Festo EMCA-EC-67 CO Series User manual

8127094
EMCA-EC-67-...-CO/-EC/-EP/-PN
Integrated drive
8127094
2020-03d
[8127096]
Operating instructions

Translation of the original instructions
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1 Introduction................................................................................................................. 7
2 Safety and requirements for product use.................................................................... 10
2.1 Safety............................................................................................................................ 10
2.1.1 General safety instructions..................................................................................... 10
2.1.2 Intended use...........................................................................................................11
2.2 Requirements for product use...................................................................................... 11
2.2.1 Transport and storage conditions........................................................................... 11
2.2.2 Technical prerequisites...........................................................................................12
2.2.3 Training of qualified personnel............................................................................... 12
2.2.4 Product conformity and approvals.......................................................................... 12
3 Product description..................................................................................................... 13
3.1 Product overview.......................................................................................................... 13
3.1.1 General features of the product.............................................................................. 14
3.1.2 Scope of delivery.................................................................................................... 15
3.1.3 System structure.....................................................................................................17
3.2 Software for configuration and commissioning............................................................ 17
3.2.1 FCT (Festo Configuration Tool)................................................................................17
3.2.2 Web server..............................................................................................................18
3.3 Connections and display components.......................................................................... 19
3.4 Drive functions............................................................................................................. 21
3.4.1 Dimension reference system...................................................................................22
3.4.2 Homing................................................................................................................... 26
3.4.3 Jog operation (only via FHPP or with FCT)................................................................33
3.4.4 Teach mode (only via FHPP or with FCT)..................................................................35
3.4.5 Positioning mode....................................................................................................35
3.4.6 Velocity mode......................................................................................................... 38
3.4.7 Force/torque mode.................................................................................................42
3.4.8 Stop (halt), Quick-Stop........................................................................................... 44
3.4.9 Holding brake (only EMCA-EC-...-...-B).....................................................................45
3.5 Controller (overview).................................................................................................... 46
3.6 Operational principle for record selection..................................................................... 47
3.6.1 Record switching.................................................................................................... 48
3.6.2 Record sequencing................................................................................................. 50
3.7 Monitoring of the drive behaviour................................................................................ 52
3.7.1 Messages................................................................................................................52
3.7.2 Comparators........................................................................................................... 55
3.7.3 Protective functions................................................................................................58
3.7.4 Error management.................................................................................................. 59
3.7.5 Diagnostic memory.................................................................................................60
3.8 Interfaces..................................................................................................................... 60
Table of contents

3.8.1 Parameterisation interface [X1] (Ethernet interface).............................................. 60
3.8.2 Control interface [X2], [X3] (fieldbus)..................................................................... 61
3.8.3 STO interface [X6].................................................................................................. 62
3.8.4 Functions of the base inputs/outputs.................................................................... 62
4 Assembly......................................................................................................................68
4.1 Dimensions EMCA-EC-67 -...- CO....................................................................................68
4.2 Dimensions EMCA-EC-67 -...- EC/-EP/-PN...................................................................... 69
4.3 Performing mounting.....................................................................................................70
5 Installation...................................................................................................................72
5.1 Safety instructions.........................................................................................................72
5.2 EMC-compliant wiring....................................................................................................73
5.3 Parameterisation interface [X1]..................................................................................... 74
5.4 Control interface [X2], [X3]............................................................................................. 75
5.4.1 Control interface EMCA-...-CO (CANopen).............................................................. 75
5.4.2 Control interface EMCA-...-EC/-EP/-PN (EtherCAT, EtherNet/IP, PROFINET)............ 77
5.5 Connection of plugs [X4] ... [X10]................................................................................... 78
5.5.1 Power supply [X4].................................................................................................. 81
5.5.2 Braking resistor [X5]............................................................................................... 83
5.5.3 STO interface [X6].................................................................................................. 84
5.5.4 Limit or reference switch [X7], [X8]......................................................................... 85
5.5.5 I/O interface [X9].................................................................................................... 85
5.5.6 External battery [X10]............................................................................................. 86
5.6 Requirements for ensuring IP degree of protection....................................................... 87
6 Commissioning.............................................................................................................87
6.1 Notes on commissioning............................................................................................... 87
6.2 FCT (Festo Configuration Tool).......................................................................................88
6.2.1 Installing FCT......................................................................................................... 88
6.2.2 Starting FCT........................................................................................................... 88
6.2.3 Notes on commissioning with FCT.......................................................................... 88
6.3 Network connection via Ethernet...................................................................................90
6.3.1 Displaying or changing network configuration....................................................... 91
6.3.2 Safety in the network............................................................................................. 92
6.4 Master control............................................................................................................... 93
6.5 Online connection with the web server..........................................................................94
6.6 Commissioning steps.................................................................................................... 95
6.6.1 Configuration and parameterisation...................................................................... 96
6.6.2 Checking STO function........................................................................................... 96
6.6.3 Check signal characteristics of the limit and reference switches.............................97
6.6.4 Providing required signals (digital I/Os)................................................................ 97
6.6.5 Checking direction of rotation/travel direction...................................................... 97
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6.6.6 Execute homing...................................................................................................... 98
6.6.7 Testing positioning behaviour (test mode)............................................................. 98
6.6.8 Optimising controller setting (optional).................................................................. 98
6.6.9 Configuring fieldbus and testing control profile...................................................... 99
6.6.10 Completing commissioning.....................................................................................99
6.7 Saving or loading parameter file................................................................................... 99
6.8 Instructions for operation............................................................................................. 100
6.8.1 Maximum write cycles of the flash memory............................................................ 100
7 Diagnostics and fault clearance.................................................................................. 100
7.1 Access to the diagnostic memory................................................................................. 101
7.2 Diagnostics via LEDs..................................................................................................... 102
7.2.1 Behaviour during the switch-on phase....................................................................105
7.2.2 Behaviour in the operating phase...........................................................................105
7.2.3 Identification sequence active................................................................................ 106
7.2.4 Behaviour with errors in the firmware update phase.............................................. 106
7.2.5 Bus-specific LEDs....................................................................................................106
7.3 Diagnostic messages, causes and remedies................................................................. 107
7.3.1 Explanations for the diagnostic messages.............................................................. 107
7.3.2 Diagnostic messages with information for fault clearance...................................... 108
7.4 Problems with the Ethernet connection........................................................................ 125
7.5 Other problems and remedies...................................................................................... 126
8 Maintenance, care, repair and replacement................................................................ 126
8.1 Maintenance and care.................................................................................................. 126
8.2 Disassembly................................................................................................................. 127
8.3 Repair............................................................................................................................128
8.4 Replacement and disposal............................................................................................ 128
8.4.1 Disposal..................................................................................................................128
9 Technical appendix..................................................................................................... 128
9.1 Technical data.............................................................................................................. 128
9.1.1 General technical data............................................................................................ 128
9.1.2 Product conformity and approvals.......................................................................... 129
9.1.3 Mechanical data......................................................................................................129
9.1.4 Operating and ambient conditions..........................................................................130
9.1.5 Data for the integrated motor................................................................................. 131
9.1.6 Data for the integrated rotor position encoder........................................................131
9.1.7 Holding brake (only EMCA-EC-...-...-B).....................................................................132
9.1.8 Parameterisation interface [X1]...............................................................................132
9.1.9 Control interface [X2], [X3]...................................................................................... 132
9.1.10 Power supply [X4]................................................................................................... 133
9.1.11 Braking resistor [X5]................................................................................................134
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9.1.12 STO interface [X6].................................................................................................. 134
9.1.13 Reference or limit switch [X7], [X8]......................................................................... 134
9.1.14 I/O interface [X9].................................................................................................... 135
9.1.15 Connection for external battery [X10] (only EMCA-EC-67-...-1TM)........................... 135
9.1.16 Materials................................................................................................................ 136
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1 Introduction
Notes regarding this documentation
This documentation describes the functions, commissioning and error messages of the integrated
drive EMCA.
Target group
This documentation is intended exclusively for technicians trained in control and automation techno-
logy who have experience in installation, commissioning, parameterisation, programming and dia-
gnostics of electrical drive systems.
Product identification
The product is available in various designs. The order code indicates the equipment features (see
product labelling). This documentation describes the following product variants:
Characteristic Order code Type
Integrated drive EMCA–Motor with controller, series A
Motor technology EC–EC motor
Flange size, motors 67–67mm
W–mediumSize (with reference to the over-
all length of the motor) S–short
Nominal operating voltage 1 24 V DC
Electrical connection T Terminal box
I Single-turn absolute encoderMeasuring unit
W Multi-turn absolute measurement system
–without holding brakeBrake
B–with holding brake
CO CANopen
EC EtherCAT
EP EtherNet/IP
Bus protocol/control
PN PROFINET
–Standard (IP54)IP protection
S1 IP65
Tab. 1 Product labelling (e.g.EMCA-EC-67-M-1TEB-CO)
Introduction

Product labelling – example Meaning Example
Order code EMCA-EC-67-S-1TE-CO
Part number 8034238
Serial number FN98
Product key 123456789…
Nominal rotary speed nG[rpm] 3100
Nominal torque MN[Nm] 0.37
Nominal voltage UN[V DC] 24
Nominal current IN[A] 5.7
123456789...
EMCA-EC-67-S-1TE-CO
8034238 FN98
nG: 3100 rpm
MN: 0,37 Nm
UN: 24 V DC
IN: 5,7 A
IP54
Degree of protection IP54
Tab. 2 Product labelling – EMCA-EC-67-S-1TE-CO as example
All available documents for the product èwww.festo.com/sp.
Versions
For current versions of the firmware, FCT software and user documentation for the product
èwww.festo.com/sp.
This document refers to the following versions:
• EMCA with an order code specified in Tab. 1 Revision1.0.0 or later
• Firmware version1.2.0 or later
• FCT plug-in EMCA Version1.2.0 or later
The Product Key for the product can be used as a search term in the Festo Support Portal to find the
revision of the device èwww.festo.com/sp.
Before starting to use a new firmware version, check whether a newer version of the FCT plug-in and
new user documentation are available èwww.festo.com/sp.
Service
Consult the regional Festo contact if you have technical problems.
Manufacturing period
The first 2 characters of the serial number on the product labelling indicate the manufacturing period
in encrypted form (Tab. è Product labelling – EMCA-EC-67-S-1TE-CO as example). The letter specifies
the year of manufacture and the following character (number or letter) the month of manufacture.
Introduction
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Year of manufacture
X = 2009 A = 2010 B = 2011 C = 2012 D = 2013 E = 2014 F = 2015
H = 2016 J = 2017 K = 2018 L = 2019 M = 2020 N = 2021 P = 2022
R = 2023 S = 2024 T = 2025 U = 2026 V = 2027 W = 2028 X = 2029
Tab. 3 Year of manufacture (20-year cycle)
Month of manufacture
1 January 2 February 3 March
4 April 5 May 6 June
7 July 8 August 9 September
O October N November D December
Tab. 4 Month of manufacture
Documentation for the product
The complete documentation for the product includes the following documents:
Identifier Contents
Short documentation
EMCA-…
Brief device and functional description for initial information
Manual
EMCA-EC-SY-…
Device and functional description
– Mounting installation (pin allocations)
– Drive functions
– Commissioning information
– Error Messages
– Technical data
Manual
EMCA-EC-S1-…
Description of the safety function “Safe torque off” (Safe torque
off/STO)
Manual
EMCA-EC-C-HP-…
Description of the device profile FHPP (Festo Handling and Posi-
tioning Profile)
Manual
EMCA-EC-C-CO-…
Description of the device profile CiA 402
Help system for the FCT soft-
ware
(Help for the EMCA plug-in)
Online help for the Festo Configuration Tool (FCT) for commission-
ing 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. 5 Documentation for the product
Introduction
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Further information for the product is available at the Festo Support Portal (èwww.festo.com/sp).
• Operating instructions for Festo configurable electromechanical drives
• Function blocks for controllers
• Certificates, declaration of conformity
Overview of accessories (catalogue) èwww.festo.com/catalogue
2 Safety and requirements for product use
2.1 Safety
2.1.1 General safety instructions
– Always observe the safety instructions and warnings in the documentation of the product and the
other components.
– Before mounting and installation work, switch off supply voltage and secure it to prevent it from
being switched on again. Do not switch on the supply voltage until mounting and installation work
is complete.
– Never remove or insert a plug when the motor controller is powered.
– Observe the handling specifications for electrostatically sensitive devices.
– 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!
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!
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!
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.
Safety and requirements for product use
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2.1.2 Intended use
The product is intended for the actuation and control of electromechanical drives. The integrated elec-
tronics enable regulation of torque (current), rotational speed and position of the mounted drive. The
product is intended for installation in a machine.
Depending on the order, the product contains a motor with holding brake (EMCA-EC-…-…B). The hold-
ing brake is intended to hold the motor position/drive position at standstill.
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 (è 9.1 Technical data)
– in an industrial environment
The product is intended for use in industrial environments. Outside industrial environments, e.g.in
commercial and mixed-residential areas, actions to suppress interference may have to be taken.
In the event of damage caused by unauthorised manipulation or any form of use other than the inten-
ded use, the warranty will be invalidated and the manufacturer will not be liable for damages.
The product supports the safety function “safe torque off” (Safe torque off/ STO).
The safety function STO (Safe torque off) is described in detail in the document EMCA-EC-S1-…. The
safety function STO should only be used in the manner described in this document. Additional inform-
ation èdescription of STO safety function, EMCA-EC-S1-….
2.2 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 throughout the entire product lifecycle.
– Always comply with the specifications of the documentation. The documentation for the other
components and modules (e.g.for the gear unit or axial kit) must also be taken into account.
– Take into consideration the legal regulations for the installation location and also:
– regulations and standards
– regulations of the testing organisations and insurers
– national specifications
For correct and safe use of the STO function:
– Observe the additional information in the description EMCA-EC-S1-….
2.2.1 Transport and storage conditions
– Protect the product during transport and storage from excessive stress factors. Excessive stress
factorsinclude:
– mechanical stresses
– impermissible temperatures
– moisture
– aggressive atmospheres
Safety and requirements for product use
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– Store and transport the product in its original packaging. The original packaging offers sufficient
protection from typical stresses.
2.2.2 Technical prerequisites
For correct and safe use of the product:
– Comply with the connection and ambient conditions of the product (è 9.1 Technical data) and all
connected components specified in the technical data. Compliance with the limit values and load
limits permits operation of the product in compliance with the relevant safety regulations.
– Observe the notes and warnings in this documentation.
2.2.3 Training of qualified personnel
The following work may only be carried out by qualified specialists:
– fitting
– installation
– commissioning
The qualified personnel must be familiar with the following items:
– electrical control technology
– the applicable regulations for operating safety-related systems
– the applicable regulations for accident prevention and occupational safety
– the documentation for the product:
2.2.4 Product conformity and approvals
Standards and test values with which the product must be in conformity èTechnical data
(è 9.1 Technical data). EU Directives relevant to the product è declaration of conformity.
Certificates and the declaration of conformity for this product èwww.festo.com/sp
Certain configurations of the product are certified by Underwriters Laboratories Inc. (UL) for the USA
and Canada. These configurations are marked with the following symbol.
Fig. 1
UL Recognized Component Mark for Canada and the United States
Only for connection to a NEC Class 2 supply.
Raccorder Uniqement a un circuit de Class 2.
Rules for observing the UL certification can be found in the separate UL special documentation. The
technical data stated therein take priority. The technical data in this documentation may show values
deviating from this.
Safety and requirements for product use
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Specified standards
Editions
DIN EN 60068-2-6:2008-10 DIN EN 60068-2-27:2010-02
Tab. 6 Editions of the directives and standards specified in the document
3 Product description
3.1 Product overview
The integrated drive consists of the following components:
– brushless DC motor (EC motor) with
– integrated encoder (single-turn absolute encoder or multi-turn absolute measurement sys-
tem)
– motor shaft for power transmission
– motor flange for coupling and mounting
– device electronics with power, control and regulation electronics
– terminal box with interfaces for electrical installation
Product description
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1Terminal box
2Housing for device electronics
3EC motor
4Motor flange
5Motor shaft
6Cover (covering for additional connections)
Fig. 2 Components of the device (here EMCA-EC-67 -...- CO)
The device has a compact design. The terminal box provides all of the necessary electrical connec-
tions. The parameterisation interface (X1) and the control interface (X2, X3) are freely accessible. All
other electrical connections are under the cover of the terminal box (è Fig.4).
The device can be commissioned via the parameterisation interface (Ethernet). Control via the control
interface is based on a device profile (e.g.FHPP or CiA 402). Depending on the device profile, various
operating modes and drive functions are available (Tab. è Drive functions).
3.1.1 General features of the product
Property Description
EC motor brushless DC motor with:
– integrated encoder (single-turn absolute encoder or multi-turn
absolute measurement system)
– holding brake (optional)
Product description
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Property Description
electronics – power stage for motor activation and control
– nominal voltage 24 V DC
– integrated brake chopper - braking resistor1) (accessory)
– must be connected externally
– integrated electronic controls, e.g.with:
– closed-loop controller for position, rotational speed and cur-
rent regulation
– Ethernet interface (parameterisation interface)
– EMCA-…-CO: CAN interface (control interface; CANopen com-
munication profile; FHPP and CiA 402 device profile)
– EMCA-…-EC: EtherCAT interface (EtherCAT control interface;
FHPP and CiA 402 device profile)
– EMCA-…-EP: EtherNet/IP interface (EtherNet/IP control inter-
face; FHPP device profile)
– EMCA-…-PN: PROFINET interface (PROFINET IO control inter-
face; FHPP device profile)
– STO safety function (Safe torque off)
– Diagnostic memory
Power Supply shared load and logic power supply 24 V DC
Commissioning via the Ethernet interface with FCT
Diagnostics LED display, web server, FCT software, via bus/network
Web server software integrated into the device with the following functions:
– display of status information and I/O data
– readout of the diagnostic memory
– uploading and downloading of a parameter file for easy device
replacement
call via web browser (Internet Explorer or Firefox)
1) available separately as an accessory (èwww.festo.com/catalogue)
Tab. 7 Overview of EMCA product features
3.1.2 Scope of delivery
Number Component
1 EMCA-…with cover, screws for cover mounting
1 – Brief description EMCA-EC-67-…-CO/-EC/-EP/-PN
– For product variants with UL identification: special documentation EMCA-EC_UL-…
1 Sealing insert assortment
Tab. 8 EMCA scope of delivery
Below are some examples ofthe available accessories:
– Axial kits EAMM-A
Product description
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– Battery box EADA-A-9 (for EMCA-EC-67-1TM)
– Braking resistor CACR-LE2-6-W60
– Seal set (seals for axial kit) EADS-F
– Motor flange EAMF-A
– Parallel kits EAMM-U
– Planetary gear unit EMGC
– Assortment of plugs NEKM-C (mating plug for plug on the printed circuit board)
– Connecting cable for the Ethernet interface NEBC-D12G4-…
– Connecting cable for power supply NEBM-L4G2-…
– Connecting cable for the STO and the I/O interface NEBM-L5G6-…
Current information on accessories èwww.festo.com/catalogue
Product description
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3.1.3 System structure
1Main switch
2PELV fixed power supply
3Braking resistor – example
4Coupling/axial kit – example
5Electromechanical drive – example (here
electric cylinder ESBF)
6Reference switch/limit switch – example
(here without)
7EMCA
8PC with Festo Configuration Tool (FCT)
9Bus/network
Fig. 3 System structure (example)
3.2 Software for configuration and commissioning
3.2.1 FCT (Festo Configuration Tool)
The Festo Configuration Tool (FCT) is the Windows-based software platform for configuration, para-
meterisation and commissioning of various Festo components and devices. FCT also allows configura-
tion and commissioning of the integrated drive EMCA.
The FCT consists of the following components:
– a framework as program start and entry point with uniform project and data management for all
supported types of equipment
Product description
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– one plug-in each for the special requirements of a device type (e.g.EMCA) with the necessary
descriptions and dialogues
The plug-ins are managed and started from the framework. The EMCA plug-in supports performance of
all the steps necessary for configuration, parameterisation and commissioning of the product. The
product can be parameterised offline (without connection to the EMCA) on a PC. This enables prepara-
tion for the actual commissioning, e.g.in the planning office in the project engineering of a system.
FCT makes possible the following functions, forexample:
– administration of the following data/files via the Ethernet interfaces (online):
– device data (parameterisation)
– firmware file (firmware download)
– manual operation (e.g.jogging, teaching)
– diagnostics
– recording of measurement data
– automatic calculation of the controller data for selected Festo motor-gear unit-axis combinations
– manual precision adjustment of the controller data
For further information on commissioning with FCT è 6 Commissioning. Detailed information about
FCT èHelp system for the software.
3.2.2 Web server
A web server is integrated into the device. The web server provides access to a dynamic English-lan-
guage website for the device. The website of the web server provides access to the following func-
tions:
– display of the status information of the device (e.g.current position, target position)
– display of the signal statuses of digital I/Os
– display of the I/O data of the FHPP protocol
– readout and display of the diagnostic memory
– upload of a parameter file - e.g.to save current settings on the PC
– download of a parameter file - e.g.to restore settings
– activation of LED flashing for visual identification of the device
In the factory setting, the DHCP server (DHCP stands for Dynamic Host Configuration Protocol) of the
device is activated and the device has the following IP address: 192.168.178.1.
Product description
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3.3 Connections and display components
EMCA-EC-67-…-CO (CANopen bus interface)
1[X1]: parameterisation interface (bushing
M12)
2LED light guide (6x) - 3 used
3Cable through-feed of the terminal box (each
here with seal insert)
4Mounting thread (4x) thread M4
5Plugs
6Motor flange
7Shaft
8Through-hole for mounting (4x)
9[X3]: CAN OUT – continuation line (M12
bushing)
10 [X2]: CAN IN – incoming line (plug M12)
Fig. 4 Control sections and connections EMCA-EC-67-...-CO
Product description
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EMCA-EC-67-…-EC/-EP/-PN (EtherCAT or EtherNet/IP or PROFINET)
1[X1]: parameterisation interface (bushing
M12)
2LED light guides (6x)
3[X3]: bus/network IN – port 1 (bushing M12,
control interface)
4Cable through-feed of the terminal box (each
here with seal insert)
5Mounting thread (4x) thread M4
6Plugs
7Motor flange
8Shaft
9Through-hole for mounting (4x)
10 [X2]: bus/network OUT – port 2 (M12 bush-
ing, control interface)
Fig. 5 Control sections and connections EMCA-EC-67-...-EC/-EP/-PN
Product description
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