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Teknic EF-785 Installation Manual

Power distribution and safety control center
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I
G
NSTALLATION
UIDE
F-785 P
D
E
OWER
ISTRIBUTION AND
S
C
C
AFETY
ONTROL
ENTER
V
1.42 / A
26, 2005
ERSION
UGUST
T
, I
F
( 5 8 5 ) 7 8 4 - 7 4 6 0
V
( 5 8 5 ) 7 8 4 - 7 4 5 4
E K N I C
N C
A X
O I C E

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  • Page 1 NSTALLATION UIDE F-785 P OWER ISTRIBUTION AND AFETY ONTROL ENTER 1.42 / A 26, 2005 ERSION UGUST ( 5 8 5 ) 7 8 4 - 7 4 6 0 ( 5 8 5 ) 7 8 4 - 7 4 5 4 E K N I C O I C E...
  • Page 2 HIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 3: Table Of Contents

    EN1050 risk assessment ..........10 Select Guard-locks or Interlocks (for each guarded Hazard) ..................10 Step 2: Select eF-785 configuration options........ 11 Definitions ................ 11 Step 3: Mount the eF-785 ............21 Important Mounting Dimensions........21 Mounting Orientation ............. 22 Cooling................
  • Page 4 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T Safety alarm check ............53 Recovering after an E-Stop event ........53 Shutting down..............53 Finding and replacing a blown fuse..........55 DC Power Over-current Alarm ........

  • Page 5: E F-785 Overview

    Purchase the eF-785, and most of that work is already done. The eF-785 provides all of the critical “foundation” functions you need in a pre- tested, value priced, off-the-shelf assembly.
  • Page 6 Disconnect Switch Power Supplies On/Off Reset Control Computer eF-785 Simplified Context Diagram As shown in the context diagram above, the eF-785 manages a number of critical functions in your machine including: • Power control • Power sequencing • Safety disconnect •...
  • Page 7 N S T A L L A T I O N A N U A L single fault. You won’t need any additional safety control components (safety relays or controllers) when using the eF-785. Hooking up the eF-785 (585)784-7460 V...

  • Page 8: Ef-785 Benefits

    ...Plus , if you need to control more than 4KVA of power, use 3- phase power, or if your machine has other hazards you’d like the eF-785 to manage, you can extend the system’s capabilities by utilizing the eF- 785’s safety control and feedback signals. These signals are readily available on the rear panel connector, P13.

  • Page 9: Ef-785 Safety Features

    EGMENTED ACHINE UPPORT The eF-785 can be configured so that AC power to mechanical hazards is controlled independently in two different functional areas of a machine. This means that an operator can easily power down the mechanical hazards in one part of a machine (Load Area) while the Main Area of the...

  • Page 10: Controlled Stopping Function (Controlpoint™ Only)

    ™ O ONTROL OINT The eF-785 can act as a network hub for connecting Teknic’s open ControlPoint™ networked motion and I/O control nodes. These nodes can control servomotor or stepper motor axes. When using the eF-785 with ControlPoint™ components in charge of the motion control, controlled stopping of the motion axes within a machine can be automatically initiated by the eF-785 when a safety shutdown occurs.
  • Page 11 OEM Machine Manufacturer, in mind. Our objective is to provide you with all of the information you need to successfully visualize, integrate and install the eF-785 in your machine. To that end we’ve included a complete set of cable drawings, each with a comprehensive bill of materials.

  • Page 12: Integration Steps

    EN 954-1 (levels B, 1, 2, 3 or 4) for each hazard. The eF-785 can meet levels B,1,2, and 3. Therefore, in order to use the eF-785 as a “stand-alone” safety control center, none of the hazards in your machine can exceed EN 954-1 level 3 requirements.

  • Page 13: Step 2: Select Ef-785 Configuration Options

    2: S F-785 ELECT E CONFIGURATION OPTIONS Now it’s time to specify your eF-785. For this task you should know a few things: Your machine’s operational and power requirements 2. The definitions of a few key terms used in this section 3.
  • Page 14 OWER ONTROL PTIONS The eF-785 offers you several options as to how you distribute power to AC and DC servo or stepper motor drives in your automated machine. Not only can you power multiple AC and/or DC motor drives simultaneously through the eF-785, but you can control the flow of power to these drives in two separate areas of your machine (Main and Load Area) under separate safety and power control.
  • Page 15 It supports both AC and DC powered motor drives in the Main Area, and both AC and DC powered motor drives in the Load Area. Example part number: EF-785-AAxx-xxx-x AA Configuration To general hazardous...
  • Page 16 Main Area, but no Load Area drives. In the AN configuration, the J8 circuits, normally reserved for Load Area functionality, may be used as additional Main Area circuits. Example part number: EF-785-ANxx-xxx-x. AN Configuration To general hazardous loads...
  • Page 17 (Q). TAGE ILTERING The basic level of EMI filtering offered for the eF-785 is two-stage (Dual) filtering indicated by the letter D in the position shown above. The 2- stage option is standard in configurations where only DC powered motor drives are present in the machine (i.e.
  • Page 18 OFF DELAY PTIONS The eF-785 offers you some options as to how quickly hazardous power is removed from the Main Area of your machine. Q: When can this option be valuable? A: In cases where the sudden removal of power from a motor axis could cause significant (read expensive) damage to the machine, its payload, or both.
  • Page 19 Power up with Soft Shutdown enabled - An operator initiates the machine power-up cycle by pressing the machine’s front panel “on” button (which is wired into the eF-785). The machine powers up and the eF-785 sends AC power to the host computer which then powers up as well.
  • Page 20 U G U S T Power down with Soft Shutdown enabled – When the operator powers down the host PC, the USB signal to the eF-785 turns off. When the eF-785 no longer detects the USB signal, it shuts down the entire machine.
  • Page 21 Hazardous power availability vs. E-Stop switch status EVISION RMWAR The final position of the eF-785 part number contains the firmware revision of the embedded Teknic ControlPoint™ network hub (NC-540). The firmware revision will appear as three numbers separated by hyphens (e.g. 2-0-0 or 2-10-3). This is not typically a user-specified option.
  • Page 22 EF-785- EF-785- F F E 2-0-1 Example eF-785 part number Power Control Options DC powered servo or stepper drives/motors in Main Area only DC powered servo or stepper drives/motors in Main and Load Areas AC and DC powered servo or stepper drives/motors in Main Area...

  • Page 23: Step 3: Mount The Ef-785

    N S T A L L A T I O N A N U A L 3: M F-785 OUNT THE E This section describes how to properly mount the eF-785 to your machine. It includes the unit’s physical dimensions, mounting hole specifications, minimum clearances, and recommended spatial orientations. MPORTANT...

  • Page 24: Mounting Orientation

    If a vertical mount is chosen, the fan should be “up” to assure proper ventilation and cooling action (see diagram). Never mount the eF-785 such that the front panel faces directly down or up. Refer to the “Unacceptable Mounting Orientation” diagram below.

  • Page 25: Rack Slides

    Often, the bottom of a machine offers the coolest ambient air temperatures. LIDES If you plan to rack mount your eF-785, Teknic recommends the Accuride model c 2807-20 rack drawer slides. This model is compatible with the thread inserts on the side panel of the eF-785.

  • Page 26: Step 4: Set Up The 24Vdc Power Distribution

    OWER SUPPLIES The 24VDC supplies are connected to the 24VDC Supply connector J5 (see figure below), located on the rear panel of the eF-785. This connector not only serves to provide two different control modes for AC line voltage to power the supplies (described below), it also receives the...
  • Page 27 Please refer to the following schematic fragments for details. Note that although the eF-785 can remove AC power to externally connected 24VDC supplies, it does not provide any means for quick-discharge of the connected supplies once AC power is removed. This is usually not an issue if a switching supply is used for the 24V, which is common, the 24VDC will usually drop very quickly, in less than a few hundred milliseconds.
  • Page 28 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T ONFIGURATION PTIONS FOR SINGLE OR DUAL 24VDC SUPPLIES A. A single 24VDC power supply that is on continuously whenever AC Control Power is on.

  • Page 29: Connecting 24Vdc Loads (P9-P11)

    (this is typical of most commercially available drives). Refer to Appendix C for a typical cable diagram for connecting the 24VDC supply to the eF-785. 24VDC (P9-P11)
  • Page 30 Daisy-chained loop This topology is similar to the daisy- chained wiring described above, the difference being that the “last” load in the chain is connected back to the eF-785. This type of wiring offers the advantages of not only being redundant...
  • Page 31 In this method, each load is wired individually to the eF-785 by using a terminal block or distribution panel to bring power to each load separately. Central star wiring topology...

  • Page 32: Step 5: Set Up Dc Motor Power Distribution 48-90Vdc

    Connector P6, on the rear panel of the eF-785, provides switched Main AC power to the DC power supply, and connects the DC output of the supply back to the eF-785. Though we often refer to this as the “75VDC Power Distribution” in the manual, the permissible voltage range for this supply is 48-90VDC.

  • Page 33: Connecting The Loads (Dc Motor Drives) (P7A, P7B, J8A, J8B)

    The negative (return) lead of the power supply should not be connected to safety ground at the power supply. This connection is made internally in the eF-785, and to avoid any ground loops, should not be done externally.
  • Page 34 Refer to Appendix C for cable drawings. The Main DC motor power connectors (P7A, B) are keyed differently than the Load DC motor power connectors (J8A, B) to prevent incorrect connections during installation of the eF-785. See illustration below.
  • Page 35 There are three methods by which you can distribute DC power to servo or stepper motor drives in your machine. If you are using Teknic servo drives in your machine, you can take advantage of our unique dual power connector design to create a power distribution “daisy chain”...
  • Page 36 Each drive is wired individually to the eF-785 by using a terminal block or distribution panel to bring power to each drive...
  • Page 37 F - 7 8 5 I N S T A L L A T I O N A N U A L eF-785 DC Servo or Stepper Motor Drives Main Terminal Block Option Central star wiring topology (585)784-7460 V...

  • Page 38: Step 6: Connect Ac Powered Motor Drives (P3, J4)

    The eF-785 automatically discharges any DC power stored within the drives when the hazardous power is interrupted to those drives. 25 ohm resistors within the eF-785 dissipate the power that is typically generated during load deceleration. Thus, the issues presented by the...

  • Page 39: Wiring Configurations

    AC servo drives is the total sum of AC servo drives in both the Main and Load areas that are to have their AC power managed by the eF-785. If you are using non-Teknic drives, contact Teknic for the maximum number of drives that can be used.

  • Page 40: Step 7: Connecting Other Miscellaneous Ac Loads (J2)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 7: C (J2) ONNECTING OTHER MISCELLANEOUS LOADS AC power is also available for miscellaneous hazardous loads on connector J2.

  • Page 41: Step 8: Connect Incoming Ac Power

    OWER Incoming AC power to the eF-785 is supplied through connector P2. The eF-785 can be powered directly from a 115 or 230 nominal VAC single- phase source. Input voltage is selected by setting the line voltage switch , located on the rear panel, to either the 115V or 230V setting.
  • Page 42 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T other hand, the machine has a plug and cord for AC input power, the plug must offer sufficient breaking capacity for the load presented by the machine.

  • Page 43: Step 9: Connect The Embedded Control Computer

    PC, display and any other peripherals, up to 8A max. A suitable IEC 60320 detachable cord set must have a Type C-14 plug (on the eF-785 end) and a Type C-13 connector (on the Host PC or display end). Note: These cords should be marked as indicated below.
  • Page 44 ONNECTIONS Two USB connectors (one Type A and one Type B) are provided on the rear panel of the eF-785. These USB connectors provide only a pass- through connection and are necessary only if the Soft Shutdown feature is enabled.

  • Page 45: Step 10: Mount And Connect The Power/Enable Switch(Es)

    Using a combination switch such as this not only allows you to provide front panel controls using only one component, but also the front panel wiring harness from P14 on the eF-785 to this switch can be wired with one straight point-to-point cable. Teknic recommends a 22 mm rotary switch such as the Omron/A22W-3AG-24A-11.
  • Page 46 “actuation” of the Off button from the control computer. This feature, known as the Soft Shutdown, works by connecting the control computer to P16 on the eF-785 via a standard USB cable. When the control computer is shut down, the 5V from the USB port is removed. The eF- 785 immediately detects the USB voltage change of state from +5v to 0V and turns off AC Control Power.

  • Page 47: Step 11: Mount And Connect The Safety Control Components

    e F - 7 8 5 I N S T A L L A T I O N A N U A L 11: M OUNT AND CONNECT THE SAFETY CONTROL COMPONENTS ELECTING XTERNAL AFETY EVICES WITCHES E-Stop switch selection requirements •...
  • Page 48 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T NTERLOCK WITCHES Interlock switch selection considerations • The switch must be a DPST type switch, with normally closed, and positively guided contacts.
  • Page 49 e F - 7 8 5 I N S T A L L A T I O N A N U A L • The actuator key should be mounted to the gate/guard using tamper- resistant hardware/screws. • Refer to EN 1088 for information regarding selection and mounting of guard-locks.

  • Page 50: Safety Harness For Non-Segmented Machine (P12)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T (P12) AFETY HARNESS FOR NON SEGMENTED MACHINE The safety harness for a non-segmented machine is quite simple (see schematic below) featuring two redundant loops through all of the interlock switches and E-stop switches.

  • Page 51: Safety Harness For Segmented Machine (P12)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L (P12) AFETY HARNESS FOR SEGMENTED MACHINE The safety harness for a segmented machine is very similar in structure to the non-segmented machine safety harness shown above.

  • Page 52: Auxiliary Safety Connector (P13)

    (P12, AFETY YSTEM OWER ONSIDERATIONS P13, P14) All safety control circuits are powered by a dedicated, high reliability 24VDC supply internal to the eF-785. This supply is used to power the safety control relay logic circuits, internal (and external) control...
  • Page 53 Allowable power available from the safety supply If the eF-785 is to be powered from a low AC line voltage (i.e. below 105VAC or 210VAC) the allowable external power draw figures in the above table must be derated by 5%.

  • Page 54: Step 12: Optional: Connect Controlpoint™ Components

    The eF-785 was designed with Teknic’s ControlPoint (CP) customers in mind. Creating a network of CP motion and I/O control products off of the eF-785 is a relatively simple matter. Teknic I/O devices, integrated controller/drives and indexers all connect to the eE-785 (and each other) with standard Category 5 patch cables and standard RJ-45 (Ethernet) plugs.

  • Page 55: Running A Machine With The E F-785

    PC. If the eF-785 has been configured with the soft-shutdown feature enabled, one of the host PC’s USB ports must be connected to the eF-785 (to either P15 or P16) in order for the machine to latch into the power-on state.
  • Page 56 Soft Shutdown enabled When the Soft Shutdown feature is enabled, the operator needs only to start a shutdown sequence on the host PC. The eF-785 will then power off automatically when the host PC turns off, thereby removing power from the machine.

  • Page 57: Finding And Replacing A Blown Fuse

    OWER CURRENT LARM All DC power circuits managed by the eF-785 are protected against over- current events by front panel fuses or circuit breakers. This includes not only DC Motor Supply power and 24VDC sensor/actuator power, but also the 24VDC internally supplied safety power and 40VDC ControlPoint™...
  • Page 58 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 115V F1, F2 Host Pwr. 8A Max Load AC Motor Power Safety Harness AC Control Power rear panel fuses (F1 and F2)

  • Page 59: Extending The System

    ONTROL In this example, 3-phase AC power is switched along with other Main area power. In order for the eF-785 to be able to control and monitor the switching of 3-phase AC power, an external 3-phase contactor must be used. This contactor must be of the type that has three normally open contacts for switching power as well as one normally closed contact that monitors the state of the power contacts.

  • Page 60: Appendix A: Meeting The Eu Machinery Directive For Ce Compliance

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T A: M EU M PPENDIX EETING THE ACHINERY IRECTIVE FOR COMPLIANCE HAT IS THE ACHINERY IRECTIVE ND WHY IS IT IMPORTANT EVEN OUTSIDE OF All machinery with mechanical hazards that is to be sold to the European Union must meet the requirements of the CE Machinery Directive...
  • Page 61 All you have to do is to assess whether you need a level 2 or 3 safety control system based upon your risk assessment. If you need a level 3 system, install the eF-785 with guard- locks on any movable guards (i.e. protective doors or covers). If you...
  • Page 62 Power Distribution and Safety Control Center. These assumptions (and a test setup consistent with them) were used in the FMEA and fault testing to assure that the eF-785 meets the requirements of EN-954-1 and EN 1050. The objective of this section is to make it clear how to use the eF-785 while complying with requirements EN 954-1 and EN 1050.
  • Page 63 These hazards can likely be controlled and monitored by a safety control system based upon the eF-785, however, no attempt has been made to consider them herein. 17. The machine must pass (or be able to pass) EN61010-1.
  • Page 64 Mode Effects Analysis (FMEA) for their machine safety system and decide if the level of protection is appropriate. Teknic can furnish you with an FMEA for the eF-785 that has been provided to us by a third party testing laboratory which you can use to help you prepare this;...

  • Page 65: Appendix B: Specifications

    e F - 7 8 5 I N S T A L L A T I O N A N U A L B: S PPENDIX PECIFICATIONS Operating Environment 0-40° C, 0-90% humidity Input power 100-120/ 200-240VAC 50/60Hz (selectable), up to 20A RMS (4KVA@200VAC Input Power ranges 115 range: 100-126 Vrms, 50-60Hz...

  • Page 66: Appendix C: Cable Diagrams

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T C: C PPENDIX ABLE IAGRAMS 48–90VDC L (J8A, J8B) REA TO...

  • Page 67: 48-90Vdc Main Area To Sst (P7A, P7B)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L 48–90VDC M (P7A, P7B) REA TO (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 68: 48-90Vdc Load Area To Isc (J8A, J8B)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 48–90VDC L ISC (J8A, J8B) REA TO...

  • Page 69: Vdc Main Area To Isc / Sst-Isc (P7A, P7B)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L 48–90 VDC M ISC / SS -ISC (P7A, P7B) REA TO (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 70: Ac Servo Power Cable, Load Area (J4)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T AC S (J4) ERVO OWER ABLE...

  • Page 71: Ac Servo Power Cable, Main Area (P3)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L AC S (P3) ERVO OWER ABLE (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 72: Sst-6000, 3000 Dc Power Jumper Cable

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T -6000, 3000 DC P OWER UMPER ABLE...

  • Page 73: Sst-6000, 3000 Ac Input Cable

    e F - 7 8 5 I N S T A L L A T I O N A N U A L -6000, 3000 AC I NPUT ABLE (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 74: Single 24Vdc Supply Cable (J5)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 24VDC S (J5) INGLE UPPLY ABLE...

  • Page 75: Dual 24Vdc Supply Cable (J5)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L 24VDC S (J5) UPPLY ABLE (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 76: 90Vdc Supply Cable - Sst-Emf75 (P6)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 70 – 90VDC S – SS -EMF75 (P6) UPPLY ABLE...

  • Page 77: 24Vdc Dist. Cable/Ioc-Apc (P9-P11)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L 24VDC D /IOC-APC (P9-P11) ABLE (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 78: 40Vdc Power Tap Distribution Cable (P18)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T 40VDC P (P18) OWER ISTRIBUTION ABLE...

  • Page 79: Front Panel Harness Power/Enable Circuits (P14)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L (P14) RONT ANEL ARNESS POWER ENABLE CIRCUITS (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 80: Integration & Testing Cheater Plug Safety Control Ckts (P12)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T & T NTEGRATION ESTING HEATER LUG SAFETY CONTROL (P12) CKTS...

  • Page 81: Extension Cheater Plug (P13)

    e F - 7 8 5 I N S T A L L A T I O N A N U A L (P13) XTENSION HEATER (585)784-7460 V (585)784-7454 EKNIC OICE...

  • Page 82: Input Power Cable (J2)

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T (J2) NPUT OWER ABLE...

  • Page 83: Appendix D: Field Modifiable Options

    When enabled, the Soft Shutdown feature allows you to power off your machine by shutting down the host computer. When Soft Shutdown is disabled, you must power down the host PC and the eF-785 separately. See the Supplementary Options section for more details.
  • Page 84 Step3: Locate the jumper positions of interest JP7, JP8, and JP9 are located near each other on the board next to the rear panel of the eF-785. Refer to the photo illustration below. JP9 JP8 Jumper locations for JP7, JP8, and JP9 Step 4: Set jumpers .
  • Page 85 N S T A L L A T I O N A N U A L E: 24VDC S PPENDIX UPPLY IRING eF-785 20 Amp External 24 VDC CONNECTOR J5 Power Supply Belden/9314 (14 AWG, 2 cond, 300V, shielded) AC LINE 1...
  • Page 86 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T eF-785 20 Amp External 24 VDC CONNECTOR J5 Power Supply Belden/9314 (14 AWG, 2 cond, 300V, shielded)

  • Page 87: Safety Standards Referenced In This Manual

    e F - 7 8 5 I N S T A L L A T I O N A N U A L F: S PPENDIX AFETY TANDARDS EFERENCE AFETY STANDARDS EFERENCED IN THIS MANUAL OCUMENT UMBER ITLE BS EN 1050:1997 Safety of machinery - Principles for risk assessment Safety of machinery - Interlocking devices associated with guards - BS EN 1088:1996...
  • Page 88 1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T Safety of machinery - Safety distances to prevent danger zones being BS EN 294:1992 reached by the upper limbs Safety of machinery - Safety distances to prevent danger zones being BS EN 811:1997 reached by the lower limbs...

  • Page 89: Appendix G: Connector Reference

    e F - 7 8 5 I N S T A L L A T I O N A N U A L G: C PPENDIX ONNECTOR EFERENCE J2: Misc. Hazardous AC Out Mating Connector Terminal PN Insul Dia. Crimp Tool (manual) Crimp Die AMP/1-480700-0 AMP/640309-3...

  • Page 90: Cable Stock

    1 . 4 2 / A 2 6 , 2 0 0 5 E R S I O N U G U S T P9A-B, P10A-B, P11A-B: 24VDC Outputs Mating Connector Terminal PN Insul Dia. Crimp Tool (manual) Crimp Die Molex/39-01-2020 24-18 Molex/39-00-0039...

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