIO box labels

The following labels are attached on the back of each PAMIO
box:
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Safety
Fig. 2: PAMIO article label

This label shows the model of the PAMIO box (type code) and its
article number (Fig. 2).
Fig. 3: PAMIO ArtNo+SNo label

This label shows the serial number of the PAMIO box (Fig. 3).
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Safety
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PA 8000 PAMIO
Overview
3 Overview
Table 1: The following products belong to the PA PAMIO-Accessories:
Product Code Description See
PAMIO module boxes PAMIO 2416 PAMIO module box Ä “PAMIO Combi-
2416 / faceplate nations” on page 27
PAMIO 4ENC4A PAMIO module box Ä “PAMIO Combi-
4ENC4A / faceplate nations” on page 27
PAMIO PWM PAMIO module box Ä “PAMIO Combi-
PWM / faceplate nations” on page 27
PAMIO 2416-2416 PAMIO module box Ä “PAMIO Combi-
2416 / 2416 nations” on page 27
PAMIO PAMIO module box Ä “PAMIO Combi-
4ENC-4ENC 4ENC4A / 4ENC4A nations” on page 27
PAMIO 2416-4ENC PAMIO module box Ä “PAMIO Combi-
2416 / 4ENC4A nations” on page 27
PAMIO PWM-2416 PAMIO module box Ä “PAMIO Combi-
PWM / 2416 nations” on page 27
PAMIO PWM-4ENC PAMIO module box Ä “PAMIO Combi-
PWM / 4ENC4A nations” on page 27
PAMIO 2ENC4A PAMIO module box Ä “Special PAMIO
2ENC4A Component”
on page 28
PAMIO Accessories PAMIO PWM PAMIO PWM 5V to Ä Chapter 4.6.2.2
CONV 24V signal con- “5V to 24V signal
verter converter”
on page 90
PAMIO STOPPER PAMIO set of lat- Ä Chapter 4.2.4
eral rail stoppers “Stopping brackets”
on page 36
PAMIO TERM PAMIO termination Ä Chapter 4.2.6
plug “Termination plug”
on page 39
PAMIO cables CAB PAMIO 0.5 PAMIO cable 0.5m Ä “Available
Superbus Cables”
on page 47
CAB PAMIO 2 PAMIO cable 2m Ä “Available
Superbus Cables”
on page 47
Superbus Cables”
on page 47
Superbus Cables”
on page 47
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PA 8000 PAMIO
Overview
Product Code Description See

Superbus Cables”
on page 47
Superbus Cables”
on page 47
PAMIO plug sets PLUG 2416 Plug set for 24/16 Ä Chapter 4.4
I/O “PAMIO 2416”
on page 52
PLUG 4ENC4A Plug set for PAMIO Ä Chapter 4.5
4ENC4A “PAMIO 4ENC4A”
on page 64
PLUG PWM Plug set for PAMIO Ä Chapter 4.6
PWM “PAMIO PWM”
on page 85
PLUG 2ENC4A Plug set for PAMIO Ä Chapter 4.7
2ENC4A “PAMIO 2ENC4A”
on page 97
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PA 8000 PAMIO
PAMIO Components
4 PAMIO Components
4.1 Generality
4.1.1 General specifications
General The Power Automation Modular Input Output (PAMIO) components
are extension modules that allow a Power Automation control unit
to add more PLC digital input/output, PLC and/or NC analog out-
puts, NC analog axes.
PAMIO components are not stand-alone components. They can
only be used in conjunction with a Power Automation control unit.
PAMIO boxes can be snapped onto DIN-rails and plugged side by
side, or connected through optional cables.
4.1.2 Maximum Number of PAMIO Modules

Number Of PAMIO Modules All the control units of Power Automation are able to control up to
31 I/O modules. The total number of 31 includes the axis and I/O
modules built in the control unit.
Build-In modules
– Power Automation control units are available
with build-in axes and I/O modules.
– Control units with analog axis interface have
one axis module built in.
– One or two I/O modules (depending) on control
unit model are built in every control unit.
Refer to the installation manual of your specific control unit to

check the number of built-in modules!
The Power Automation software attributes a fixed

number of 8 bytes to each module, without consid-
eration of how many bytes are effectively required
by each module.
Calculation The following formula applies for the calculation of the maximum
configuration of a PAMIO system rack:
NBuild-In + N2416 + N4ENC4A + N2ENC4A + NPWM = 31
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PAMIO Components
Example 1
If there are only 2416 modules on the PAMIO
rack, the maximum number of I/Os is:
As an example with a control unit PA 8000 LW
with analog axes:
NBuild-In = 3 (one axis module and two I/O modules)
=> Max. number of PAMIO 2416: N2416 = 28
Max. number of digital I/Os:
– 28 x 24 Inputs = 672 inputs + (build-in inputs) =
720 inputs
– 28 x 16 Outputs = 448 outputs + (build-in out-
puts) = 480 inputs
Example 2
If a system rack requires 1 box with 2 modules
4ENC4A and 1 box with 1 module PWM, the
maximum number of modules 2416 is:
N2416 = 31 - NBuild-In - N4ENC4A - NPWM
N2416 = 31 - NBuild-In - 2 - 1
As an example with a control unit PA 8000 E2 with
SDI axes:
NBuild-In = 2 (no axis module and two I/O modules)
=> Max. number of PAMIO 2416: N2416 = 26
Max. number of digital I/Os:
– 26 x 24 Inputs = 624 inputs + (build-in inputs) =
672 inputs
– 26 x 16 Outputs = 416 outputs + (build-in out-
puts) = 448 inputs
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PA 8000 PAMIO
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4.1.3 PAMIO Boxes and PAMIO Modules

Hardware Configuration With the exception of the PAMIO module 2ENC4A (which has a
unique hardware construction), the PAMIO boxes have flexible and
adaptable hardware configuration.
Each PAMIO Box is constituted of:

– one PAMIO backplane
– one or two PAMIO single module(s)
– one cover plate (or face plate) when only one
single module is mounted in the backplane
There are 3 different models of PAMIO single mod-

ules
– 2416 (24 digital inputs + 16 digital outputs)
– 4ENC4A (4 encoder in + 4 analog out + 4
analog in)
– PWM (2 digital outputs)
PAMIO Combinations The PAMIO boxes are available either in the form of predefined
configuration or as individual components. In case of ordering indi-
vidual components, the customer is responsible for the correct
assembly of these components.
Table 2: There are 9 different predefined possible combinations:

Code Designation
PAMIO 2416 PAMIO box with one 2416 and
a faceplate
PAMIO 4ENC4A PAMIO box with one 4ENC4A
and a faceplate
PAMIO PWM PAMIO box with one PWM and
a faceplate
PAMIO 2416-2416 PAMIO box with two 2416
PAMIO 4ENC-4ENC PAMIO box with two 4ENC4A
PAMIO 2416-4ENC PAMIO box with one 2416 and
one 4ENC4A
PAMIO 2416-PWM PAMIO box with one 2416 and
one PWM
PAMIO 4ENC-PWM PAMIO box with one 4ENC4A
and one PWM
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Individual Components Table 3: There are 4 individual components:

Code Designation
PAMIO MB PAMIO Backplane with 2 slots
for single modules
PAMIO 2416 PAMIO module with 24 digital
inputs and 16 digital outputs
PAMIO 4ENC4A PAMIO module with 4 encoder
inputs, 4 analog outputs and 4
analog inputs
PAMIO PWM PAMIO module with 1 PWM
output and 1 Fast Output
PAMIO Faceplate PAMIO cover plate for unused
slot
Special PAMIO Component Table 4: There is one special PAMIO component:

Code Designation
PAMIO 2ENC4A PAMIO module with 2 encoder
inputs, 4 analog outputs, 4
analog inputs and integrated
bus termination
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4.1.4 Connection to the control unit and intercon-

nection
Connection The first PAMIO box of the configuration in use must be connected
to the control unit with a Superbus cable. The corresponding 50-
pins connector on the control unit side is numbered X13.
The Superbus cable is not included in the control

unit's basic scope of delivery. It has to be ordered
separately (see Ä Chapter 6.1.1 “Service
addresses” on page 130).
One application may require more than one PAMIO box. The
PAMIO backplanes have 50-pins connectors on each side, a male
connector on the left side (front view) as input and a female con-
nector on the right side as output. Thus it is possible to simply
press two boxes together to establish a full bus connection
between the boxes (Fig. 4).
Fig. 4: Assembling PAMIO boxes
PAMIO System With Two Racks When the total number of required PAMIO boxes is too big, it can
make sense to create two system racks, connected one to the
other by a Superbus cable (Fig. 5).
Fig. 5: PAMIO system with two racks
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4.1.5 Bus termination

Bus Termination As with other fast bus systems, the PA Superbus requires a termi-
nation to avoid line reflections that could disturb the data transmis-
sion.
The last PAMIO box of a system rack must carry a bus termination
plug on its Superbus output connector. In the particular case of a
PAMIO of model 2ENC4A, there is no Superbus output connector
and the bus termination is integrated in the module (by the way, it
is not possible to use more than one such a module per system
rack!).
4.2 Mechanical Installation

4.2.1 Dimensions
4.2.1.1 PAMIO models 2416 / 4ENC4A / PWM
General Property Value Unit
Dimensions 112 x 123 x 181.5 mm
4.4 x 4.84 x 7.15 inch
Weight of the back- 0.66 kg
plane
1.46 lb
Max. weight 1.36 kg
3.00 lb
The weight of a PAMIO box depends on the model

and the number of single modules mounted on the
backplane. The example here above gives the
weight of a box including two modules 4ENC4A.
Refer to the specific technical data of each single
module to determine the exact weight of your box.
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Fig. 6: PAMIO box dimensions
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4.2.1.2 PAMIO Modell 2ENC4A

Allgemeine Daten Eigenschaft Wert Einheit
Abmessungen 107 x 177 x 14 mm
4,21 x 6,97 x 0,55 Zoll
Gewicht der Rück- 0,55 kg
enwandplatine
1,21 lb
Fig. 7: Abmessungen des PAMIO 2ENC4A
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4.2.2 DIN rail installation

Specification The PAMIO components are designed for DIN rail installation.
For the DIN rail specification see Fig. 8.
Fig. 8: Din rail for PAMIO mounting
Because of the weight of the boxes, due to their rugged construc-

tion with metal cases, it is necessary to ensure a correct and a safe
fixation of the DIN rail to avoid any torsion.
For the suggested installation of the rail see Fig. 9.
Fig. 9: DIN rail fixation
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M6 Fixation Place M6 fixation screws every 105.3 mm (4.16 inches) (see

Fig. 10).
Fig. 10: M6 fixation
In this way the DIN rail fixation screws are placed right in the
middle of the PAMIO boxes (Fig. 11). So, optimum fixation is guar-
anteed and the user can install and/or remove PAMIO boxes
without any problem.
Fig. 11: DIN rail fixation
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4.2.3 Mechanical assembly

Mounting Of The PAMIO Boxes The PAMIO boxes must always be mounted on the rail in such a
way that the power supply connector of the modules is on the top
side.
Snap the back of the PAMIO box onto the DIN rail by inserting the
top on the rail and then pressing simultaneously down and in at the
bottom of the box. Be sure to hold the box absolutely horizontally
when pressing down. Also make sure that a fastening screw of the
DIN rail is located right in the middle of the PAMIO box bracket.
Shift the boxes together. The box should slide on the DIN rail. If it
does not slide then slightly press the box down while moving the
box.
The total length of a PAMIO box rack is given by

the formula:
– Total length = N x 105.3 mm + 5 mm
– Total length = N x 4.16 inches + 0.20 inches
where N stands for the number of PAMIO boxes
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4.2.4 Stopping brackets

Risk Of Disconnection
Stopping bracket sets are available as options
from Power Automation (see Ä Chapter 6.1.1
“Service addresses” on page 130).
Ordering code for one set:
– PAMIO STOPPER (each set = one pair of
stopping brackets)
As the boxes are fixed one to the other only by the way of the
plugged connectors, there is always a risk of disconnection (due to
any vibration) that would prevent the entire control unit from
working.
To avoid accidental disconnection of the PAMIO boxes be sure to
fix the entire rack of interconnected boxes with stopping brackets
on each side (Fig. 12). This is always necessary if a system rack
consists of more than one module box plugged into each other.
Fig. 12: Stopping brackets disposition
Space Each stopping bracket requires a space of 50 mm (1.97 inches) on

the DIN rail (Fig. 13).
Fig. 13: Stopping bracket size
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The stopping brackets are fixed on the DIN rail with a screw M4x20
(Fig. 14).
Fig. 14: Stopping bracket fixation
When another rail than the one specified is used, the length of the
stopping bracket fixation screw may have to be adapted. However
it has to be selected in such a way that this screw does not collide
with the Superbus connector or the termination plug!
If a rail in accordance with DIN-EN 50022 is used, for example, the
screw must be changed for M4x12.
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4.2.5 Ventilation
Minimum Vertical Distance To ensure proper heat dissipation, PAMIO system racks must
always be mounted horizontally.
There must be a minimum vertical distance of 100 mm (3.94
inches) between a PAMIO system rack and other devices in the
electrical cabinet (Fig. 15).
It is recommended not to place devices with high power dissipation
(like transformers or drive units) close below the PAMIO system
rack.
When the number of PAMIO boxes is so large that it requires an
assembly of two (or more) system racks, the same rules applies:
there must be a distance of at least 100 mm (3.94 inches) between
the two racks.
Fig. 15: PAMIO rack mounting for correct ventilation
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4.2.6 Termination plug

Termination
Termination plugs are available as options from
Power Automation (see Ä Chapter 6.1.1 “Service
Ordering code: PAMIO TERM
The PAMIO termination plug (Fig. 16) is used to terminate the

Superbus. As with other fast bus systems, the PA Superbus
requires a termination to avoid line reflections that could disturb the
data transmission.
Fig. 16: PAMIO termination plug
The last PAMIO box of an application must carry a bus termination

plug on its output Superbus connector (50 pin Sub-D) (Fig. 17).
Fig. 17: Position of PAMIO termination plug
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Bus Termination (PAMIO 2ENC4A) In the particular case of a PAMIO of model 2ENC4A, there is no
Superbus output connector and the bus termination is integrated in
the module (Fig. 18). It is not possible to use more than one such
module per system rack, and this module must be the last module
of the system rack!
Fig. 18: PAMIO system rack with ending PAMIO 2ENC4A
NOTICE!
Be sure that the termination plug is always plugged
in the output connector of the last PAMIO box (or
that the last box is a PAMIO 2ENC4A), and that the
termination plug is fixed against accidental discon-
nection.
For the fixation of the termination plug, the screws

that fix the 50 pin Sub-D output connector of the
last PAMIO box must be replaced by studs! These
studs are delivered with the PAMIO backplane.
If there is a need to install a new supplementary

PAMIO box in an existing system rack, it is sug-
gested to place it between the first and the last
module.
Otherwise, the termination plug and the corre-
sponding studs of the last module have to be
replaced with the corresponding screws (i.e. those
from the new module) because when studs are
mounted, the connection from box to box is not
possible. After adding the new module as new last
module, the studs and the termination plug must
be tightened on its right side.
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4.2.7 Superbus cables

Connection The first PAMIO box of the configuration in use must be connected
to the control unit by a Superbus cable (Fig. 19).
Fig. 19: Superbus cable

separately.
Superbus PAMIO Connector The corresponding 50-pins connector on the control unit side is
numbered X13 (Fig. 20).
Fig. 20: Superbus PAMIO Connector
NOTICE!
It is highly recommended to use a cable that has
been tested and certified by Power Automation, as
well as between the control unit and the system
rack, as (if required) between several racks. -If
non-adapted cables are used, there is a high risk
of data transmission errors!
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Cable Specification Property Value

Cable type round twisted pair, shielded
Number of leads 50 (25 x 2)
Lead cross section 0.09 mm2 (AWG 28)
Outside diameter 8 - 9 mm (0.3 ")
Maximum length 30 m (98 ft)
Connector types sub-D, case shielded
Connector genders male/female
Connector pins 50 (3 rows)
Connector attachment 4-40/UNC screws
NOTICE!
All cables connected to the control unit are
intended for stationary use only.
The cable shield is connected to both connector

casings.
Pin Assignment Table 5: The one-to-one wiring between the cable's connectors is
set up as follows:
Pair Pins Pair Pins
1 = 1/34 14 = 26/10
2 = 18/2 15 = 43/27
3 = 35/19 16 = 11/44
4 = 3/36 17 = 28/12
5 = 20/4 18 = 45/29
6 = 37/21 19 = 13/46
7 = 5/38 20 = 30/14
8 = 22/6 21 = 47/31
9 = 39/23 22 = 15/48
10 = 7/40 23 = 32/16
11 = 24/8 24 = 49/33
12 = 41/25 25 = 17/50
13 = 9/42
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Cable Fixation
NOTICE!
To avoid unexpected disconnections, it is neces-
sary to fix the cable on both sides as well on the
control unit, as on the first PAMIO box.
For the fixation of the Superbus cable, the screws
that fix the 50 pin Sub-D input connector of the first
PAMIO box must be replaced by studs! These
PAMIO Systems With Several

Racks
Fig. 21: PAMIO system with two racks
NOTICE!
In case of interconnection between racks, the
screws that fix the 50 pin Sub-D output connector
of the last PAMIO box in the first rack and those of
the input connector of the first PAMIO box in the
following rack must be replaced by studs! These
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Bending Radius
NOTICE!
The cables delivered from Power Automation are
only intended for stationary use!
They must not be used in moving cable chains!
Fig. 22: Superbus cable bending radius
NOTICE!
Do not bend the cable more than with a radius of
30 mm (1.18 inches) to avoid permanent damage!
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4.2.8 Changing PAMIO modules

Location Of The PAMIO Modules Any of the different types of PAMIO modules available can be
located in any available slot of the system rack of PAMIO boxes.
Therefore it is not necessary to replace the entire module box in
case of a system change. It is enough to change the respective
module.
Each module is fixed in the PAMIO box by means of six screws, 3
located on the top side and 3 on the bottom side. The location of
these screws differs slightly depending if the module is located on
the left side or on the right side of the PAMIO box.
Fig. 23: Location of mounting screws
NOTICE!
Before changing a module, always switch off the
24V power supply!
NOTICE!
When inserting a new module, be sure that the
module is connected properly in the backplane
connector.
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4.3 Electrical Installation

4.3.1 Connection to the CNC
The first PAMIO box of the configuration in use must be connected
to the control unit by a Superbus cable. The corresponding 50-pins
connector on the control unit side is numbered X13.

separately.
Fig. 24: Superbus cable
NOTICE!
It is highly recommended to use a cable that has
been tested and certified by Power Automation,
between the control unit and the system rack (if
required), as well as between several racks.
If cables that don't meet the required specification
are used, there is a high risk of data transmission
errors!
NOTICE!
Do not connect or disconnect PAMIO boxes when
the control unit is under power. The control unit
software has to initialize the input/output system
during the start-up process.
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Available Superbus Cables

Superbus cables are available as options from
Power Automation (see Ä Chapter 6.1.1 “Service
Ordering code: see Ä “Available Superbus Cables”
on page 47
Length in m Length in ft Ordering code

0.5 1.6 CAB PAMIO 0.5
2 6.5 CAB PAMIO 2
5 16.5 CAB PAMIO 5
10 33 CAB PAMIO 10
20 66 CAB PAMIO 20
25 82 CAB PAMIO 25
The PAMIO cable (0.5m / 1.6 ft) is only usable with

a PAMIO box mounted on the left side of the CNC.
4.3.2 PAMIO On-Board Logic Power Supply

On-Board Logic Power Supply Every PAMIO module requires a 24V DC power supply for its On-
Board logic. The backplane in which the module is mounted is sup-
plied as well from this input.
Depending on the model, there can be more than one power
supply connector on a PAMIO module. But all models use he same
connector X30 for the On-Board logic power supply.
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Each module has a 5 pin connector (X30) with the following pin
assignment (see Fig. 25).
Fig. 25: X30 – Power supply pins
Pin Assignment
Pin 1 Used depending on model
Pin 2 + 24 V DC power supply for
on-board logic
Pin 3 0V
Depending on the modules, the pins 1, 4 and 5 of

this connector can be used for other power supply
inputs. Refer to individual characteristics of the
model!
The 0V connection is always common to the dif-

ferent power supplies that have to be applied on
this connector.
Technical Specifications Property Value Unit

Operating voltage +24 V DC
Tolerances -15 / +12.5 %
Effective range 20.4 - 27.0 V DC
Reference Pin 3 (0 V)
NOTICE!
Remember that every PAMIO module must be sup-
plied with 24V DC separately!
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Power Requirement PAMIO model Value Unit

Backplane 0.1 A
2416 0.1 A
4ENC4A 0.5 A
2ENC4A 0.2 A
PAMIO PWM 0.1 A
The 24V power supply necessary for the on-board logic of the
complete I/O rack system has to be determined by making the sum
of all the components in use.
Power Requirement Of Standard The following table shows the requirements of the standard prede-
PAMIO Configurations fined combinations available from Power Automation.
PAMIO model Calculation Total Unit

PAMIO with 1x 0.1+0.1 0.2 A
2416
4ENC4A
PWM
PAMIO with 2x 0.1+0.1+0.1 0.3 A
2416
PAMIO with 2x 0.1+0.5+0.5 1.1 A
4ENC4A
PAMIO with 1x 0.1+0.1+0.5 0.7 A
2416 + 1x
4ENC4A
PAMIO with 1x 0.1+0.1+0.1 0.3 A
2416 + 1x
PWM
PAMIO with 1x 0.1+0.5+0.1 0.7 A
4ENC4A + 1x
PWM
NOTICE!
When the same power supply is used for the On-
Board logic and the digital inputs/outputs,
remember to add to the above values the output
currents required by the digital outputs.
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4.3.3 Protective Grounding

Grounding To ensure the best noise immunity, each PAMIO module comes
with at least one connection (X2) for the protective grounding.
Fig. 26: X30 - Power supply pins
NOTICE!
Remember that every PAMIO module must be con-
nected to the protective grounding separately!
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4.3.4 Ambient Conditions

Technical Data Property Value Unit
Operating tempera- +5 - +55 °C
ture
+32 - +131 °F
Storage tempera- -20 - +75 °C
ture
-4 - +167 °F
Relative humidity 80 %
(non-condensing)
Maximum accelera- 4.0 G
tion (non-operating)
Maximum accelera- 3.5 G
tion (operating)
Protection class (EN IP20
60529)
Do not expose the PAMIO components to the fol-

lowing conditions:
– corrosive gases
– high variation of temperature
– extremely or salt laden air
– metal chip or metal dust - splash water or other
chemicals
NOTICE!
Functional defects!
The PAMIO casing does not provide sufficient pro-
tection against environmental influences. Dust and
moisture may cause malfunctions.
– Only operate the PAMIO components inside a
cabinet that ensures at least a protection class
IP 54!
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4.4 PAMIO 2416

Connections Of The PAMIO 2416 The PAMIO module 2416 has connections for:
n 24 digital inputs (3 bytes)
n 16 digital outputs (2 bytes)
All the signals are 24V DC.
Each output byte can be supplied separately. Each output can
drive up to 0.7A, each byte being limited to 4A maximum.
The status of the inputs, the outputs and the monitor is displayed
via LEDs.
4.4.1 Technical Data

Weight 0.29 kg
0.64 lb
Connection Values Property Value Unit

Input voltage 24 V DC
Tolerance -15 / +12.5 %
Frequency 20.4 - 27.0 V DC
Max. current 0.1 A
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4.4.2 Design and Functions

Overview
Fig. 27: PAMIO 2416 overview

1 Output byte 2 (X41)
2 Power connector +24 V (X30)
4 Protective grounding tab (X2)
5 Input byte 3 (X47)
8 Status LEDs output byte 1
9 Status LEDs output byte 2
10 Module status LEDs
11 Status LEDs input byte 1
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4.4.2.1 Digital Inputs
Fig. 28: PAMIO 2416 inputs

Connection n Each byte is connected with an 8 pole terminal block (Fig. 29).
n The conductor cross-section of the wire must be 0.3 to 1.75
mm2 (AWG 22 to 15).
n The inputs are always referenced against 0 V, located in the
power connector (X30 pin 3).
Fig. 29: Input terminal block
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Pin Assignment Byte 1 +24 V Byte 2 +24 V Byte 3 +24 V

input input input
pin 1 1. in bit pin 1 9. in bit pin 1 17. in bit
Input Status LEDs The input LEDs are located in the input path and therefore show
the real state of the 24V inputs
n a HIGH input signal causes the corresponding LED to turn ON
n a LOW input signal causes the corresponding LED to turn OFF
Fig. 30: PAMIO 2416 inputs status LEDs
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Input Characteristics Property Value Unit

Number of inputs 24
Maximum DC 27 V DC
voltage
Input current at 24V 7 mA
(typical)
Power dissipation at 0.17 W
24V per input
Input impedance 2.2 kΩ
Operating DC 5 V max
voltage OFF
Operating DC 11 V min
voltage ON
Input ON delay (typ- 5 μs
ical)
Input OFF delay 35 μs
(typical)
Isolation By opto-coupler
Input ON display LED
External connection 1 block per byte
Input Schematic The following figure (Fig. 31) shows how the inputs are realized on
each PAMIO 2416 module.
Fig. 31: Inputs equivalent schematic
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4.4.2.2 Digital Outputs
Fig. 32: PAMIO 2416 outputs

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Connection n Each byte is connected with an 8 pole terminal block.

n Each output byte has its own power supply connection. This
feature can be used to turn off a whole byte by means of a
unique external switch.
n The outputs are always referenced against 0 V, located in the
power connector (X30 pin 3)
Fig. 33: Input terminal block
The current limitation of each output is 0.7 - 2.5A

per pin in case of short circuits.
– Consider that the power supply cable for one
output byte has to be chosen accordingly.
Each output has a nominal output capability of 0.7

A. Nevertheless each output byte is globally limited
to 4 A.
– Take care of this specification by appropriate
output definition toward the external actuator.
Outputs are monitored for faults. In case of errors,

the according output is switched off.
Since every 4 adjacent outputs have a common
status signal, the onboard monitor always switches
off 4 outputs in such a case (1 - 4, 5 - 8, 9 - 12, 13
- 16).
Pin Assignment Byte 1 +24 V output Byte 2 +24 V output

pin 1 1. out bit pin 1 9. out bit
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Output Status LEDs The output LEDs are located in the input path and therefore show
the real state of the 24V outputs.
n if an output is HIGH, the corresponding LED is ON
n if an output is LOW, the corresponding LED is OFF
Fig. 34: PAMIO 2416 outputs status LEDs
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Output Characteristics Property Value Unit

Number of outputs 16
Max. continuous 0.7 A
output per bit
Max. continuous 4 A
output per byte
Power dissipation 0.27 W
per bit at 24V for
0.5A
Power dissipation 0.37 W
per bit at 24V for
0.7A
Output ON delay 175 μs
(typical)
Output OFF delay 175 μs
(typical)
Watchdog (max.) 64 ms
Short circuit output 0.7 A
DC
Delay time current 100 μs
limitation (max.)
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Output Schematic The following figure shows how the outputs are realized on each
PAMIO 2416 module.
Fig. 35: Outputs equivalent schematic

1 Supplied from PCI Superbus board
2 Output supply input (-15 % - +12.5 %)
3 Output n + 1
4 Output n
5 Logic
6 Internal serial bus
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4.4.2.3 Power Supply

Each of the output bytes on the PAMIO 2416 needs a separate
+24V DC power supply. This is done on the power supply con-
nector X30 (Fig. 36).
Fig. 36: PAMIO 2416 power connection

2 Power connection (X30)
Connection Each module has a 5 pin connector (X30) with the following pin
assignment (Fig. 37):
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Pin Assignment Pin Assignment

output byte 1
Pin 2 + 24 V power supply for on-
board logic
Pin 3 0V
Pin 4 Not used
output byte 2
The 0V connection is common to the different

power supplies that have to be applied on this con-
nector.
The power supply of the output bytes being inde-

pendent from the on-board logic power supply
allows i.e. disconnecting the output byte(s) in case
of emergency stop, setting all of the output bytes to
a safe state.

Max. current for the 0.1 A
on-board logic
Max. current for the 4 A / byte
output bytes
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4.4.2.4 Status LEDs

Overview The PAMIO 2416 has four LEDs for diagnostic purposes.
Fig. 38: PAMIO 2416 module status LEDs

1 Status
2 Access
3 Bustest
4 Monitor
For a detailed assignment of the LEDs' states see Ä Chapter 5.2.1

“PAMIO 2416 LEDs” on page 119.
4.5 PAMIO 4ENC4A

Connections Of The PAMIO The PAMIO module 4ENC4A has connections for:
4ENC4A
n 4 analog axes (4 analog command outputs +/-10V DC / 16 bit)
n 4 incremental measurement systems
n 4 additional analog inputs (+/-10V DC / 12 bit)
The status of the monitor is displayed via LEDs.

Weight 0.35 kg
0.77 lb
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Tolerance -15 / +12.5 %
Max. current 0.5 A

Overview
Fig. 39: PAMIO 4ENC4A overview

1 RMS input 1. axis (X31)
2 Power supply input for RMS encoders (X35)
3 Analog out axes 1 to 4 (X37)
9 Safety function connector (X38)
10 Analog inputs 1 to 4 (X36)
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4.5.3 Axis Measurement Inputs (RMS)
Fig. 40: PAMIO 4ENC4A RMS inputs

1 RMS input 1st axis (X31)
6 RMS input 2nd axis (X32)
8 RMS input 3rd axis (X33)
11 RMS input 4th axis (X34)
Connection Each axis measurement input has a 15 pin Sub-D connector

female (Fig. 41).
Fig. 41: RMS Input Connector
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Pin 1 Track A+
Pin 2 Track A-
Pin 3 Track B+
Pin 4 Track B-
Pin 5 Track R+
Pin 6 Track R-
Pin 7 Probe input
Pin 8 Probe ground
Pin 9/11/13/15 RMS grounding
Pin 10/12/14 +5 V RMS
RMS Input Characteristics Property Value Unit

Interface type RS 422
Track common -7 - +7 V
mode range
Max. track input -11 - +14 V
voltage
Min. track input +/- 500 mV
voltage
Track input impe- 150 Ω
dance
Max. track fre- 5 MHz
quency (no filter)
Max. count fre- 20 MHz
quency (no filter)
External connector 15 pin Sub-D female / axis
Each probe input is referenced against its probe

ground.
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Probe Input Property Value Unit

Max. probe input 27 v
voltage
Probe input current 7 mA
(at 24 V)
Probe input impe- 2200 Ω
dance
Probe operating 5 V DC max.
voltage OFF
Probe operating 11 V DC min.
voltage ON
Probe input ON 200 ns
delay
Probe input OFF 300 ns
delay
Probe isolation Opto coupler
Interface type digital input 24 V
Probe wiring
When the probe input is used in an application,
each input of all used axes must be wired in par-
allel.
Input Equivalent Schematic The following figure (Fig. 42) shows how the axis measurement
inputs are realized on each PAMIO 4ENC4A module.
Fig. 42: RMS input equivalent schematic
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RMS Encoder Wiring Example The following schematic demonstrates the recommended way of
connecting the CNC RMS inputs to the encoders (or any other
device with incremental output).
Fig. 43: RMS encoder wiring example
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Precondition
The distance between the measuring systems and
the power supply can be relatively long. The ohmic
resistance of the power supply cable and the RMS'
current consumption generate a voltage drop.
Fig. 44: Schematic encoder power supply voltage drop

1 Power supply
2 Rotating measurement system (RMS)
UA Supply output voltage
U1 Voltage drop
U2 Voltage at the RMS
U3 Voltage drop
As shown in the figure, the voltage U2 equals the difference
between the output voltage UA and the voltage drop U1+U3.
Adjusted voltage U2 = UA - (U1 + U3)
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Examples The voltage drop depends on the cable length and the conductor's
cross section.
The following table shows some cable examples. The values are
typical and only offered as guidelines.
n For proper compensation, calculate the actual values as shown
in the following section.
Conductor Specific Cable length Voltage drop

cross section resistance [m] at 100 mA [V]
[mm2]/[AWG] [Ω/m]
0.08 / AWG 28 0.235 10 0.47
20 0.94
35 1.65
0.14 / AWG 25 0.131 10 0.26
20 0.52
35 0.92
0.25 / AWG 23 0.075 10 0.15
20 0.30
35 0.53
0.5 / AWG 20 0.040 10 0.08
20 0.16
35 0.28
0.75 / AWG 18 0.025 10 0.05
20 0.10
35 0.18
Calculation n Use the actual data obtained from the cable's technical
specifications.
n Double the cable's physical length.
This is necessary as there are two lines: one line to the
RMS (+5 V) and one line from the RMS (grounding).
n Calculate the voltage drop as follows:
Voltage drop [V] = 2 x L x CR x PC
L - Cable length [m]

C - CR Specific resistance per meter [Ω/m]
P - PC Power consumption [A]
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Compensation
Personnel: n Skilled electrician
1. Install a power supply with adjustable output voltage to
supply the RMS supply input.
This is a requirement for voltage drop compensation.
2. Calculate the actual voltage drop between RMS power
supply and RMS.
3. Adjust the external RMS power supply to feed a slight
overvoltage of 5.1 V to 5.5 V depending on the measured
drop.
A measurement system contains integrated elec-

tronic components. Relating to the current con-
sumption Power Automation only indicates mean
values. Current peaks of a multiple of the mean
value may occur for several microseconds during
operation.
– Select a conductor cross-section which guar-
antees a maximum voltage drop of 0.2 V.
– Set the power supply to the upper limit of the
RMS supply voltage.
These steps guarantee that the RMS' supply
voltage does not drop below the required min-
imum.
4.5.4 RMS Power Supply

Overview
Fig. 45: PAMIO 4ENC4A RMS power supply

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Connection The power supply for encoders is connected with a 2 pole terminal
block (Fig. 46).
Fig. 46: RMS power terminal block
Pin Assignment Pin Voltage Assignment

1 +5 V RMS supply
2 0V RMS ground
Technical data Property Value Unit

Tolerance 0 - +20 %
Voltage Drop
the power supply can be relatively long. The resist-
ance of the power supply cable and the RMS' cur-
rent consumption generate a voltage drop (see
Ä “Precondition” on page 70).
4.5.5 Axes Analog Outputs

Overview
Fig. 47: PAMIO 4ENC4A axes analog outputs

3 Analog outputs axes 1 to 4 (X37)
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Connection The analog outputs are connected with an 8 pole terminal block
(Fig. 48).
Fig. 48: Axes output terminal block
Pin Assignment Pin Description

Pin 1 +/- output channel 1
Pin 2 reference channel 1
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Number of analog 4
output points
Output signal range +/- 10 V
(max.)
Output current load +/- 15 mA
(max.)
Output capacitive 350 pF
load (max.)
Bipolar zero error +/- 40 mV
(max.)
Full scale error +/- 1 1%
(max.)
Channel to channel +/- 1 %
mismatch (max.)
Linearity error +/- 2.44 mV
(max.)
Resolution 305 μV
Conversion time 10 μs
(max.)
Output slew rate 0.4 μV/s
(typ.)
External connector 8 pole terminal block
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Output Schematic
Fig. 49: Analog axis output equivalent schematic
Analog output wiring

The wiring of the analog output command voltages
to the drive depends on the type of drive analog
inputs.
– During drive installation take into consideration
whether the drive's analog inputs are grounded
or not.
– If the analog inputs are grounded, connect the
drives according to the schematic for non-dif-
ferential inputs.
– If the analog inputs are not grounded, connect
the drives according to the schematic for differ-
ential inputs.
The following schematics demonstrate the recommended way of

connecting the CNC analog outputs to the analog inputs of the
drives, depending on the analog input type of the drive.
Drives With Non-Differential Inputs

(Unipolar)
Fig. 50: Schematic non-differential inputs (unipolar)
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Drives With Differential Inputs
Fig. 51: Schematic differential inputs
4.5.6 Analog Inputs

Overview
Fig. 52: PAMIO 4ENC4A analog inputs

Connection The analog inputs are connected with a 9 pole terminal block
(Fig. 53).
Fig. 53: Analog inputs terminal block
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Pin 1 + input channel 1
Pin 2 - input channel 1
Pin 9 analog ground (ACOM)

Input signal range -10 - +10 V
Common mode -15 - +15 V
range
Max. input voltage -15 - +15 V
Input impedance 16 kΩ
Max. bipolar zero +/- 10 mV
error
Max. full scale error +/- 1 %
Max. channel to +/- 1 %
channel mismatch
Max. linearity error +/- 4.88 mV
Resolution 4.88 mV
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Input Schematic
Fig. 54: Analog input equivalent schematic
UA/D = (U+IN - UACOM) - (U-IN - UACOM)
n UA/D = A/D Converter Output

n U+IN = + Differential input
n U-IN = - Differential input
n UACOM = Analog ground ACOM
4.5.7 Power Supply

Overview
Fig. 55: PAMIO 4ENC4A power connection

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assignment (Fig. 56).
Fig. 56: Power terminal block

Pin 1 Not used
board logic
Pin 3 0V
Pin 4 Not used
Pin 5 Not used

Operating voltage + 24 V DC
on-board logic
output bytes
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4.5.8 Safety Function

Overview
Fig. 57: PAMIO 4ENC4A safety function

9 Safety function connector (X38)
Fig. 58: Safety function terminal block

Pin 1 Power OK, common
Pin 2 Power OK, normally closed
Pin 3 Power OK, normally open
Pin 4 CNC ready, common
Pin 5 CNC ready, normally closed
Pin 6 CNC ready, normally open
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Number of relays 2
Max. switching 30 V DC
voltage
Max. switching cur- 1 A
rent
Typical switch on 4 ms
time
Typical switch off 3 ms
time
Relay "Power OK" The first relay is called "Power OK" and switches when the fol-
lowing conditions are met:
n The power supply voltages are in operating range.
n The operating temperature is below +60 °C (+140 °F).
Logic Condition Result

+ 5 V OK Power OK relay
active
AND +15 V OK
AND -15 V OK
AND T < 60 °C (140 °F)
NOTICE!
Damage to the control unit!
Voltage faults and/or temperatures above the
allowed specification can cause damage to the
control unit.
Properly wire the "Power OK" relay to protect the
control unit from damaging voltages and tempera-
tures.
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Relay "CNC Ready" The second relay is called "CNC Ready" and switches to active
state when the following conditions are met:
n The control unit is ready when:
– The "Power OK" relay is in active state.
– The watchdog is re-triggered. This means the software is
monitored as working properly.
– All axes measurement signals are correct.
– All axes position loops are under control.
n The RMS power supply voltage is within operation range.
n The operating temperature is below +55°C (+131°F).
Logic Condition Result

+ 5 V RMS OK CNC Ready relay
active
AND Control unit ready
AND T < 55 °C (131 °F)
NOTICE!
Damage to the machine!
If the "CNC ready" relay is not wired properly to the
machine's emergency stop circuit, the machine
may be damaged upon operation.
– Ensure that the "CNC ready" relay is wired
properly to the machine's emergency stop cir-
cuit.
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Fig. 59: Safety relays equivalent schematic
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4.5.9 Status LEDs

Overview The PAMIO 4ENC4A has ten LEDs for diagnostic purposes.
Fig. 60: PAMIO 4ENC4A module status LEDs

1 Status
2 Access
3 Bustest
4 Monitor
5 Axis 1
6 Axis 2
7 Axis 3
8 Axis 4
9 Power OK
10 CNC Ready

“PAMIO 4ENC4A LEDs” on page 121.
4.6 PAMIO PWM

Connections Of The PAMIO PWM The PAMIO module PWM has connections for:
n 1 opt. isolated output for PWM signal
n 1 opt. isolated fast output
n opt. isolated output with inverted PWM signal

Weight 0.35 kg
0.77 lb
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Tolerance -15 / +12.5 %
Max. current 0.5 A

Overview
Fig. 61: PAMIO PWM overview

2 Output byte
4 Status LEDs output byte
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4.6.2.1 Digital Outputs
Fig. 62: PAMIO PWM outputs

2 PWM and Fast Output (X25)
Connection n Each byte is connected with an 8 pole terminal block.

n The PWM and Fast Output have their own power supply con-
nection (X30, Pin1). This makes it possible to turn off the
output function by using an external switch.
n The outputs are always referenced against 0 V, located in the
power connector (X30, pin 3).
Fig. 63: Output terminal block
Pin Assignment Byte 1 +24 V output

pin 1 PWM out 5V
pin 2 Fast Out 5V
pin 3 Not used
pin 4 PWM OUT 5V Inverted
pin 5 Not used
pin 6 Not used
pin 7 Not used
pin 8 Not used
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Output Status LEDs The output LEDs are located on the front side of the PAMIO PWM
and show the current state of the PWM and Fast Output.
n if an output is HIGH, the corresponding LED is ON
n if an output is LOW, the corresponding LED is OFF
Fig. 64: PAMIO PWM Output LEDs

1 PWM Out 5V
2 FAST Out 5V

Number of outputs 2
Max. continuous 0.5 mA DC
output per bit
Output ON delay 100 ns
(typical)
Output OFF delay 100 ns
(typical)
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Output Schematic The following figure shows how the outputs are realized on each
PAMIO PWM module.
Fig. 65: Outputs equivalent schematic
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4.6.2.2 5V to 24V signal converter

Overview
The 5V to 24V converter is available as an option
from Power Automation (see Ä Chapter 6.1.1
“Service addresses” on page 130).
Ordering code for one set:
– PAMIO PWM CONV
The 5V to 24V signal converter module is intended to convert 5V

signals into 24V signals.
This converter has been developed especially for the PAMIO PWM
module, because the 24V output drivers of this module are not able
to switch at high frequencies.
Fig. 66: Signal Converter overview

1 Input Connector
2 Status LED
3 Power Supply Connector
4 Output Connector
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Input Connector (5V Signals)
Fig. 67: Input Connector

1 Input Connector
Table 6: The eight pin input connector has the following pinning:
Pin Description
Pin 1 5V signal IN
Pin 2 5V signal IN
Pin 3 5V signal IN
Pin 4 5V signal IN
Pin 5 Any signal IN
Pin 6 Any signal IN
Pin 7 Any signal IN
Pin 8 Any signal IN
Fig. 68: Eight pin input connector
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Output Connector (24V Signals)
Fig. 69: Output Connector

4 Eight pin Output Connector
Table 7: The eight pin output connector has the following pinning:
Pin Description
Pin 1 24V signal OUT
Pin 5 Any signal OUT
Fig. 70: Eight pin output connector
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Power Supply Connector
Fig. 71: Power Supply Connector

3 Two pin Power Supply Connector
Table 8: The two pin power supply connector has the following pin-
ning:
Pin Description
Pin 1 +24V
Pin 2 0V
Fig. 72: Two pin Power Supply Connector
Status LED There is a LED which gives information whether the 24V power is
applied or not.
Fig. 73: Status LED
LED state Module status

ON +24V power supply is applied
OFF +24V power supply is not
applied
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4.6.2.3 Power Supply

The output byte on the PAMIO PWM needs a separate +24V DC
power supply. This is done on the power supply connector X30
(Fig. 74).
Fig. 74: PAMIO PWM power connection

1 Power connection (X30)
assignment (Fig. 75):
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PWM and Fast Output function
board logic
Pin 3 0V
Pin 4 Not used
Pin 5 Not used
The 0V connection is common to the different

power supplies that have to be applied on this con-
nector.
The power supply of the PWM and Fast output

function is independent from the on-board logic
power supply allows e.g. disconnecting the output
byte in case of emergency stop, making the whole
byte in a safe situation.

on-board logic
PWM and Fast
output function
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4.6.2.4 Wiring Example

Wiring Example
Fig. 76: PAMIO PWM Wiring example

n Number of inputs
NOTICE!
The outputs of PAMIO PWM must be connected to
a shielded twisted pair cable. The shield is applied
to the housing of the connected device.
4.6.2.5 Status LEDs

Overview The PAMIO PWM has four LEDs for diagnostic purposes.
Fig. 77: PAMIO PWM module status LEDs

1 Status
2 Access
3 Bustest
4 Monitor
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“PAMIO PWM LEDs” on page 124.
4.7 PAMIO 2ENC4A

Connections Of The PAMIO The PAMIO module 2ENC4A has connections for:
2ENC4A
n 2 analog axes (4 analog command outputs +/- 10 V DC / 16 bit)
n 4 incremental measurement systems)
n 2 supplementary analog inputs (+/-10V DC / 12 bit)
This special module has an integrated bus termi-

nation. Because of its internal bus termination,
there can be only one such PAMIO model in a
system rack, and it must be the last module of the
rack.

Weight 0.55 kg
1.21 lb

Tolerance -15 / +12.5 %
Max. current 0.2 A
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Overview
Fig. 78: PAMIO 2ENC4A overview

7 Analog outputs 1 to 4 (X37)
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4.7.3 Axis Measurement Inputs (RMS)
Fig. 79: PAMIO 2ENC4A RMS inputs

1 Measurement input 1st axis (X31)
4 Measurement input 2nd axis (X32)
Connection Each axis measurement input has a 15 pin Sub-D connector

female (Fig. 80).
Fig. 80: RMS Input Connector
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Pin 1 Track A+
Pin 2 Track A-
Pin 3 Track B+
Pin 4 Track B-
Pin 5 Track R+
Pin 6 Track R-
Pin 7 Probe input
Pin 8 Probe ground
Pin 9/11/13/15 RMS grounding
Pin 10/12/14 +5 V RMS
RMS Input Characteristics Property Value Unit

Interface type RS 422
Track common -7 - +7 V
mode range
Max. track input -11 - +14 V
voltage
Min. track input +/- 500 mV
voltage
Track input impe- 150 Ω
dance
Max. track fre- 5 MHz
quency (no filter)
Max. count fre- 20 MHz
quency (no filter)
External connector 15 pin Sub-D female / axis
Each measurement input is referenced against its

measurement reference.
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Probe Input Property Value Unit

Max. measurement 27 v
input voltage
Measurement input 7 mA
current (at 24 V)
Measurement input 3300 Ω
impedance
Measurement oper- 10.8 V DC max.
ating voltage OFF
Measurement oper- 11 V DC min.
ating voltage ON
Measurement input 300 ns
ON delay
Measurement input 100 ns
OFF delay
Measurement isola- Opto coupler
tion
Interface type digital input 24 V
Probe wiring
When the probe input is used in an application,
each input of all used axes must be wired in par-
allel.
Input Equivalent Schematic The following figure (Fig. 81) shows how the axis measurement
inputs are realized on each PAMIO 2ENC4A module.
Fig. 81: RMS input equivalent schematic
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RMS Encoder Wiring Example The following schematic demonstrates the recommended way of
connecting the CNC RMS inputs to the encoders (or any other
device with incremental output).
Fig. 82: RMS encoder wiring example
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Precondition
the power supply can be relatively long. The ohmic
resistance of the power supply cable and the RMS'
current consumption generate a voltage drop.
Fig. 83: Schematic encoder power supply voltage drop

1 Power supply
2 Rotating measurement system (RMS)
UA Supply output voltage
U1 Voltage drop
U2 Voltage at the RMS
U3 Voltage drop
As shown in the figure, the voltage U2 equals the difference
between the output voltage UA and the voltage drop U1+U3.
Adjusted voltage U2 = UA - (U1 + U3)
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Examples The voltage drop depends on the cable length and the conductor's
cross section.
The following table shows some cable examples. The values are
typical and only offered as guidelines.
n For proper compensation, calculate the actual values as shown
in the following section.
Conductor Specific Cable length Voltage drop

cross section resistance [m] at 100 mA [V]
[mm2]/[AWG] [Ω/m]
0.08 / AWG 28 0.235 10 0.47
20 0.94
35 1.65
0.14 / AWG 25 0.131 10 0.26
20 0.52
35 0.92
0.25 / AWG 23 0.075 10 0.15
20 0.30
35 0.53
0.5 / AWG 20 0.040 10 0.08
20 0.16
35 0.28
0.75 / AWG 18 0.025 10 0.05
20 0.10
35 0.18
Calculation n Use the actual data obtained from the cable's technical
specifications.
n Double the cable's physical length.
This is necessary as there are two lines: one line to the
RMS (+5 V) and one line from the RMS (grounding).
n Calculate the voltage drop as follows:
Voltage drop [V] = 2 x L x CR x PC
L - Cable length [m]

C - CR Specific resistance per meter [Ω/m]
P - PC Power consumption [A]
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Compensation
Personnel: n Skilled electrician
1. Install a power supply with adjustable output voltage to
supply the RMS supply input.
This is a requirement for voltage drop compensation.
2. Calculate the actual voltage drop between RMS power
supply and RMS.
3. Adjust the external RMS power supply to feed a slight
overvoltage of 5.1 V to 5.5 V depending on the measured
drop.
A measurement system contains integrated elec-

tronic components. Relating to the current con-
sumption Power Automation only indicates mean
values. Current peaks of a multiple of the mean
value may occur for several microseconds during
operation.
– Select a conductor cross-section which guar-
antees a maximum voltage drop of 0.2 V.
– Set the power supply to the upper limit of the
RMS supply voltage.
These steps guarantee that the RMS' supply
voltage does not drop below the required min-
imum.
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4.7.4 RMS Power Supply

Overview
Fig. 84: PAMIO 2ENC4A RMS power supply

Connection The power supply for encoders is connected with a 2 pole terminal
block (Fig. 85).
Fig. 85: RMS power terminal block
Pin Assignment Pin Voltage Assignment

1 +5 V RMS supply
2 0V RMS ground
Technical data Property Value Unit

Tolerance 0 - +20 %
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Voltage Drop
the power supply can be relatively long. The impe-
dance of the power supply cable and the RMS' cur-
rent consumption generate a voltage drop (see
Ä “Precondition” on page 70).
4.7.5 Axes Analog Outputs

Overview
Fig. 86: PAMIO 2ENC4A axes analog outputs

7 Analog outputs 1 to 4 (X37)
Connection The analog outputs are connected with an 8 pole terminal block
(Fig. 87).
Fig. 87: Axes output terminal block
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Number of analog 4
output points
Output signal range +/- 10 V
(max.)
Output current load +/- 15 mA
(max.)
Output capacitive 350 pF
load (max.)
Bipolar zero error +/- 40 mV
(max.)
Full scale error +/- 1 1%
(max.)
Channel to channel +/- 1 %
mismatch (max.)
Linearity error +/- 2.44 mV
(max.)
Resolution 305 μV
(max.)
Output slew rate 0.4 V/us
(typ.)
External connector 8 pole terminal block
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Output Schematic
Fig. 88: Analog axis output equivalent schematic
Analog output wiring

The wiring of the analog output commands to the
drive depends on the type of drive analog inputs.
– During drive installation take into consideration
whether the drive analog inputs are grounded
or not.
– If the analog inputs are grounded, connect the
drives according to the schematic for non-dif-
ferential inputs.
– If the analog inputs are not grounded, connect
the drives according to the schematic for differ-
ential inputs.
The following schematics demonstrate the recommended way of

connecting the CNC analog outputs to the analog inputs of the
drives, depending on the analog input type of the drive.
Drives With Non-Differential Inputs

(Unipolar)
Fig. 89: Schematic non-differential inputs (unipolar)
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Drives With Differential Inputs
Fig. 90: Schematic differential inputs
4.7.6 Analog Inputs

Overview
Fig. 91: PAMIO 2ENC4A analog inputs

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Connection The analog inputs are connected with a 9 pole terminal block
(Fig. 92).
Fig. 92: Analog inputs terminal block

Pin 9 analog ground (ACOM)

Input signal range -10 - +10 V
Common mode -15 - +15 V
range
Max. input voltage -15 - +15 V
Input impedance 16 kΩ
Max. bipolar zero +/- 10 mV
error
Max. full scale error +/- 1 %
Max. channel to +/- 1 %
channel mismatch
Max. linearity error +/- 4.88 mV
Resolution 4.88 mV
Conversion time / 160 μs
4points
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Input Schematic
Fig. 93: Analog input equivalent schematic
UA/D = (U+IN - UACOM) - (U-IN - UACOM)
n UA/D = A/D Converter Output

n U+IN = + Differential input
n U-IN = - Differential input
n UACOM = Analog ground ACOM
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4.7.7 Power Supply

Overview
Fig. 94: PAMIO 2ENC4A power connection

Fig. 95: Power terminal block

Pin 1 Not used
board logic
Pin 3 0V
Pin 4 Not used
Pin 5 Not used
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PA 8000 PAMIO
PAMIO Components

Operating voltage + 24 V DC
on-board logic
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PA 8000 PAMIO
PAMIO Components
4.7.8 Status LEDs

Overview

The PAMIO 2ENC4A has six LEDs for diagnostic purposes.
1 Status
2 Access
3 Bustest
4 Monitor
5 Axis 1
6 Axis 2

“PAMIO 2ENC4A LEDs” on page 126.
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PA 8000 PAMIO
PAMIO Components
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PA 8000 PAMIO
Troubleshooting
5 Troubleshooting
General Information 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 6 “Service and return process” on page 129).
5.1 Safety notes

Personnel 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 8000 PAMIO
Troubleshooting
In Case Of Faults The following general rules apply:

Personnel: n Qualified personnel
Protective equipment: n Ground strap
n ESD safety shoes
n ESD safety pad
n ESD clothing
n Protective glasses
n Ear protection
n Antistatic gloves
1. In the event of faults that pose immediate danger to man or

machine, activate the emergency shutoff function immedi-
ately.
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.
5.2 Malfunction indicators

Overview The following components indicate malfunctions or improper con-
figuration of the PAMIO components.
Module Description
PAMIO 2416 LEDs The LEDs of the PAMIO
2416 module indicate
operating states and mal-
functions regarding digital
inputs and outputs.
PAMIO 4ENC4A LEDs The LEDs of the 4AXLX
module indicate operating
states and malfunctions
regarding analog inputs
and outputs.
PAMIO PWM LEDs The LEDs of the PAMIO
PWM module indicate
operating states and mal-
functions regarding digital
outputs.
PAMIO 2ENC4A LEDs The LEDs of the 2ENC4A
module indicate operating
states and malfunctions
regarding analog inputs
and outputs.
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PA 8000 PAMIO
Troubleshooting
5.2.1 PAMIO 2416 LEDs

Overview The PAMIO 2416 has four LEDs for diagnostic purposes.
Fig. 97: PAMIO 2416 module status LEDs

1 Status
2 Access
3 Bustest
4 Monitor
LED "Status" (1) The LEDs' states are assigned the following status messages:

Off No power supply (24 V)
OR Hardware error
Slow flash The module is not configured
Quick flash The module is configured but the outputs are disa-
bled because the watchdog is not re-triggered
On The module is configured and the digital outputs
are enabled
LED "Access" (2) LED state Module status

Off Default
On Access to this module
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PA 8000 PAMIO
Troubleshooting
LED "Bustest" (3) LED state Module status

Off Default
On Bustest between control unit and the last PAMIO
module is active
LED "Monitor" (4) LED state Module status

Off Error 1: The ambient temperature is above 60 °C
(140 °F) and all outputs are disabled by the
onboard logic
OR Error 2: The watchdog is re-triggered but the 24 V
output supply has been interrupted for more than
60 seconds. In this case the onboard logic switches
off the corresponding 24 V outputs.
Flashing Warning 1: The ambient temperature is above
55 °C (131 °F)
OR Warning 2: The watchdog is re-triggered but the 24
V output supply has been interrupted for more than
15 seconds
OR Warning 3: Outputs are overloaded
On The 24 V output supply is correct (Default)
AND There is no temperature error
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PA 8000 PAMIO
Troubleshooting
5.2.2 PAMIO 4ENC4A LEDs

Overview The PAMIO 4ENC4A has ten LEDs for diagnostic purposes.

1 Status
2 Access
3 Bustest
4 Monitor
5 Axis 1
6 Axis 2
7 Axis 3
8 Axis 4
9 Power OK
10 CNC Ready

OR Hardware error
On The module is configured and the analog outputs
are enabled

Off Default
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PA 8000 PAMIO
Troubleshooting

Off Default
module is active

onboard logic
Flashing Warning: The ambient temperature is above 55 °C
(131 °F)
On Default
LED "Axis 1" - LED "Axis 4" (5 - 8) LED state Module status
Off Axis is not connected
OR Axis is connected and an encoder wire break has
been detected
Flashing Axis is connected and a wrong sequence of signals
on track A and B has occurred
On Axis is connected and no wire break has been
detected
NOTICE!
A wrong sequence of axis signals is detected when
the A and B track of an incremental measuring
system shows incorrect sequence of rising and
falling edges. This can occur in case of interfer-
ences on the signals.
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PA 8000 PAMIO
Troubleshooting
LED "Power OK" (9) LED state Module status

Off The power supply voltage for
the onboard logic is outside its
tolerances
OR The ambient temperature is
above 60 °C (140 °F)
On The power supply voltage for
the onboard logic is OK
AND The +/- 15 V supply voltage for
the analog I/O functions is OK
AND The ambient temperature is
below 60 °C (140 °F)
LED "CNC Ready" (10) LED state Module status

Off The CNC is not ready or the
power supply for the RMS is
outside of the tolerated values
or the ambient temperature is
T>55 °C (131 °F). In all these
cases, the analog outputs are
set to 0V.
On The CNC is ready, the power
supply for the RMS is OK and
the ambient temperature is
T>55°C (131°F). The analog
outputs are enabled.
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PA 8000 PAMIO
Troubleshooting
5.2.3 PAMIO PWM LEDs

Overview The PAMIO PWM has four LEDs for diagnostic purposes.
Fig. 99: PAMIO PWM module status LEDs

1 Status
2 Access
3 Bustest
4 Monitor

OR Hardware error
are enabled

Off Default
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PA 8000 PAMIO
Troubleshooting

Off Default
module is active

onboard logic
OR Error 2: The watchdog is re-triggered but the 24 V
output supply has been interrupted for more than
60 seconds. In this case the onboard logic switches
off the corresponding 24 V outputs.
Flashing Warning 1: The ambient temperature is above
55 °C (131 °F)
OR Warning 2: The watchdog is re-triggered but the 24
V output supply has been interrupted for more than
15 seconds
OR Warning 3: Outputs are overloaded
On The 24 V output supply is correct (Default)
AND There is no temperature error
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PA 8000 PAMIO
Troubleshooting
5.2.4 PAMIO 2ENC4A LEDs

Overview

The PAMIO 2ENC4A has six LEDs for diagnostic purposes.
1 Status
2 Access
3 Bustest
4 Monitor
5 Axis 1
6 Axis 2

OR Hardware error
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PA 8000 PAMIO
Troubleshooting

are enabled

Off Default

Off Default
module is active

onboard logic
Flashing Warning: The ambient temperature is above 55 °C
(131 °F)
On Default
LED "Axis 1" - LED "Axis 2" (5/6) LED state Module status
Off Axis is not connected
OR Axis is connected and an encoder wire break has
been detected
Flashing Axis is connected and a wrong sequence of signals
on track A and B has occurred
On Axis is connected and no wire break has been
detected
NOTICE!
A wrong sequence of axis signals is detected when
the A and B track of an incremental measuring
system shows an incorrect sequence of rising and
falling edges. This can occur in case of interfer-
ences on the signals.
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PA 8000 PAMIO
Troubleshooting
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PA 8000 PAMIO
Service and return process
6 Service and return process

6.1 Service
Service At Power Automation By Phone
PA's well-educated service staff is available to answer your tech-
nical questions. Due to the close co-operation with our customers,
our engineers can solve problems often immediately by phone.
If on-site support is necessary, our service staff will diagnose the
problem and will prepare our field service engineer beforehand.
This is to make on-site service as much effective as possible.
By Remote Control Software

Every PA CNC is equipped with an Ethernet interface. If you have
a network on-site, you only have to integrate the CNC system to
your network for world-wide-web access.
Power Automation provides a remote control software which allows
our service staff to log into your CNC. This provides all the informa-
tion available on the machine. They can check all the data like the
PLC program, machine parameters, or the NC programs directly
on the real system under real conditions. This is the fastest and
most 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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PA 8000 PAMIO
6.1.1 Service addresses

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
Power Automation Office Turkey

Kustepe Mah. Mecidiyekoy Yolu Cad.
Trump Towers No. 12 Kule: 2 K:18
Daire no: 3211022839 Sisli / Istanbul
Turkey
Tel: +90-212-306-3280
Fax: +90-212-306-3101
sales.turkey@powerautomation.com
Shenzhen Double CNC Tech Co., Ltd

8th Floor,WeiXinDa Building
Bao Min Road 2
Xi Xiang Town
Bao'an District, Shenzhen, Guangdong
PR China
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PA 8000 PAMIO
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
6.2 Spare parts

Spare Parts Due to the high quality of our products we can assure you that you
will not need this service often. Spare parts are often urgent so
Power Automation provides the relevant spare parts at the local
service centers for immediate dispatch.
Our 3 service centers in Europe, North America and Asia allow us
to deliver all needed parts typically within 24 hours.
Only trust PA's original parts - because every part passes our tight
quality checks.
We also offer consulting services to identify the most critical parts
for the machines in your production facilities. We suggest what crit-
ical stock may be required to ensure a minimum downtime of your
machines. Our specialists look for common parts to keep your
inventory levels at a minimum.
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PA 8000 PAMIO
6.3 Return policy and procedure

Policy
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.
Acquiring RMA Number

1. Contact Power Automation to receive an RMA form in Excel
format. Ä “RMA Form” on page 133
2. Open the 'RMA Process' form provided by Power Automa-
tion.
Use one form for each single part you want to ship back to
Power Automation.
3. 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).
ð We will check the data and send the form back to you as
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 compo-
nents and documents.
6. After the check and repair the components will be shipped to
you immediately.
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PA 8000 PAMIO
RMA Form
Fig. 101: RMA Form
12.01.2017 | 133
PA 8000 PAMIO
Return
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 dam-
ages to the control unit. This will void the
material warranty. PA does not bear any lia-
bilities for damages in transit.
2. Write the RMA number on the cardboard box clearly read-

able from outside.
The incoming goods department rejects all deliveries
without a visible, valid RMA number.
3. Ship the goods FREE DOMICILE / DDU. Other deliveries will
be rejected.
Conditions Of Supply The goods have to arrive within 4 weeks after the date of the
approved RMA form.
6.4 Training
Training Courses Having the best CNCs is one thing, to bring out the best of it is the
other.
The PA training program comprises of a number of individually
combinable training modules which offer you a well-founded knowl-
edge for using PA CNCs. At our training centers we bring your
employees - beginners and experts- up to scratch in CNC tech-
nology. We also offer individual training courses at your site. The
contents of the courses will be customized to your requirements.
For more information see Ä Chapter 6.1.1 “Service addresses”

on page 130.
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PA 8000 PAMIO
Proof of Change
7 Proof of Change
Proof Of Change Version Change Date
1 Original Version 12/15/2014
2 Changes in Chapter 5.2.1 08/19/2015
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PA 8000 PAMIO
Proof of Change
12.01.2017 | 136
PA 8000 PAMIO
Index
8 Index
1, 2, 3 ... I
2ENC4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Input
Analog . . . . . . . . . . . . . . . . . . . . . . . . . . 78, 111
A
Input equivalent . . . . . . . . . . . . . . . 68, 79, 101, 112
Abmessungen . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Instructed person . . . . . . . . . . . . . . . . . . . . . . . . 12
Analog axes
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 109
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 L
Axes Analog Outputs . . . . . . . . . . . . . . . . . . 73, 107 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LED
B
Module 2ENC4A status . . . . . . . . . . . . 115, 126
Bus Termination . . . . . . . . . . . . . . . . . . . . . . . . . 30
Module 4ENC4A status . . . . . . . . . . . . . 85, 121
C Module 2416 status . . . . . . . . . . . . . . . . 64, 119
Cable specification . . . . . . . . . . . . . . . . . . . . . . . 42 Module PWM status . . . . . . . . . . . . . . . . 96, 124
Changing PAMIO modules . . . . . . . . . . . . . . . . . 45 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . 9
Connection to the CNC . . . . . . . . . . . . . . . . . . . . 46 M
Connection to the control unit . . . . . . . . . . . . . . . 29
Maximum configuration . . . . . . . . . . . . . . . . . . . . 25
Connection values . . . . . . . . . . . . . . . 52, 65, 86, 97
Mechanical assembly . . . . . . . . . . . . . . . . . . . . . 35
Connectors 54, 58, 62, 66, 73, 74, 77, 80, 81,
87, 94, 99, 106, 107, 111, 113 N
Customer's responsibility . . . . . . . . . . . . . . . . . . . 11 Non-differential inputs . . . . . . . . . . . . . . . . . 76, 109
D O
Differential inputs . . . . . . . . . . . . . . . . . . . . . 77, 110 Operating conditions . . . . . . . . . . . . . . . . . . . . . . 51
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Output
DIN rail installation . . . . . . . . . . . . . . . . . . . . . . . 33 Analog . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 108
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 109 power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 94
E Output equivalent . . . . . . . . . . . . . . . . . . . . 76, 109
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 88
Electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electronic components . . . . . . . . . . . . . . . . . . . . 19 P
Environmental hazard . . . . . . . . . . . . . . . . . . . . . 19 PAMIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
G PAMIO 2ENC4A . . . . . . . . . . . . . . . . . . . . . . . . . 97
PAMIO 4ENC4A . . . . . . . . . . . . . . . . . . . . . . 27, 64
General specifications . . . . . . . . . . . . . . . . . . . . . 25
PAMIO 2416 . . . . . . . . . . . . . . . . . . . . . . . . . 27, 52
H PAMIO Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PAMIO Combinations . . . . . . . . . . . . . . . . . . . . . 27
PAMIO configurations . . . . . . . . . . . . . . . . . . . . . 49
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PA 8000 PAMIO
Index
PAMIO Modules . . . . . . . . . . . . . . . . . . . . . . . . . 27 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

PAMIO Power requirement . . . . . . . . . . . . . . . . . 49 Stopping brackets . . . . . . . . . . . . . . . . . . . . . . . . 36
PAMIO PWM . . . . . . . . . . . . . . . . . . . . . . . . . 27, 85 Superbus cable . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Personal protective gear . . . . . . . . . . . . . . . . . . . 14 Superbus cables . . . . . . . . . . . . . . . . . . . . . . 41, 47
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
T
Pictures
Technical specifications . . . . . . . . . . . . . . . . . . . . 48
in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pins
Termination plug . . . . . . . . . . . . . . . . . . . . . . . . . 39
Input . . . . . . . . . . . 55, 67, 73, 78, 100, 106, 111
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Output . . . . . . . . . . . . . . . . . . . . 58, 74, 87, 108
power . . . . . . . . . . . . . . . . . . . . . 63, 80, 95, 113 U
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Unintended use . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Probe input . . . . . . . . . . . . . . . . . . . . . . . . . 68, 101
V
Proof of Change . . . . . . . . . . . . . . . . . . . . . . . . 135 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protective Grounding . . . . . . . . . . . . . . . . . . . . . 50 W
Q Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Qualification Wiring
electrician . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Analog axes . . . . . . . . . . . . . . . . . . . . . . 76, 109
requirements . . . . . . . . . . . . . . . . . . . . . . . . . 12
technician . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unauthorized person . . . . . . . . . . . . . . . . . . . 12
Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . 12
R
Relay "CNC Ready" . . . . . . . . . . . . . . . . . . . . . . 83
Relay "Power OK" . . . . . . . . . . . . . . . . . . . . . . . . 82
RMA form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
RMA-number . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
RMS input . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 100
S
Safety
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Schematic
Analog axes wiring . . . . . . . . . . . . . . . . . 76, 109
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Service Addresses . . . . . . . . . . . . . . . . . . . . . . 130
Signal Converter . . . . . . . . . . . . . . . . . . . . . . . . . 90
12.01.2017 | 138

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Installation instructions

© 2015 Power Automation GmbH

4.2.1.1 PAMIO models 2416 / 4ENC4A / PWM................ 30

4.6.2.4 Wiring Example.................................................... 96

1.2 Explanation of symbols

… emphasizes useful hints and recommendations

n .. Highlights single or unordered instructions and lists.

1.3 Limitation of liability

1.5 Warranty terms

1.6 Customer service

Moreover, the customer is also responsible for keeping the control

2.2 Personnel requirements

The following qualifications are specified for different areas of

2.2.2 Unauthorized persons

n When selecting personnel, ensure that the personnel can work

2.3 Intended use

2.4 Unintended use

2.5 Personal protective gear

ESD safety pad

ESD safety shoes

2.6 Specific dangers

n In the event of damage to insulation, switch off the power

n Do not throw batteries into fire or expose to high temperature.

2.7 PAMIO safety devices

n Before initial commissioning of the machine, ensure that all

2.8 Machine Safety

Further Applicable Documents

2.8.1 'CNC ready' signal - Emergency stop inter-

n Properly integrate the 'CNC ready' relay into the machine's

2.8.2 'Power ok' signal

– When an external 5V power supply (RMS) is

2.8.3 Control Units and associated PAMIO 4ENC4A

2.9 Conduct in a dangerous situation and in

In Case Of Accidents n Disconnect power supply immediately.

2.10 Environmental protection

The following environmentally hazardous components or sub-

Fig. 1: PAMIO box labels

Fig. 2: PAMIO article label

Fig. 3: PAMIO ArtNo+SNo label

Product Code Description See

4.1.2 Maximum Number of PAMIO Modules

Refer to the installation manual of your specific control unit to

The Power Automation software attributes a fixed

NBuild-In + N2416 + N4ENC4A + N2ENC4A + NPWM = 31

4.1.3 PAMIO Boxes and PAMIO Modules

Each PAMIO Box is constituted of:

There are 3 different models of PAMIO single mod-

Table 2: There are 9 different predefined possible combinations:

Individual Components Table 3: There are 4 individual components:

Special PAMIO Component Table 4: There is one special PAMIO component:

4.1.4 Connection to the control unit and intercon-

The Superbus cable is not included in the control

Fig. 4: Assembling PAMIO boxes

Fig. 5: PAMIO system with two racks

4.1.5 Bus termination

4.2 Mechanical Installation

The weight of a PAMIO box depends on the model

Fig. 6: PAMIO box dimensions

4.2.1.2 PAMIO Modell 2ENC4A

Fig. 7: Abmessungen des PAMIO 2ENC4A

4.2.2 DIN rail installation

Fig. 8: Din rail for PAMIO mounting

Because of the weight of the boxes, due to their rugged construc-