Festo EMCA-EC-67-DIO Series Parts list manual

EMCA-EC-67-...-DIO
Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
[phone]
www.festo.com
Brief description 8046849
1605
[8046842]
Original: de
Integrated drive EMCA-EC-67-...-DIO English..............................
Translation of the original instructions
For all available documents relevant to the delivery status of the product
èwww.festo.com/pk.
This brief description is intended solely for initial information. The user document
ation for the product also includes the following documents:
User documentation for the product
Manual
GDCE-EMCA-EC-DIO-...
Device and functional description;
Mounting, installation, commissioning and diagnostics
Manual
GDCE-EMCA-EC-S1-...
Description of the safety function “Safely switched-off torque”
(Safe torque off/STO)
Help for the EMCA FCT
plug-in
Online help of 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)
1 Safety
 Always observe the safety information and warnings in the documentation of
the product and of the other components used.
 Before mounting and installation work, switch off supply voltage and secure it
against being switched on again. Only switch on the supply voltage again when
mounting and installation work is complete.
 Never remove or insert a plug connector when the motor controller is powered.
 Observe the handling specifications for electrostatically sensitive devices.
 Only enable the controller if the drive has been professionally installed and fully
parameterised.
 Do not carry out repairs on the device. If defective, replace the device.
 Do not loosen any screws except for the 4 screws on the housing cover.
Warning
Danger of burns from hot housing surfaces.
Touching the motor 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.
 Make sure that personnel cannot touch the motor housing.
 Inform operating and maintenance staff about the possible hazards.
 Let the drive cool down to room temperature before maintenance work.
Warning
Rapidly rotating motor shaft with high torque.
Clothing, jewellery and hair can be caught and wrapped around the shaft. People
can be injured as a result.
 Make sure that clothing, jewellery or hair can not be caught by the rotating
motor shaft.
 Ensure that clothing fits tightly.
 Personnel with long hair must wear hair nets.
Caution
Rapidly 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.
Note
Gas formation with fire risk.
If cleaning agents make contact with the hot surface of the motor, gases can
form and ignite.
 Prior to cleaning work, let the drive cool down to room temperature.
 Pay attention to the instructions for use of the cleaning agent.
1.1 Use for intended purpose
The product is intended for driving and controlling electromechanical drives.
The product is intended for installation in a machine.
Use exclusively:
– In perfect technical condition
– In original status without unauthorised modifications; only the expansions
described in the documentation supplied with the product are permitted
– Within the limits of the product defined through the technical data
– In an industrial environment
The product is intended for use in industrial environments. Outside of industrial
environments, e.g. in commercial and mixed-residential areas, actions to suppress
interference may have to be taken.
1.2 Intended use of the STO function
The STO function (safe torque off ) in accordance with EN61800-5-2 is intended to
shut down the torque of the integrated motor. The STO function prevents unexpec
ted start-up of the integrated motor. The STO function may only be used in applica
tions in which the specified safety characteristics suffice.
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)
– SIL CL2 in accordance with EN62061 (Claim Limit/CL)
The achievable safety level depends on the other components used to implement
the safety function.
To protect against unintended motor start-up, the controller of the product must
be activated via the connection [X6] with the category required for the application
in accordance with ENISO 13849-1, e.g. via an external safety relay.
Training of specialized personnel (requirements for staff )
The product may only be commissioned by an electrotechnically qualified person
who is familiar with the topics:
– installation and operation of electrical control systems
– applicable regulations for operating safety-engineering 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 specified diagnostic
coverage, the status of the acknowledgment contact must be evaluated by the control
system every time the STO function is requested. If a potentially dangerous malfunction
is recognised during the diagnostics, appropriate measures must be taken to maintain
the safety level.
Note
The device cannot detect a cross circuit in the input circuit by itself.
 If required, use a safety relay with cross-circuit detection.
1.3 Foreseeable misuse of the STO function
The following foreseeable misuses are not approved as intended use:
– Bridging of the STO function
– Applications where switching off can result in hazardous movements or conditions
Note
The STO function must not be used as the sole safety function for drives that are
subject to permanent torque or force (e.g. suspended loads, vertical axes).

1.4 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 fre
quency of these tests must be determined by the machine operator based on the
specifications of the machine manufacturer.
 Check the EMCA at least once per year.
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
 Store the documentation 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).
 Comply with all of the legal regulations that are applicable for the destination,
as well as the following documents:
– regulations and standards
– regulations of the testing organisations and insurers
– national specifications
For correct and safe use of the STO function:
 Conduct a risk evaluation for your machine.
 Comply with the specified safety characteristics (èChapter 9, Technical data).
Range of application and certifications
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
have been certified by Underwriters Laboratories Inc. (UL).
Certificates and declaration of conformity for the product
èwww.festo.com/sp.
Specified directives and standards
Version statuses
2006/42/EC ENISO13849-1:2008-06/AC:2009-03 EN62061:2005-04
2014/30/EU EN 61800-5-2:2007-10 -
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
 Store and transport the product in its original packaging. The original packaging
offers sufficient protection from typical stresses.
2.2 Technical prerequisites
For correct and safe use of the product:
 Comply with the specified connection and ambient conditions for all of the con
nected components èChapter 9. Only compliance with the limit values or load
limits will enable operation of the product in compliance with the relevant safety
regulations.
3 Product description
3.1 Product overview
1[X1]: Parameterisation
interface (Ethernet
interface)
2LED light guide (6x) –
2 used
3Cable throughfeeds
(6x)
4Motor flange
5Through-hole for
mounting (4x)
6Mounting thread (4x)
thread M4
7Shaft
8Cover
12
3
4
5
7
6
8
View with open cover
12 3 4
5678
9
aJ
1[X5]: Braking resistor
2[X10]: External battery (...-1TM)
3[X6]: STO interface
4[X9]: I/O interface
5[X8]: Reference or limit switch 1
6[X7]: Reference or limit switch 2
7FE connection (flat plug)
8[X4]: Power supply
9OK LED (green)
aJ ERROR LED (red)
4 Mounting
Note
Excessive axial and radial forces on the motor shaft can damage the motor.
 Comply with maximum permissible shaft loads (è Chapter 9).
The mounting flange offers the following options for fastening:
– Fastening via 4 through-holes for screws of size M6
– Fastening via 4 female threads of size M4 (screw-in depth [mm]: 5).
Observe the assembly instructions for the additional components used
(e.g. axial kit, parallel kit, gear unit, shaft).
The drive must be mounted securely and free of tension.
1. Move the slide or cantilever of the driven mechanical system into a safe posi
tion.
2. Connect the EMCA to the driven mechanical system (èAssembly instructions
of the additional components used).
3. Tighten the mounting screws (4x). Tightening torque èAssembly instructions
of the additional components used.
5 Electrical installation
Caution
Unexpected and unintended movement of the drive during mounting, installation
and maintenance work.
 Before starting work: Switch off power supplies. Removal of the enable signal
at the EMCA is not sufficient.
 Secure the power supplies against accidental reactivation.
5.1 Connections and cables
Caution
Unexpected and unintended movement of the drive as a result of incorrectly
assembled cables.
 Only use the plug connectors provided and preferably the cables listed in
the specified accessories èwww.festo.com/catalogue.
 Lay all flexible cables so that they are free of kinks and mechanical stress,
e.g. in an energy chain. Observe the instructions for the axis and the additional
components.
ESD protection
At unassigned plug connectors, there is the danger that damage may occur to
the product or to other system parts as a result of ESD (electrostatic dis
charge).
 Comply with the handling specifications for electrostatically sensitive
devices.
 Seal unassigned plug connectors with protective caps.
 Earth system parts prior to installation.
 Use appropriate ESD equipment (e.g. shoes, earthing straps).
The plugs for the connectors are included in the scope of delivery (assortment of
plugs NEKM-C).

5.2 Parameterisation interface (Ethernet) [X1] – socket M12, 5-pin, D-coded
 Connect the EMCA to your network or directly to the PC via a hub/switch. Observe
line specification (èDevice and functional description, GDCE-EMCA-EC-DIO-...).
Recommendation: Use the connecting cable NEBC-D12G4-... from Festo.
Note
Unauthorised access to the device can cause damage or malfunctions.
When connecting the device to a network:
 Protect the network against unauthorised access.
Measures to protect the network include:
– firewall
– intrusion prevention system (IPS)
– network segmentation
– virtual LAN (VLAN)
– virtual private network (VPN)
– security at physical access level (port security)
Additional information èGuidelines and standards for security in information
technology, 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/F E Shield/functional earth
5.3 Power supply [X4]
Warning
Danger of electric shock from voltage sources without safeguarding.
 For the electrical power supply, use only PELV circuits (protective extra-low
voltage, PELV) in accordance with EN 60204-1.
 Also observe the general requirements for PELV circuits in accordance with
EN 60204-1.
 Use only voltage sources which guarantee reliable electrical isolation of
the operating and load voltage in accordance with EN 60204-1.
[X4] Pin Description
1+24 V DC Power supply (logic and load voltage)
+19.2 V DC … +28.8 V DC
20 V GND, reference potential
If a screened supply cable is used, the cable screening can be connected to
the functional earth connection (flat plug).
Flat plug Pin Description
-FE Optional connection for the cable screening
counterplug: flat connector sleeve (6.3 x 0.8 mm²)
5.4 Braking resistor
[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
5.5 STO interface [X6]
The STO safety function (safe torque off ) is described in detail in the document
GDCE-EMCA-EC-S1-.... The STO function should only be used in the manner
described in this document.
Recommendation for initial motor start-up without safety equipment:
– The setup must at least include an emergency stop switching device
– 2-channel switch-off via the control ports STO1 [X6.4] andSTO2 [X6.5]
[X6] Pin Description
1 NC1 Acknowledgment contact:
– Potential-free
– Low impedance if the STO function has been reques
ted and activated via 2 channels
2 NC2
3+24 V DC
LOGIC OUT
Logic voltage output (from [X4.1]), pin [X6.6] or [X4.2] is
the reference potential (0 V) (internally bridged)
Not overload-proof! Max. 100 mA permissible.
4STO 1 Control ports for STO function
5STO 2
6GND Reference potential 0 V
5.6 End/reference switch [X7], [X8]
[X7] Pin Description
1+24 V DC Voltage output 24 V to power the reference or limit
switch 1 (configurable with FCT, not short-circuit safe).
2Switch 1 Signal input for reference switch or limit switch 1
3GND Reference potential 0 V
[X8] Pin Description
1+24 V DC Voltage output 24 V to power the reference or limit
switch 2 (configurable with FCT, not short-circuit safe).
2Switch 2 Signal input for reference switch or limit switch 2
3GND Reference potential 0 V
5.7 I/O interface [X9]
[X9] Pin Type1) Mode 0 Mode 1
1 DIN Record selection 1
2 DIN Record selection 2
3 DIN Record selection 4
4 DIN Record selection 8
5 DIN Record selection 16
6 DIN Record selection 32 Jog+
7 DOUT Ready
8 DOUT configurable
9 – Output 24 V DC, looped through from [X4.1]
10 DOUT Acknowledge Setpoint Acknowledge
11 DOUT Motion Complete
12 DIN Control mode 0/1
Low level = mode 0
Control mode 0/1
High level = mode 1
13 DIN Start Teach
14 DIN Brake control/Delete
remaining path
Jog–
15 DIN Stop
16 DIN Control enable/Acknowledge error
17 – Do not connect
18 – GND (reference potential)
1) DIN = digital input; DOUT = digital output
5.8 External battery [X10] – only EMCA-EC-...-1TM
[X10] Pin Description
1Battery + Connection for external battery (Position changes are
recorded for up to 7 days without supply voltage and
without battery (after charging for approx. 24 hours)). With
the EADA-A-9 battery from Festo, the duration is extended
up to 6 months.
2Battery –
(GND)
5.9 Ensuring the IP degree of protection
 Comply with requirements for securing the IP degree of protection
(èDevice and functional description, GDCE-EMCA-EC-DIO-...).
6 Commissioning
Communication of the product with a connected PC takes place via the TCP/IPv4
protocol.
Create network connection – example “point-to-point connection”
Requirement:
– The PC is configured as a DHCP client (usually the default setting 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 server
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.
Comply with the documentation for the product (èwww.festo.com/pk).
Before switching on the power supply:
Check the installation:
 Check all connections.
Check readiness to operate
1. Make sure that controller enable is switched off (pin X9.16).
2. Switch power supply on. The OK LED on the front of the device should now flash
green.
If the OK LED stays off, the device is not ready for operation. If the ERROR LED is
illuminated red, an error is reported whose cause must be found.
Further steps for commissioning èHelp on the EMCA plug-in and device
and functional description GDCE-EMCA-EC-DIO-...
7 Diagnostics and fault clearance
LED LED status Event/status
Behaviour during the switch-on phase
OK Flashes green Start-up phase, bootloader active
ERROR Flashes red
Behaviour in the operating phase
OK Off Hardware is not ready for operation; an error is present.
Flashes green Hardware is ready for operation, but the signal “Control
enable” is not present.
Green Normal operating status; hardware is ready for
operation; signal “Control enable” is present
ERROR Off No error, no warning
Flashes red A warning is indicated.
Red An error is reported.
Identification sequence active
OK Flashing at the
same time
Feedback to the optical identification active
(can be activated via the web server)
ERROR
Behaviour with errors in the firmware update phase
OK Off Firmware update was cancelled due to an error.
ERROR Flashes red
8 Cleaning, repair and disposal
Regarding care:
 Clean the outside of the product with a soft cloth.
Repair or maintenance of the product is not permissible. If necessary,
replace the product.
Observe the local regulations for environmentally friendly disposal of elec
tronic components.
9 Technical data
For detailed technical data on the STO interface èDescription of
the safety function STO GDCE-EMCA-EC-S1-...
For additional technical data èDevice and functional description
GDCE-EMCA-EC-DIO-...
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.
Safety reference data and safety specifications
Safety function STO Safe Torque Off (securely switched-off torque)
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
SIL Claim Limit SILCL 2 In accordance with EN 62061
DCavg [%] 90 Average diagnostic coverage
(Average diagnostic coverage)
HFT 1Hardware failure tolerance
(Hardware fault tolerance)
SFF [%] > 90 Safe failure fraction
PFH [1/hr] 1 x 10-9 Probability of dangerous failure per hour
(Probability of dangerous failure per hour)
T
Proof Test Interval [Years] 20 Inspection interval
Duration of use [years] 20 In accordance with EN ISO 13849-1
Type test The STO function has been certified by an independent
testing body. EMCA certificate èwww.festo.com/sp
Component/function Suitable for use in category-1 systems and above according
to ENISO138491
Fig. 1 Safety reference data and safety specifications
General technical data EMCA-...-S-... EMCA-...-M-...
Environmental and operating conditions
Mounting position Any
Ambient temperature [°C] With nominal power: 0 … +20
With power reduction of 1.75 % per °C:
20 … +50
Storage temperature [°C] –25 … +70
Relative air humidity at 25 °C [%] 0 … 95 (non-condensing)
Degree of protection EMCA... (without -S1)
EMCA...-S1
IP54
IP65; motor shaft IP54
Control interface Digital I/O interface
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
Rotary position encoder Absolute single turn
encoder
Absolute multi-turn
encoder
Resolution [bit] 12 (4096 increments per revolution)
Absolute encoder operating duration (at average ambient temperature)
– Without external battery
– With external battery
-
-
7 days
6 months
Digital I/O modules
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 rotary speed [rpm] 3100 3150
Maximum rotational speed [rpm] 3500 3300
Mass moment of inertia of rotor [kgcm²] 0.175 0.301
Permissible axial shaft load [N] 60 60
Permissible radial shaft load [N] 100 100
Holding brake (only EMCA-...-...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 line [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 certifications
CE marking (declaration of conformity
èwww.festo.com/sp)
in accordance with EC Machinery Directive
2006/42/EC
in accordance with EU EMC Directive
2014/30/EU2)
Approvals3) RCM (Regulatory Compliance Mark)3)
c UL us - Recognised (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. Interference suppression measures may
be required in residential areas.
3) Only valid for product variants with corresponding marking