Festo EMCA-EC-67-CO Series Reference guide

EMCA-EC-67-...-CO-...
Integrated drive
Festo SE & Co. KG
Ruiter Straße 82
73734 Esslingen
Deutschland
[phone]
www.festo.com
Brief instruction | Safety manual
8157997
2022-02c
[8157999]
Translation of the original instructions
© 2022 all rights reserved to Festo SE & Co. KG
CANopen®, CiA® are registered trademarks of the respective trademark owners
in certain countries.
1Applicable documents
All available documents for the product è www.festo.com/sp
User documentation for the product
Manual
EMCA-EC-SY-…
Device and functional description;
Mounting, installation, commissioning and diagnostics
Manual
EMCA-EC-S1-…
Description of the “safe torque off” safety function (Safe torque off/
STO)
Manual
EMCA-EC-C-HP-…
Description of device profile FHPP (Festo Handling and Positioning
Profile)
Manual
EMCA-EC-C-CO-…
Description of the device profile CiA 402
Help for the FCT plug-in
EMCA
Online help for the Festo Configuration Tool (FCT) for commissioning
and parameterisation
Special documentation
EMCA-EC_UL-…
Requirements for operating the product in the USA and Canada in
accordance with certification by Underwriters Laboratories Inc. (UL)
Tab. 1
2Safety
–Always observe the safety instructions and warnings in the documentation of
the product and the other components.
–Before mounting and installation work, switch off the supply voltage and
secure it against being switched on again. Do not switch on the supply voltage
again until all mounting and installation work has been completed.
–Never remove or insert a plug when the motor controller is powered.
–Handhabungsvorschriften für elektrostatisch gefährdete Bauelemente ein-
halten.
–Do not enable the closed-loop controller until the drive has been professionally
installed and fully parameterised.
–Do not carry out repairs on the device. If it is defective, replace the device.
–Do not loosen any screws except for the 4 screws on the housing cover.
WARNING
Risk of injury from touching hot surfaces.
Contact with housing can cause burn injuries. This can frighten people and cause
them to act in an unpredictable manner. This can lead to other forms of secondary
damage.
• Avoid unconscious touching of the housing.
• Inform operating and maintenance staff about the possible hazards.
• Before maintenance work: Let the drive cool down to below 40°C.
WARNING
Fast rotating motor shaft with high torque.
Contact with the motor shaft can cause burn injuries and abrasions.
• Ensure that the rotating motor shaft and components attached to it cannot be
touched.
WARNING
Gas formation with fire risk.
If cleaning agents come into contact with the hot surface of the drive, gases may
be formed and may ignite.
•Allow the drive cool down to room temperature before starting cleaning.
2.1 Intended use
The product is intended for the actuation and control of electromechanical drives.
The product is intended for installation in a machine.
Use exclusively:
–in perfect technical condition
–in original condition without unauthorised modifications; only the extensions
described in the documentation supplied with the product are permitted.
–within the limits of the product defined by the technical data
–in an industrial environment.
Outside industrial environments, e.g. in commercial and residential mixed-use
areas, measures to suppress interference may be required.
2.2 Intended use of the STO function
The STO "Safe torque off" function (Safe torque off) in accordance with
EN 61800-5-2 is intended for use in switching off the torque of the integrated
motor. The STO function prevents unexpected start-up of the integrated motor.
The STO function may only be used in applications in which the specified safety
characteristics are sufficient.
Safety characteristics
The product’s STO function fulfils requirements for the following characteristic
safety values:
–PL d/cat. 3 in accordance with EN ISO 13849-1 (Performance Level/PL)
–SIL 2 in accordance with EN 61800-5-2 (Safety Integrity Level/SIL)
–SILCL 2 in accordance with EN 62061 (Claim Limit/CL)
The achievable safety level depends on the other components used to implement
a safety function.
For protection against unexpected start-up, the product must be actuated via the
connection [X6] with the category required for the application in accordance with
EN ISO 13849-1, e.g. by an external safety relay unit.
Qualification of the specialist technicians (requirements for staff)
The product may be commissioned only by a person with electrical engineering
qualifications who is familiar with the following:
–Installation and operation of electrical control systems
–Applicable regulations for operating safety-related systems
–Applicable regulations for accident prevention and occupational safety
–Documentation for the product
Diagnostic coverage (DC) for the safety function
Diagnostic coverage is determined by including the product in the control chain
and the measures implemented for the diagnostics. In order to achieve the speci-
fied diagnostic coverage, the status of the feedback contact must be evaluated by
the control system every time the STO function is requested. If a potentially dan-
gerous malfunction is detected during diagnostics, appropriate measures must be
taken to maintain the safety level.
The device cannot detect a cross circuit in the input circuit by itself.
• If required, use a safety relay unit with detection of shorts across contacts.
2.3 Foreseeable misuse of the STO function
The following are examples of foreseeable misuse and are not approved as
intended use:
–Bypassing the STO function
–Use in applications where switching off can result in hazardous movements or
conditions
The STO function is not sufficient as the sole safety function for drives that are
subject to permanent torque or force (e.g. suspended loads, vertical axes).
2.4 Obligations of the operator for the safety function
The implemented safety function must be subjected to a regular and documented
performance test by a specialist during the period of use of the machine. The
frequency of these tests must be determined by the machine operator based on
the specifications of the machine manufacturer.
–Check the EMCA at least once a year.
3 Requirements for product use
–Provide the complete product documentation to the following personnel:
–the design engineer and the installer of the machine or system
–the personnel responsible for commissioning
–Keep the documentation available throughout the entire product lifecycle.
–Ensure compliance with the specifications in this documentation. Also observe
the information in the documentation for the other components and modules,
e.g. axial kit, gear unit, actuator, lines.
–Observe all of the legal regulations applicable for the installation site and the
following documents:
–instructions and standards
–regulations of the testing organisations and insurers
–national specifications
For correct and safe use of the STO function:
–Conduct a risk assessment for your machine.
–Comply with the specified safety characteristics è 10 Technical data.

Range of application and approvals
The EMCA with integrated STO safety function is a safety-related part of control
systems. The product has the CE marking. Certain configurations of the product
are certified by Underwriters Laboratories Inc. (UL).
Certificates and declaration of conformity for the product è www.festo.com/sp.
Product conformity
The directives and standards applicable for the product are listed in the declara-
tion of conformity è www.festo.com/sp.
Product conformity
in accordance with EU EMC Directive
in accordance with EU Machinery Directive
in accordance with EU RoHS Directive
to UK EMC Regulations
to UK Supply of Machinery Regulations
to UK RoHS Regulations
Tab. 2: Product conformity
Specified standards
Version
EN ISO 13849-1:2015
EN 61800-5-2:2007, EN 61800-5-2:2017
EN 62061:2005 + AC:2010 + A1:2013 + A2:2015
Tab. 3
3.1 Transport and storage conditions
–Protect the product from excessive stress factors during transport and storage.
Excessive stress factors include:
–mechanical stresses
–impermissible temperatures
–moisture
–aggressive atmospheres
–Store and transport the product in its original packaging. The original pack-
aging offers sufficient protection from typical stresses.
3.2 Technical prerequisites
For correct and safe use of the product:
–Comply with the specified connection and ambient conditions for all connected
components è 10 Technical data. Only compliance with the limit values and/or
load limits will enable operation of the product in accordance with the relevant
safety directives.
4 Product description
4.1 Product overview
1
2
3
4
5
6
7
8
9
10
Fig. 1: Design of the drive
1
LED light guide (6x) - 3 used
2
[X1]: parameterisation interface
(Ethernet interface)
3
[X3]: CAN OUT
4
Cable throughfeeds (6x)
5
Motor flange
6
Through-hole for mounting (4x)
7
Mounting thread (4x) thread M4
8
Shaft
9
Cover
10
[X2]: CAN IN
12 3 4
5
678910
11
12
Fig. 2: View with cover open
1[X5]: braking resistor
2DIL switch (terminating resistor
for CAN bus)
3[X10]: external battery (...-1TM)
4[X6]: STO interface
5[X9]: I/O interface
6[X8]: reference or limit switch 2
7[X7]: reference or limit switch 1
8FE connection (flat plug)
9[X4]: power supply
10 OK LED (green)
11 ERROR LED (red)
12 Bus status LED (bi-colour)
5 Mounting
The mounting flange offers the following options for mounting:
–Mounting via 4 through-holes for M6 screws
–Mounting via 4 M4 female threads (screw-in depth: 5 mm).
Observe the assembly instructions for the additional components used (e.g. axial
kit, parallel kit, gear unit, axis).
The drive must be mounted securely and without tension.
1. Move the slide or cantilever of the driven mechanism into a safe position.
2. Connect the EMCA to the driven mechanism è Assembly instructions for the
additional components.
3. Tighten the retaining screws (4x). Tightening torque è Assembly instructions
for the additional components.
6 Electrical installation
WARNING
Risk of injury due to unexpected movement of the product.
Electrical energy can cause unexpected movement of the product.
• Before working on the product: Switch off the power supply, ensure that it is off
and secure it against being switched on again.
6.1 Connections and cables
NOTICE
Unexpected and unintended movements
Incorrectly assembled cables can cause malfunctions.
• Use only the supplied plugs and preferably the cables listed in the specified
accessories.
• Lay all flexible cables so that they are free of kinks and mechanical stress,
e.g. in a carrier chain.
ESD protection
Damage may be caused to the product or to other system parts at unassigned
push-in connectors as a result of ESD (Electrostatic Discharge).
–Comply with the handling specifications for electrostatically sensitive compo-
nents.
–Seal unassigned plugs with protective caps.
–Earth system parts prior to installation.
The mating plugs for the plug connectors are not included in the scope of delivery
(assortment of plugs NEKM-C).
6.2 Parameterisation interface (Ethernet) [X1] – M12 bushing, 5-pin,
D-coded
–Connect the EMCA to your network via a hub/switch or directly to
the PC. Observe cable specifications è Device and function description,
EMCA-EC-SY-….
Recommended: use NEBC-D12G4-… connecting cable from Festo.
NOTICE
Unauthorised Access to the Device Can Cause Damage or Malfunction.
• When connecting the device to a network, protect the network from unauthor-
ised access.
Standards for security in information technology can be used for network pro-
tection measures, e.g. IEC 62443, ISO/IEC 27001.
[X1] Pin Description
1 TD+ Transmitted data +
2 RD+ Received data +
3 TD- Transmitted data –
4 RD- Received data –
5 – not connected
Housing Shield/FE Shield/functional earth
Tab. 4
6.3 CAN interface [X2], [X3]
–[X2]: CAN IN (incoming line) – M12 plug, 5-pin, A-coded
–[X3]: CAN OUT (continuation line) – M12 bushing, 5-pin, A-coded
[X2] Pin Description
1 CAN_SHLD Shield, capacitive connection to housing
2 NC not connected
3 CAN_GND CAN bus reference potential
4 CAN_H CAN bus high
5 CAN_L CAN bus low
Housing Shield/FE Shield/functional earth
Tab. 5

[X3] Pin Description
1 CAN_SHLD Shield, capacitive connection to housing
2 NC not connected
3 CAN_GND CAN bus reference potential
4 CAN_H CAN bus high
5 CAN_L CAN bus low
Housing Shield/FE Shield/functional earth
Tab. 6
DIL switch Function
S1.1 Terminating resistor for CAN bus (120 Ω); ON = ON, OFF = OFF
S1.2 reserved
Tab. 7
6.4 Power supply [X4]
WARNING
Risk of injury due to electric shock.
• For the electrical power supply, use only PELV circuits in accordance with IEC
60204-1/EN 60204-1 (Protective Extra-Low Voltage, PELV).
•Observe the general requirements of IEC 60204-1/EN 60204-1 for PELV circuits.
• Only use voltage sources that ensure a reliable electric separation from the
mains network in accordance with IEC 60204-1/EN 60204-1.
[X4] Pin Description
1 +24 V DC Power supply (logic and load voltage)
+19.2 V DC … +28.8 V DC
2 0 V GND, reference potential
Tab. 8
If a shielded supply cable is used, the cable shield can be connected to the
functional earth connection (flat plug).
Flat plug Pin Description
– FE Optional connection for the cable shield
Mating connector: flat connector sleeve (6.3 x 0.8 mm2)
Tab. 9
6.5 Braking resistor [X5]
[X5] Pin Description
1 ZK+ Connection for the external braking resistor RBR 6 Ω; the
braking resistor CACR-LE2-6-W60 from Festo is suitable.
2 BR-CH
Tab. 10
6.6 STO interface [X6]
The STO safety function is described in detail in the EMCA-EC-S1-… document. The
STO function should only be used in the manner described in this document.
Recommendation for initial motor start-up without safety engineering:
–minimum circuitry with emergency stop switching device
–two-channel switch-off via control inputs STO1 [X6.4] and STO2 [X6.5]
[X6] Pin Description
1 NC1 Acknowledgement contact:
–potential-free
–low impedance if the STO function has been
requested and activated via 2 channels.
2 NC2
3 +24 V DC
LOGIC OUT
Logic voltage output (from [X4.1]), reference potential
(0 V) is pin [X6.6] or [X4.2] (internally bridged)
Not overload-proof! Max. 100 mA permissible.
4 STO 1 Control inputs for STO function
5 STO 2
6 GND Reference potential 0 V
Tab. 11
6.7 Limit/reference switch [X7], [X8]
[X7] Pin Description
1 +24 V DC Voltage output 24 V for supply of the reference or limit
switch 1 (configurable with FCT, not short-circuit proof).
2 Switch 1 Signal input for reference switch or limit switch 1
3 GND Reference potential 0 V
Tab. 12
[X8] Pin Description
1 +24 V DC Voltage output 24 V for supply of the reference or limit
switch 2 (configurable with FCT, not short-circuit proof).
2 Switch 2 Signal input for reference switch or limit switch 2
3 GND Reference potential 0 V
Tab. 13
6.8 I/O interface [X9]
[X9] Pin Type1) Name Description
1 DOUT Ready signals the ready status
2 DOUT configu-
rable
Output behaviour configurable with FCT
3 – +24 V DC Output 24 V DC; looped through from
[X4.1]
4 DIN Enable Enable/block closed-loop controller
5 DIN Sample Signal for saving the actual position
(Flying measurement)
6 – GND Reference potential 0 V
1) DIN = digital input; DOUT = digital output
Tab. 14
6.9 External battery [X10] - only EMCA-EC -...- 1TM
[X10] Pin Description
1 Battery + Connection for external battery (position changes are
recorded for a maximum of 7 days (best case) without
supply voltage and without battery (after charging for
approx. 24 hours)). With the EADA-A-9 battery from
Festo, the duration can be extended to a maximum of
6 months.
2 Battery –
(GND)
Tab. 15
6.10 Ensuring the IP degree of protection
–Comply with the requirements for securing the IP degree of protection
è Device and function description, EMCA-EC-SY-….
7Commissioning
The product communicates with a connected PC with the TCP/IPv4 protocol.
Establishing network connection – example “point-to-point connection”
Requirement:
–The PC is configured as a DHCP client (usually standard for PCs).
–The EMCA is configured as a DHCP server (factory setting).
–At initial commissioning connect the EMCA directly to the PC.
Factory setting
DHCP server: active
IP address: http://192.168.178.1
Subnet mask: 255.255.255.0
Gateway: - (a gateway is not assigned.)
Web servers
The integrated web server provides read access to an English-language website.
FCT (Festo Configuration Tool)
The EMCA plug-in for the Festo Configuration Tool (FCT) supports all the steps
necessary for commissioning of the device.
Observe the documentation for the product è www.festo.com/sp.
Before switching on the power supply:
Check installation:
–Check all connections.
Check readiness for operation
1. Make sure that controller enable signal is switched off (pin X9.4).
2. Switch on the power supply. The OK LED on the front panel of the device
should now flash green.
If the OK LED stays off, the device is not ready for operation. If the ERROR-LED
shows red, an error is reported and the cause of the error must be remedied.
Further steps for commissioning è Help for the EMCA plug-in and device and
function description EMCA-EC-SY-…
8Diagnostics and fault clearance
Information on the bus status LED è Description for the device profile.
LED LED status Event/state
Behaviour during the switch-on phase
OK flashing green Start-up phase, bootloader active
ERROR flashing red

LED LED status Event/state
Behaviour in the operating phase
OK off Hardware is not ready for operation; an error is pending.
flashing green Hardware is ready for operation; but the “Enable” signal is
not pending.
green Normal operating status; hardware is ready for operation;
“Enable” signal is pending.
ERROR off no error, no warning
flashing red A warning is reported.
red An error is reported.
Behaviour during waving
OK simultaneous
flashing
Wink function active (for visual identification, can be acti-
vated via the webserver)
ERROR
Behaviour with errors in the firmware update phase
OK off Firmware update was cancelled due to an error.
ERROR flashing red
Tab. 16
9Cleaning, repair and disposal
Clean the outside of the product with a soft cloth.
Repair or maintenance of the product is not permissible. If necessary, replace the
complete product.
Observe the local regulations for environmentally friendly disposal of electronic
components.
10 Technical data
Further technical data can be found in the following documents:
• Detailed technical data for the STO interface è Description of the STO safety
function EMCA-EC-S1-…
• Additional technical data è Device and function description EMCA-EC-SY-…
•Requirements for complying with the certified UL conditions if the product
is operated in the USA or Canada can be found in the separate UL special
documentation.
Technical data, safety engineering
Approval information, safety engineering
CE
Type-examination The functional safety engineering of the product has
been certified by an independent testing body, see EC-
type examination certificate è www.festo.com/sp
Certificate issuing authority TÜV Rheinland, Certification Body of Machinery, NB
0035
Certificate no. 01/205/5514.01/21
UKCA
Type-examination The functional safety engineering of the product has
been certified by an independent body, see UK-type
examination certificate è www.festo.com/sp
Certificate issuing authority TUV Rheinland UK Ltd, UK Approved Body No. 2571
Certificate no. 01/205U/5514.00/22
Tab. 17: Approval information, safety engineering
Safety reference data and safety specifications
Safety function STO Safe Torque Off (safe torque off)
Category 3 in accordance with EN ISO 13849-1
Performance Level PL d in accordance with EN ISO 13849-1
Safety Integrity Level SIL 2 in accordance with EN 61800-5-2 (safety integrity
level)
SIL Claim Limit SILCL 2 in accordance with EN 62061 (SIL claim limit)
DCavg [%] 90 Average diagnostic coverage
(average diagnostic coverage)
SFF [%] > 90 Safe Failure Fraction (safe failure fraction)
PFHD[1/h] 1 x 10-9 Probability of dangerous failure per hour
(probability of dangerous failure per hour)
T
Proof Test Interval [years] 20 Test interval
Service life [years] 20 in accordance with EN ISO 13849-1
Type test The STO function has been certified by an independent testing
body. EMCA certificate è www.festo.com/catalogue.
Tab. 18: Safety reference data and safety specifications
General technical data EMCA-…-S-… EMCA-…-M-…
Environmental and operating conditions
Mounting position any
Ambient temperature [°C] at nominal power: 0 … 20
with power reduction 1.75% per °C: 20 … 50
General technical data EMCA-…-S-… EMCA-…-M-…
Storage temperature [°C] –25 … +70
Relative humidity at 25 °C [%] 0 … 95 (non-condensing)
Degree of protection EMCA… (without
S1)
EMCA…-S1
IP54
IP65; motor shaft IP54
Protocol CANopen
Communication profile CiA 402, FHPP
Power supply [X4]
Nominal voltage [V DC] 24
Permissible voltage fluctuations [%] ± 20 –
Nominal current [A] 6.9 7.2
Peak current [A] 10.2 10.3
Rotor position encoder absolute single-turn absolute multi-turn
Resolution [Bit] 12 (4096 increments
per revolution)
12 bits (4096 incre-
ments per revolution)
and 4294967729 (±
2147483648) revolu-
tions; 32 bit
Absolute encoder operating duration (at medium ambient temperature)
without external battery
Note: the maximum storage period depends on
the charge status of the internal capacitor, the
ambient temperature and ageing effects.
– 3 days (worst case);
maximum of 7 days
(best case)
with external battery
Note: the maximum service life of the battery
depends on the state of charge, ambient temper-
ature and ageing effects.
– maximum 6 months
Digital inputs/outputs
Switching logic inputs/outputs PNP (positive switching)
Characteristics of digital logic outputs freely configurable in some cases
not galvanically isolated
Peak current to digital logic outputs [mA] 100
Characteristics of logic inputs galvanically connected to logic potential
Specification of logic inputs based on IEC 61131-2
Operating range of logic input [V DC] 24
Motor data
Nominal power [W] 120 150
Nominal torque [Nm] 0.37 0.45
Nominal rotational speed [rpm] 3100 3150
Max. rotational speed [rpm] 3500 3300
Mass moment of inertia of rotor [kgcm2]0.175 0.301
Permissible axial shaft load [N] 60 60
Permitted radial shaft load [N] 100 100
Holding brake (only EMCA-EC-…-…B)
Brake holding torque [Nm] 1
Brake power consumption [W] 9
Mass moment of inertia, brake [kgcm2]0.021
Max. line lengths (for ensuring EMC conformity)
Power supply cable [m] £ 30
STO and I/O interface [m] £ 30
Limit/reference switch, battery [m] £ 3
Product weight (without [B], without
[M])1)
[g] 1900 2260
Product conformity and approvals
CE marking (declaration of conformity
è www.festo.com/catalogue)
in accordance with EU Machinery Directive
in accordance with EU EMC Directive 2)
Approvals3) RCM (Regulatory Compliance Mark)3)
c UL us – Recognized (OL)3)
1) Holding brake [B] +350 g, multi-turn absolute displacement encoder [M] +25 g
2) The device is intended for use in an industrial environment. Measures may be required in residential areas
for interference suppression.
3) only valid for product variants with corresponding identification
Tab. 19