Festo EMCA-EC-67 DIO Series Operating Instructions Manual
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Festo EMCA-EC-67 DIO Series Operating Instructions Manual

Integrated drive
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EMCA-EC-67-...-DIO
Integrated drive
Operating instructions
8127157
8127157
2020-03d
[8127159]

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Summary of Contents for Festo EMCA-EC-67 DIO Series

  • Page 1 EMCA-EC-67-...-DIO Integrated drive Operating instructions 8127157 8127157 2020-03d [8127159]...
  • Page 2 Translation of the original instructions Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 3: Table Of Contents

    General features of the product................14 3.1.2 Scope of delivery....................15 3.1.3 System structure.....................16 Software for configuration and commissioning............17 3.2.1 FCT (Festo Configuration Tool)................17 3.2.2 Web server......................17 Connections and display components................18 Drive functions......................19 3.4.1 Dimension reference system...................20 3.4.2...
  • Page 4 6.2.1 Installing FCT......................95 6.2.2 Starting FCT......................96 6.2.3 Notes on commissioning with FCT................96 Network connection via Ethernet...................97 6.3.1 Displaying or changing network configuration............99 6.3.2 Security in the network..................99 Master control....................... 100 Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 5 Technical data......................132 9.1.1 General technical data.................... 132 9.1.2 Product conformity and approvals................133 9.1.3 Mechanical data......................133 9.1.4 Operating and ambient conditions................133 9.1.5 Data for the integrated motor................. 135 9.1.6 Data for the integrated rotor position encoder............135 Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 6 9.1.10 Braking resistor [X5]....................137 9.1.11 STO interface [X6]....................137 9.1.12 Reference or limit switch [X7], [X8]................. 137 9.1.13 I/O interface [X9]....................137 9.1.14 Connection for external battery [X10] (only EMCA-EC-67-...-1TM)......138 9.1.15 Materials........................ 139 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 7: Introduction

    Electrical connection Terminal box Measuring unit Single-turn absolute encoder Multi-turn absolute measurement system Brake without holding brake with holding brake Control digital I/O interface IP protection Standard (IP54) IP65 Tab. 1 Product labelling (e.g. EMCA-EC-67-M-1TEB-DIO) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 8 • 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.
  • Page 9 Description of device profile FHPP (Festo Handling and Positioning EMCA-EC-C-HP- Profile) … Help system for the FCT soft- Online help for the Festo Configuration Tool (FCT) for commission- ware ing and parameterisation (Help for the EMCA plug-in) Special documentation Requirements for operating the product in the USA and Canada in EMCA-EC_UL- accordance with certification by Underwriters Laboratories Inc.

  • Page 10: Safety And Requirements For Product Use

    Safety and requirements for product use Further information for the product is available at the Festo Support Portal (è www.festo.com/sp). • Operating instructions for Festo configurable electromechanical drives • Certificates, declaration of conformity Overview of accessories (catalogue) è www.festo.com/catalogue Safety and requirements for product use Safety 2.1.1...

  • Page 11: Intended Use

    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 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 12: Technical Prerequisites

    Standards and test values with which the product complies and fulfils 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 product configurations have Underwriters Laboratories Inc. (UL) certification for the USA and Canada.

  • Page 13: Product Description

    (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 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 14: General Features Of The Product

    I/O interface or the Ethernet interface with Modbus TCP and the FHPP device profile. 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) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 15: Scope Of Delivery

    – 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...

  • Page 16: System Structure

    6 Electromechanical drive – example (here electric cylinder ESBF) 2 PELV fixed power supply 7 EMCA 3 Braking resistor – example 8 PC with Festo Configuration Tool (FCT) 4 Coupling/axial kit – example 9 Higher-order controller (PLC/IPC) 5 Reference switch/limit switch – example (here without) Fig.

  • Page 17: Software For Configuration And Commissioning

    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.

  • Page 18: Connections And Display Components

    6 Motor flange 3 Cable throughfeed of the terminal box 7 Shaft 4 Through-hole for mounting (4x) 8 Mounting thread (4x) thread M4 Fig. 4 Control section and connections The following plugs are below the cover: Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 19: Drive Functions

    3.4.4 Teach-in mode è target position in the selected record) Positioning mode The EMCA calculates the positioning 3.4.5 Positioning mode è curve (point-to-point positioning) from the specified parameters (e.g. target position, acceleration, velocity) and controls the motor accordingly. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 20: Dimension Reference System

    With FCT, the direction of rotation can be adjusted (èFCT, page "Application Data", Register "Envir- onment", option "Inverse Rotation Polarity"). Example: rotary drives with limited positioning range Fig. 6 Dimension reference system - rotary drives with limited positioning range Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 21 Recommendation: check direction of movement in jog operation. If necessary, activate the reversal of the direction of rotation to reverse the direction (è FCT, page "Application Data", Register "Environ- ment", option "Inverse Rotation Polarity"). Example: linear drives with limited working stroke Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 22 Reference point Calculation rule Axis zero point = REF Project zero point = AZ = REF a + b Negative software end position = AZ = REF Positive software end position = AZ = REF Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 23: Homing

    The reference point of the dimensional reference system is determined with the homing. All points of reference and drive limits of the dimension reference system refer directly or indirectly to the refer- ence point. The homing point is the absolute reference point for the axis zero point Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 24 Recommended: FCT displays the distance between the switching edge and index (è FCT, online tab "Homing"). • Align the reference switch in the middle between two index signals. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 25 The position of the limit switch is searched during – positive direction homing. When successful, the drive travels back to – negative direction the next index of the encoder. This position becomes the reference point. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 26 Then the stop position is left by travel to the axis zero point. If the drive system does not have a stop (axis of rotation), homing will never be completed. The drive then continues to travel at the parameterised search velocity. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 27 1) Limit switches are ignored during travel to the stop. 2) With this homing method, the option “Travel to axis zero point” is always active (Tab. è Homing option). Tab. 17 Homing method – homing to stop Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 28 This position is accepted as the reference point. 3. Optional: travel to the axis zero point (Tab. Homing option). è Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 29 3. Optional: travel to the axis zero point (Tab. Homing option). è Direction: positive (method 17 ; 23) Direction: negative (method 1B ; 27) Reference switch Reference switch Tab. 20 Homing method – homing to reference switch without index Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 30 (Drive Velocity) Acceleration Acceleration and deceleration for all phases of homing (Acceleration) Axis zero point Distance of the axis zero point from the reference point in pos- (Axis Zero Point) itive or negative direction (offset) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 31: Jog Mode

    Setpoint value for the velocity when starting a jog movement (Crawling velocity) Duration of creep phase Setpoint value for the duration of creeping (Slow moving time) Max. velocity Maximum velocity at the end of creeping (Maximum velocity) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 32 If the jog signal continues after the end of the creeping time, the drive accelerates to jog velocity. Longer strokes can thus be completed more rapidly. – With a falling edge of the jog signal, the drive is braked to a standstill. 1 t1: creeping time Fig. 9 Jogging – example Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 33: Teach-In Mode

    Variants of the target specification in positioning mode) è Velocity (Velocity) Setpoint value for velocity Acceleration (Acceleration) Setpoint value for acceleration Deceleration (Deceleration) Setpoint value for the deceleration Jerk acceleration (Jerk for accelera- Maximum value for the jerk during the acceleration tion) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 34 Tab. 26 Variants of the target specification in positioning mode Start Acceleration Deceleration Speed Target position Motion Complete Fig. 10 Setpoint value path – example: starting velocity and setpoint final velocity 0 mm/s, without smoothing Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 35 Limitation of the force (linear drive) or the torque (rotational (Force Limit/ Torque Limit) drive) that can be generated during execution of the order Max. following error Determination when the “following error” message should be (Max. Following Error) output ( Fig.19) è Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 36: Velocity Mode

    Setpoint value for the deceleration Jerk acceleration (Jerk for Accelera- Maximum value for the jerk during the acceleration phase tion) Jerk deceleration (Jerk for Decelera- Maximum value for the jerk during the deceleration phase tion) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 37 The stroke limitation remains active. Tab. 30 Target recognition in velocity mode Variants The following variants of velocity regulation are available: – velocity regulation without stroke limitation – velocity regulation with stroke limitation Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 38 Example: target velocity was not reached – without jerk limitation Stroke limit Actual position Target speed Actual Velocity Motion Complete Stroke limit reached (internal) Fig. 11 Stroke limitation reached before target velocity – without jerk limitation Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 39 Example: target velocity was reached – without jerk limitation Stroke limit Actual position Target speed Actual Velocity Motion Complete Stroke limit reached (internal) Fig. 12 Stroke limitation reached after reaching target velocity – without jerk limitation Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 40: Force/Torque Mode

    Deviations between the actual and the desired force can be reduced by adjusting the paramet- erisation. The path of an order in force/torque mode is largely influenced by the following parameters: Parameter Description Force (Force) Target specification for force (in of the parameterised base value of the motor current) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 41 If no other drive function is to be executed, the drive will stop at the stroke limitation in a position-controlled manner. Standstill monitoring is activated and the “Motion Complete” signal is set. Tab. 34 Stroke limitation parameters Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 42: Stop (Halt), Quick-Stop

    Removal of closed-loop controller enable. After completion of the Quick Stop delay, the drive is blocked (power stage switched off). The drive is uncontrolled. – For errors for which the “Quick-Stop deceleration” error reaction has been parameterised (è error management) – Reaching the stroke limit (velocity mode, force/torque mode) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 43: Holding Brake (Only Emca-Ec

    2. No orders are processed until the switch-on delay has elapsed to allow the holding brake to release completely. 3. Orders are accepted after the switch-on delay has elapsed. The holding brake should then be completely released. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 44: Operational Principle For Record Selection

    Start delay the step enabling conditions for continuation are met – MC visible (Tab. – End velocity Parameters for influencing the movement path) è – Following record Tab. 37 Options for sequence control in record selection Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 45: Record Switching

    Tab. 38 Possible settings for the “Start condition” parameter Example: “Ignore” start condition The start signal (here for record B) is ignored. The current command (here record A) is completed. Target position record A Start record Motion Complete Fig. 14 Start condition "Ignore" Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 46 The current task (here record A) is interrupted immediately and the newly addressed task (here record B) is then executed immediately. Target position, record B Target position record A Start record Motion Complete Fig. 16 “Interrupt” start condition Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 47: Record Sequencing

    Force comparator active the force is in the force/torque window for the duration of … the cushioning time Time comparator active the length of time for which order processing is in the time … window Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 48: Monitoring Of The Drive Behaviour

    3.6.1 Messages Messages can be output via the freely configurable digital output [X9.8] (è Functions of the freely configurable digital output). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 49 "Motion Complete" mes- sage (target recognition) is triggered. 1 Actual velocity 3 t1: cushioning time, Motion Complete 2 Target window Fig. 18 Motion Complete - example of velocity control Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 50 EMCA issues the diagnostic message “Actual position lies outside the standstill window” (act- ive = 1: axis has left the standstill window; inactive = 0: axis is located in the standstill window). – The position controller attempts to return the drive to the standstill window. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 51: Comparators

    (è 3.5 Operational principle for record selection, record sequencing). For the direct mode, the parameters of the comparators are administered as global parameters for dir- ect mode (preset for direct mode). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 52 The position limits are always specified in absolute values, even for relative position records. Velocity comparator The message “Velocity comparator active” is set if the following 2 conditions are fulfilled: – The actual velocity is within the parameterisable limits(³ minimum and £ maximum). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 53 (maximum) 1) The limit values can only be positive. If the minimum value is greater than the maximum value, the condition for the time comparator is never fulfilled. Tab. 46 Parameters for the time comparator Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 54: Protective Functions

    3.6.4 Error management The error management of the FCT makes it possible to parameterise the reaction to diagnostic mes- sages of the device (è FCT, "Error Management" page). The diagnostic messages can be classified as Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 55 1) for certain errors (è FCT error management) Tab. 49 Possible reactions to errors The system event can be stored in the diagnostic memory with the “Save Diagnosis” option. For additional information on determining error responses è FCT Help, keyword Error management. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 56: Diagnostic Memory

    The Ethernet interface [X1] enables the following: – Configuration, parameterisation, commissioning, diagnostics and firmware download with FCT (è 6.2 FCT (Festo Configuration Tool) and FCT Help) – Diagnostics with the help of the web server using a web browser (è 6.5 Online connection with the web server and è 7.1 Access to the diagnostic memory) –...
  • Page 57 The following Modbus transactions are supported: Modbus transactions Function code Read Holding Registers 0x03 Read Exception Status 0x07 Write Multiple Registers 0x10 Read/Write Multiple Registers 0x17 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 58: Sto Interface [X6]

    Control input STO channel 2 channel 2) Description of STO safety function, EMCA-EC-S1- è … [X7.2] Switch 1 Input for reference switch or limit switch 1 Reaching the reference/end position is signalled with the configured edge of switch 1. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 59 1) Switch function (reference switch or limit switch) and switch type (N/C contact or N/O contact) can be configured with FCT. Tab. 54 Functions of the digital base inputs – connections [X6], [X7], [X8] and [X9] Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 60 If FCT or the Web server has master control, the enable signal at the input “Control enable/Acknow- ledge error” must be present before the controller enable can be requested by the Ethernet interface. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 61 Control enable at [X9.16] with enable logic “DIN + control interface” – Controller enabled via the connection that has master control (e.g. FHPP, FCT) – No error If all requirements are met, the READY output is set. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 62 “Sample” input. The device has separate memories for falling and rising edges. The memory can be read by a higher-order controller via the fieldbus. Information on reading out the measured positions è Description for the FHPP device profile, EMCA-EC-C-HP-… Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 63 Standstill monitoring  High level, if the “Standstill monitoring” … message is active. Homing Homing active  High level, if homing is being carried out. … (Homing) Reference position valid  High level, if reference position is valid. … Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 64: Functions Of The Additional Inputs/Outputs

    No function [X9.1] Record selection 1 [X9.2] Record selection 2 [X9.3] Record selection 4 [X9.4] Record selection 8 [X9.5] Record selection 16 [X9.6] Record selection 32 Jog+ [X9.13] Start Teach [X9.14] Brake control/Delete remaining Jog– path Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 65 Low level: automatic activation of the holding brake [X9.15] Stop – High level: no stop/intermediate stop – Low level: stop the drive at the parameterised decel- eration of the active position record (stop/interme- diate stop) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 66 High level: activate mode 1 (jog/teach). [X9.1]    Record selection 1   16 Selection of the record number (binary coded). 31 … … [X9.5] records (record 1 to 31) can be selected via these 5 inputs. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 67 Low level: order in progress Tab. 63 Function overview mode 1 Record selection for jog/teach (mode 1) Record selection 1 … 16 … 16 (2 … 8 (2 … 4 (2 … 2 (2 … 1 (2 Record number         … … Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 68: Control Via The I/O Interface

    3 Ready for operation Fig. 22 Time diagram, establish ready status 3.8.2 Set mode for the I/O interface The mode for the I/O interface is set by the digital input “Control mode 0/1”: Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 69: Enabling And Disabling The Closed-Loop Controller

    When controller enable is revoked, the holding brake is closed. Additional information on the holding brake The activation of the holding brake is coupled to the con- troller enable (è 3.4.9 Holding brake (only EMCA-EC-...-...-B) and è 3.8.11 Release holding brake (only EMCA-EC-...-...-B)). Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 70: Acknowledge Errors

    In other cases, the cause for the error must be remedied first (e.g. temperat- ure error, load voltage error). Acknowledgeable error messages can be acknowledged as follows: – via the Festo Configuration Tool (è FCT Online Help) – by a rising edge at the input “Control enable/Acknowledge error” Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 71: Execute Homing

    Execute homing To run homing , record number 0 must be addressed at inputs “Record selection 1…32”. Homing is started by input “Start”. After the successful completion of the homing, the output “Motion Complete” is set. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 72: Jog, Teach (Mode 1)

    In position mode, the target positions for 31 absolute command sets can be taught via the I/O inter- face. The teach signals are edge-triggered. If the teach signal was set and the process cannot be executed, the teach signal needs to be reset. A new process cannot be started until then. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 73: Start Record (Mode 0)

    “Start Condition” parameter specifies how the device should react to the start signal for the record if another record is still being processed (Tab. è Possible settings for the “Start condition” parameter). The time diagram shows the time behaviour for the start of a job in mode 0. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 74 Product description 1 Start record 3 Time delay t ³ 2 ms 2 Target recognition (Motion Complete) Fig. 28 Time diagram Start record (mode 0) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 75: Start, Stop And Continue Record (Mode 0)

    Start, stop and continue record (mode 0) 1 Start record 4 Target recognition (Motion Complete) 2 Stop record (intermediate stop) 5 Time delay t ³ 2 ms 3 Continue record Fig. 29 Start, stop and continue record time diagram Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 76: Start And Stop Record, Delete Remaining Path (Mode 0)

    Start and stop record, delete remaining path (mode 0) 1 Start record 4 Task completed (Motion Complete) 2 Stop record (intermediate stop) 5 Time delay t ³ 2 ms 3 Delete remaining path Fig. 30 Start, stop record time diagram, delete remaining path Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 77: Record Switching

    The inertia of the holding brake can be adapted to the behaviour of the device by paramet- ers (è 3.4.9 Holding brake (only EMCA-EC-...-...-B)). Further information about the holding brake è 3.4.9 Holding brake (only EMCA-EC-...-...-B). Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 78: Assembly

    Assembly Assembly Dimensions Fig. 32 Type Dimen sion ±0.5 -0.3 ±0.8 ±0.3 -0.1 EMCA- [mm] [mm] 169.9 117.2 52.7 … … +0.8/-1.1 EMCA- 187.4 +0.8/-1.1 70.2 ±0.8 … … Tab. 66 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 79: Performing Mounting

    The device is mounted with a gear unit or directly onto an axis with axial kits or parallel kits. Any mounting position can be used. Axial kits, parallel kits and gear unit è www.festo.com/catalogue During mounting the shaft of the drive is connected to the shaft of the axis by a coupling (è Assembly instructions for axial or parallel kit).
  • Page 80 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 of the additional compon- ents used. 3. Tighten the retaining screws (4x). Tightening torque è Assembly instructions of the additional components. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 81: Installation

    Long signal lines reduce the immunity to interference (EMC). • Observe the maximum permissible signal line lengths. The device can generate high frequency malfunctions, which may make it necessary to implement interference suppression measures in residential areas. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 82: Emc-Compliant Wiring

    External battery £ 1) between the network devices Tab. 68 Information for EMC-compliant wiring Ethernet interface [X1] The Ethernet interface on the top of the connection box permits connection to a PC or a network. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 83 Shield/functional earth Tab. 70 Ethernet interface connection [X1] Connecting the Ethernet interface Recommended: use connecting cable NEBC-D12G4-… from Festo. – Connect EMCA to your network via a hub/switch or directly to the PC. Note cable specification. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 84: Connection Of Plugs [X4]

    Crimp pliers Identifier: Identifier: Identifier: JST WC-930 or AMP 91501-1 (AWG24   AWG20) or JST WC-491 … JST YC-930R AMP 91502-1 (AWG30   AWG26) … Manufacturer: JST Manufacturer: AMP JST WC- ZH2632 JST YRS-491 Manufac- turer: JST Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 85 When making the connecting cables, observe the current specifications/crimp instructions of the named manufacturers (Tab. è Overview of cable specifications). Recommended: use connecting cable NEBM-… from Festo (è www.festo.com/catalogue). Make all required connecting cables before connecting the plug connectors. 1. Strip cable ends and attach crimp contacts (è crimp instructions/specifications of the manufac- turers).
  • Page 86 – Seal inserts for lines with outside diameter 8.5 … 9.6 mm The seal insert assortment is also available as an accessory (è www.festo.com/catalogue). Connecting the internal plugs The cover of the terminal box must be removed for the electrical installation. Before removing the cov- 1.

  • Page 87: Power Supply [X4]

    EN 60204-1 (Electrical equipment of machines, General requirements) is guaranteed with the use of PELV circuits. A 24 V fixed power supply used in the system must satisfy the requirements of EN 60204-1 for DC power supply (behaviour during power interruptions, etc.). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 88 (flat plug). Flat plug Description optional connection for the cable shield if a shielded supply cable is to be used Mating connector: Flat connector sleeve (6.3 x 0.8 mm²) Tab. 74 Flat plug (FE) – optional Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 89: Braking Resistor [X5]

    Impermissibly high voltages can result from energy feedback into the intermediate circuit of the device. This can damage the device and cause malfunctions. • Connect a braking resistor adapted to the braking output that occurs in the desired application. Fig. 38 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 90: Sto Interface [X6]

    Connection for external braking resistor R 6 Ω BR-CH Tab. 75 Pin allocation for braking resistor [X5] Braking resistor CACR-LE2-6-W60 from Festo is suitable (6 Ω/60 W). 5.4.3 STO interface [X6] 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.

  • Page 91: Limit Or Reference Switch [X7], [X8]

    V for supply of the reference or limit switch 1 (configur- able with FCT, not short-circuit proof) Switch 1 Signal input for reference switch or limit switch 1 Reference potential 0 V Tab. 77 Pin allocation of reference or limit switch 1 [X7] Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 92: I/O Interface [X9]

    Signal input for reference switch or limit switch 2 Reference potential 0 V Tab. 78 Pin allocation of reference or limit switch 2 [X8] 5.4.5 I/O interface [X9] The remaining digital I/Os are combined to connection [X9]. Fig. 42 Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 93 Control enable/Acknow- Enable ledge error do not connect (do not con- Sample nect) – GND (reference potential) 1) DIN = digital input; DOUT = digital output Tab. 79 Pin allocation for I/O interface (PNP logic) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 94: External Battery [X10]

    Battery – (GND) Tab. 80 Pin allocation connection for the external battery [X10] (only EMCA-EC-...-1TM) The battery box EADA-A-9 from Festo is suitable. Requirements for ensuring IP degree of protection – Use only connection technology with the corresponding IP degree of protection (è www.festo.com/catalogue).

  • Page 95: Commissioning

    The FCT EMCA V 1.0.0 plug-in supports devices with firmware version V 1.0.x or later. • With newer firmware versions check that an updated plug-in is available (è www.festo.com/sp). Windows administrator rights are required for installing the FCT. The FCT is installed on the PC with an installation program.

  • Page 96: Starting Fct

    Tab. 81 Adobe Reader is recommended for viewing and printing PDF files. Loading firmware The Festo Configuration Tool (FCT) makes it possible to update the device firmware. Festo makes new firmware versions available on the internet in the support portal (è www.festo.com/sp).

  • Page 97: Network Connection Via Ethernet

    At initial commissioning, connect the device directly to the PC, because the DHCP server of the device is active in the factory setting (è 3.7.1 Ethernet interface [X1]). Recommended: use the connecting cable NEBC-D12G4-… from Festo (accessories è www.festo.com/catalogue). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 98 Start FCT and establish an online connection (è FCT, command "Component" è "Online" è "Login"). Actions in case of communication problems – Check the TCP/IPv4-settings of the Ethernet interface used on the PC (è Windows Control Panel): – "Retrieve IP Address automatically" – “Obtain DNS server address automatically” Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 99: Displaying Or Changing Network Configuration

    Recommended: activate password protection to prevent accidental access to the device (è FCT, "Component" è "Online" è "Password" command). Password protection Password protection for the device is not activated in delivery status. FCT allows password protection to be activated by entering a password (è FCT Help). Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 100: Master Control

    The enable signal of the interface that currently has the master control is always valid. If, for example, the FCT switches over to the control interface, the enable signal of the control interface applies from the switchover time. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 101 For the FCT to control the connected device, the "Enable" checkbox must be activated after takeover of the master control. If the master control is released again by FCT, it automatically returns to the control interface. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 102: Online Connection With The Web Server

    2. Enter the IP address of the device in the address line of the Internet browser. Then the website of the device appears. Fig. 45 Website of the web server Active signals are marked with a blue dot. Inactive signals are marked with a grey dot. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 103: Commissioning Steps

    Configuration and parameterisation – Perform configuration and parameterisation precisely. – Do not operate the device with unknown settings. – If the system structure consists of Festo components, parameters and limit values are preset by the plug-in. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 104: Checking Sto Function

    The device needs the following signals for commissioning and operation: – Signals STO 1 and STO 2 (STO interface) è Description of safety function STO, EMCA-ECS1-… – For DIN + controller enable logic (Tab. è Enable logic): Signal Control enable (I/O interface) Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 105 Commissioning 1 Switch setting with switched-on controller 2 Optional; output in the Festo Configuration enable Tool (FCT) freely configurable (e.g. “common error”) Fig. 46 Connection: digital inputs/outputs for operation – enable logic: DIN + controller Circuitry of the digital inputs and outputs for control via the I/O interface...

  • Page 106: Checking Direction Of Rotation/Travel Direction

    Commissioning 1 Switch setting with switched-on controller 2 Optional; output in the Festo Configuration enable Tool (FCT) freely configurable (e.g. “common error”) Fig. 47 Connection: digital inputs/outputs for operation 6.6.5 Checking direction of rotation/travel direction FCT provides access to jog operation in the "Manual Move" online tab. The motor can be moved manually by jogging for a visual check of the direction of rotation.

  • Page 107: Execute Homing

    The temporarily stored data are lost when the power supply is switched off. To complete commissioning: – Recommended: activate password protection (è Help for the EMCA plug-in). – Save parameters permanently in the device (è Help for the EMCA plug-in). Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 108: Saving Or Loading Parameter File

    Tab. 88 Commands in the parameter upload/download section Further options A parameter file can be imported into the current project with FCT and parameters of the current project can be exported into a parameter file (è FCT, "Component" è "Import/Export" command). Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 109: Instructions For Operation

    The device will have to restarted after some errors, e.g.  encoder error. Error-specific information on readiness for acknowledgement è 7.3.2 Diagnostic messages with information for fault clearance. Acknowledgeable error messages can be acknowledged as follows: Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 110: Access To The Diagnostic Memory

    Diagnostics and fault clearance – Festo Configuration Tool (è FCT Online Help) – rising edge at the “Control enable” input The device must be switched on again if errors cannot be acknowledged (Power OFF/ON). Diagnostic events that are parameterised as warnings are displayed once and do not need to be acknowledged.

  • Page 111: Diagnostics Via Leds

    (HH = hours, MM = minutes, SS = seconds, nnn = milli- seconds). The time base is the time the device was switched on. Additional info Additional information for Festo service (Additional Info) Tab. 90 Information for diagnostic messages Deleting the diagnostic memory The content of the diagnostic memory can be deleted: –...

  • Page 112: Behaviour In The Operating Phase

    – Restart firmware download. – If the error occurs repeatedly, contact your local Festo service. Diagnostic messages, causes and remedies The FCT error management makes it possible to parameterise the device's reaction to diagnostic mes- sages (è 3.6.4 Error management).
  • Page 113 Record deceleration - turn off braking ramp of the cur- rent position record End record - execute record to end until Motion Com- plete (MC) Tab. 96 Possible error reactions (can be parameterised) Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 114: Diagnostic Messages With Information For Fault Clearance

    An error has occurred during evaluation of the encoder. The current position values may be incor- rect. – Reset the software and run homing. – Acknowledgement option: cannot be acknowledged, software reset required. Parameterisable error response(s): A Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 115 Can be parameterised as: F/-/- (General error) Diagnostic memory: always An internal error has occurred. – Restart device. If the error occurs frequently, contact Festo service. – Acknowledgement option: error can be acknowledged. Parameterisable error response(s): B Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 116 (internal) motor cables. Replace device. – Error occurs only with active brake chopper: check external braking resistor for short circuit or insufficient resistance value. – Acknowledgement option: cannot be acknowledged, software reset required. Parameterisable error response(s): A Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 117 This error can be acknowledged immediately. Afterwards start a corresponding positioning record or move the drive by using the jogging function. Movements in a negative direction are blocked. – Acknowledgement option: error can be acknowledged. Parameterisable error response(s): A, [B], C, E, F Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 118 Check the mechanical system for sluggishness. – Reduce the ambient temperature; improve heat dissipation. Check ambient temperature. Consider power derating. – Acknowledgement option: error can only be acknowledged after eliminating the cause. Parameterisable error response(s): A, B, [C], D Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 119 Check whether multiple connections have been established to the device. If yes, terminate the unneeded connections. Further remedial measures: do without trace drawings; reduce bus load – Acknowledgement option: error can be acknowledged. Parameterisable error response(s): A, [B] Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 120 For parameterisation as an error: the error can only be acknowledged after the cause is eliminated. Parameterisable error response(s): B, C, D, E, [F], G – If parameterised as a warning: the warning disappears when a valid telegram entry is writ- ten. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 121 The error may be caused by the actual velocity or the actual accel- eration being too high at the switching point. – Acknowledgement option: error can be acknowledged. Parameterisable error response(s): A Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 122 Check the following: is an error that can be acknowledged first pending? When downloading a parameter file, check that the version of the parameter file matches the firmware. If the error occurs again, please contact Festo service. – Acknowledgement option: error can be acknowledged.
  • Page 123 The firmware update could not be performed. The firmware version is incompatible with the hard- ware. – Determine the version of the hardware. You can check the compatible firmware versions and download appropriate firmware from the Festo website. – If parameterised as an error: error can be reset immediately. Parameterisable error response(s): [A] –...
  • Page 124 For parameterisation as an error: the error can only be acknowledged after the cause is eliminated. Parameterisable error response(s): [A] – If parameterised as a warning: the warning is no longer active if a braking resistor is connec- ted. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 125 Wait until the process is complete. The time between downloading two parameter files should be less than 3 seconds. – Acknowledgement option: error can only be acknowledged after eliminating the cause. Parameterisable error response(s): [F], G Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 126 If parameterised as a warning: the warning is no longer active if the following TEACH attempt is successful or if there is a switch from the Teach mode (mode 1) to normal opera- tion (mode 0). Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 127 Check connection and perform a reset, – Acknowledgement option: error can be acknowledged. Parameterisable error response(s): [B], C, D, E, F, G – If parameterised as a warning: the warning disappears if the connection to the controller is re-established. Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 128 A short circuit or overload has occurred to an external 24 V supply voltage of the device. – Check wiring of the STO interface, reference switch and digital inputs and outputs. – Acknowledgement option: error can only be acknowledged after eliminating the cause. Parameterisable error response(s): A, [B] Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 129: Problems With The Ethernet Connection

    3. Check whether the devices are accessible in the same subnet. Contact your network administrat- or, if necessary. The ping command can be used to determine whether the device can be reached in the network. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 130: Other Problems And Remedies

    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. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 131: Disassembly

    7. Place cover on the terminal box and screw it tight – tightening torque 1.5 Nm. Disassembly 1. Loosen the 4 retaining screws between the motor and additional components. 2. Disconnect device from the driven mechanical components. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 132: Repair

    TCP/IP, Modbus TCP (FHPP) Control interface digital I/O interface Modbus TCP Communication profile FHPP Protective functions I²t monitoring – Temperature monitoring – Current monitoring – Voltage failure detection – Following error monitoring – Software end-position detection Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 133: Product Conformity And Approvals

    Ambient temperature At nominal power [°C] 0   +20 … With power reduction of 1.75% per °C: [°C] 20   50 … Storage temperature [°C] -25   +70 … Relative humidity at 25 °C 0   95 (non-condensing) … Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 134 … … – – … … Tab. 103 Shock load Acceleration [m/s Duration [ms] Shocks per direction ±150 ±300 Tab. 104 Continuous shock load Acceleration [m/s Duration [ms] Shocks per direction ±150 1000 Tab. 105 Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 135: Data For The Integrated Motor

    6 months Note: the maximum service life of the battery depends on the state of charge, ambient temperature and ageing effects. Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 136: Holding Brake (Only Emca-Ec

    è Logic and load supply Nominal voltage [V DC] Perm. voltage fluctuations ±20 Nominal current Peak current 10.2 10.3 Protection against electric shock PELV circuit (Protected Extra-Low Voltage) Tab. 110 Connection data: power supply [X4] Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 137: Braking Resistor [X5]

    Galvanically connected to logic potential Specification Based on IEC 61131-2 Tab. 112 Reference or limit switch [X7], [X8] 9.1.13 I/O interface [X9] I/O interface [X9] I/O interface [X9] Max. cable length < Cable specification Overview of cable specifications è Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 138: Connection For External Battery [X10] (Only Emca-Ec-67

    9.1.14 Connection for external battery [X10] (only EMCA-EC-67-...-1TM) Connection for external battery [X10] EMCA-EC-67-… Max. cable length £ Cable specification Overview of cable specifications è Voltage [V DC] Tab. 114 Connection for external battery [X10] Festo — EMCA-EC-67-...-DIO — 2020-03d...

  • Page 139: Materials

    Terminal box Plastic – lower housing part (power electronics) Die-cast zinc Seal Motor – Shaft Steel – Flange Die-cast zinc – Profile barrel Aluminium Note on materials – Contains PWIS Tab. 115 Technical data: materials Festo — EMCA-EC-67-...-DIO — 2020-03d...
  • Page 140 Copyright: Festo SE & Co. KG Ruiter Straße 82 73734 Esslingen Germany Phone: +49 711 347-0 Internet: www.festo.com © 2020 all rights reserved to Festo SE & Co. KG...

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