Festo EMCA-EC-67 EC Series

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EMCA-EC-67-...-EC/-EP/-PN

Festo SE & Co. KG

Ruiter Straße 82

73734 Esslingen

Germany

+49 711 347-0

www.festo.com

Brief description

Translation of the original instructions

8074569

1710a

[8074562]

Integrated drive EMCA-EC-67-...-EC/-PN/-EP English.......................

EtherCAT

, EtherNet/IP

and PI PROFIBUS PROFINET

are registered trademarks

of the respective trademark owners in certain countries.

All available documents for the product è www.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

EMCA-EC-SY-...

Device and functional description;

Mounting, installation, commissioning and diagnostics

Manual

EMCA-EC-S1-...

Description of the safety function “Safely switched-off torque” (Safe

torque off/STO)

Manual

EMCA-EC-C-HP-...

Description of the device profile FHPP (Festo Handling and Position

ing Profile)

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.

 Besides the 4 screws on the housing cover, do not loosen any additional screws.

Warning

Danger of burns from hot housing surfaces.

Contact with 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 unintentional contact is not possible.

 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 cannot 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 de

scribed 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, measures may need to be implemented for radio interference sup

pression, e.g. in commercial and mixed-residential areas.

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 ISO13849-1 (Performance Level/PL)

– SIL 2 in accordance with EN61800-5-2 (Safety Integrity Level/SIL)

– SILCL2 in accordance with IEC62061 (Claim Limit/CL)

The achievable safety level depends on the other components used to implement a

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 ISO 13849-1, e.g. via an external safety relay.

Qualification of the specialist staff (requirements for staff)

The product may be placed in operation only by a qualified electro technician, 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 inclusion of the product in the control chain

and the measures implemented for the diagnostics. In order to achieve the spe

cified 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, appropri

ate 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 switching device with cross circuit detection.

1.3 Foreseeable misuse of the STO function

The following foreseeable misuses are among those not approved as intended use:

– Bridging of the STO function

– Applications where switching off can result in hazardous movements or condi

tions

Note

The STO function is not sufficient as the sole safety function for drives that are

subject to permanent torque or force (e.g. suspended loads, vertical axes).

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This document provides a brief description and technical specifications for the Festo EMCA-EC-67-...-EC/-EP/-PN integrated drive, which is designed for driving and controlling electromechanical systems within machines. It covers various aspects including safety, intended use, installation, electrical connections, and maintenance.

Function Description

The EMCA-EC-67-...-EC/-EP/-PN is an integrated drive that combines motor and control functionalities. It is designed to operate electromechanical drives in industrial environments. The device supports various communication protocols including EtherCAT®, EtherNet/IP®, and PROFINET®, making it versatile for integration into different control systems.

A key safety feature of this drive is the STO (Safe Torque Off) function, compliant with EN 61800-5-2. The STO function is intended to safely shut down the torque of the integrated motor, preventing unexpected start-up. It achieves a Performance Level (PL) d/cat. 3 according to ISO 13849-1, Safety Integrity Level (SIL) 2 according to EN 61800-5-2, and SIL CL 2 according to IEC 62061. The STO function requires activation via connection [X6] with the appropriate safety category. The diagnostic coverage (DCavg) for the safety function is 90%, and the hardware failure tolerance (HFT) is 1. The probability of dangerous failure per hour (PFHD) is 1 x 10^-9.

The device includes various interfaces for control and communication:

Parameterisation interface [X1]: An M12, 5-pin, D-coded Ethernet interface for connecting to a network or directly to a PC for configuration.
Bus/network interfaces [X2], [X3]: M12, 5-pin, D-coded sockets for EtherCAT®, PROFINET®, or EtherNet/IP® communication, depending on the product variant. [X2] serves as the IN (Port 2) and [X3] as the OUT (Port 1).
STO interface [X6]: A dedicated interface for the safe torque off function, including control ports (STO 1 and STO 2) and an acknowledgment contact.
End/reference switch interfaces [X7], [X8]: Inputs for connecting reference or limit switches, providing 24 V DC power output for the switches.
I/O interface [X9]: Includes digital inputs (DIN) for control enable and sampling, and digital outputs (DOUT) for status signals (e.g., "Ready").
External battery [X10]: For EMCA-EC-...-1TM variants, this connection allows an external battery to extend the operating duration of the absolute encoder, recording position changes for up to 6 months with a Festo EADA-A-9 battery.
Braking resistor [X5]: Connection for an external braking resistor (RBR 6 Ω) to dissipate excess energy.

The device features LED indicators for various statuses, including LINK/ACTIVITY, OK, ERROR, EC RUN, MS (Module status), NS (Network status), IDENT/STATE (Identification/Status), and NF (Network failure), depending on the product variant. These LEDs provide visual feedback during switch-on, operation, and in case of errors or warnings.

Commissioning is facilitated via the TCP/IPv4 protocol, with the EMCA configured as a DHCP server by default. A web server provides read access to an English-language website, and the Festo Configuration Tool (FCT) plug-in supports all commissioning steps.

Important Technical Specifications

Environmental and Operating Conditions:

Installation position: Optional.
Ambient temperature: 0 to +20 °C (nominal power), with power reduction of 1.75 % per °C from +20 to +50 °C.
Storage temperature: -25 to +70 °C.
Relative air humidity at 25 °C: 0 to 95 % (non-condensing).
Degree of protection: IP54 (EMCA... without -S1), IP65 (EMCA...-S1); motor shaft IP54.

Power Supply [X4]:

Nominal voltage: 24 V DC.
Permissible voltage fluctuations: ±20 %.
Nominal current: 6.9 A (EMCA-...-S-...), 7.2 A (EMCA-...-M-...).
Peak current: 10.2 A (EMCA-...-S-...), 10.3 A (EMCA-...-M-...).
Power supply (logic and load voltage): +19.2 V DC to +28.8 V DC.

Motor Data:

Rotor position encoder: Absolute single-turn encoder (EMCA-...-S-...) or Absolute multi-turn encoder (EMCA-...-M-...).
Resolution: 12 bit (4096 increments per revolution).
Absolute encoder operating duration (at medium ambient temperature): 7 days (without external battery), 6 months (with external battery).
Nominal power: 120 W (EMCA-...-S-...), 150 W (EMCA-...-M-...).
Nominal torque: 0.37 Nm (EMCA-...-S-...), 0.45 Nm (EMCA-...-M-...).
Nominal rotational speed: 3100 rpm (EMCA-...-S-...), 3150 rpm (EMCA-...-M-...).
Max. rotational speed: 3500 rpm (EMCA-...-S-...), 3300 rpm (EMCA-...-M-...).
Mass moment of inertia of rotor: 0.175 kgcm² (EMCA-...-S-...), 0.301 kgcm² (EMCA-...-M-...).
Perm. axial shaft load: 60 N.
Perm. radial shaft load: 100 N.

Holding Brake (only EMCA-...-...B):

Brake holding torque: 1 Nm.
Brake power consumption: 9 W.
Mass moment of inertia, brake: 0.021 kgcm².

Max. Line Lengths (for EMC conformity):

Power supply line: ≤ 30 m.
STO and I/O interface: ≤ 30 m.
Limit/reference switch, battery: ≤ 3 m.

Product weight (without [B], without [M]): 1900 g (EMCA-...-S-...), 2260 g (EMCA-...-M-...).

Product Conformity and Certifications:

CE marking (in accordance with EU EMC Directive and EU Machinery Directive).
RCM (Regulatory Compliance Mark).
c UL us - Recognised (OL) for specific product variants.

Usage Features

Intended Use: The product is designed for installation in a machine and for driving and controlling electromechanical drives in industrial environments. It must be used in perfect technical condition, in its original status (without unauthorized modifications), and within the defined technical data limits.
Safety: The STO function is a critical safety feature, preventing unintended motor start-up. It is crucial to ensure that the STO function is used only in applications where its specified safety characteristics are sufficient. The device requires a qualified electro technician for installation and operation, familiar with electrical control systems, safety regulations, and product documentation.
ESD Protection: Handling of electrostatically sensitive devices requires adherence to specific guidelines, including sealing unassigned plug connectors, earthing system parts, and using appropriate ESD equipment.
Network Security: When connecting the device to a network, measures such as firewalls, intrusion prevention systems, network segmentation, VLANs, VPNs, and physical access security (Port Security) should be implemented to protect against unauthorized access and potential malfunctions.
Mounting: The drive must be mounted securely and free of tension. The mounting flange offers options for fastening via M6 through-holes or M4 female threads. It is essential to comply with maximum permissible shaft loads (axial and radial) to prevent damage.
Electrical Installation: Only counter-plugs from the NEKM-C assortment and specified accessories should be used. Flexible cables must be laid without kinks and mechanical stress. The electrical power supply must use PELV (protective extra-low voltage) circuits in accordance with EN 60204-1, ensuring reliable electrical isolation.
IP Degree of Protection: Compliance with requirements for securing the IP degree of protection is necessary for proper operation.
Foreseeable Misuse: Bridging the STO function or using it in applications where switching off can result in hazardous movements are not approved. The STO function alone is not sufficient for drives subject to permanent torque or force (e.g., suspended loads, vertical axes).

Maintenance Features

Care and Cleaning: The outside of the product can be cleaned with a soft cloth.
Repair and Disposal: Repair or maintenance of the product is not permissible; if defective, the complete product must be replaced. Local regulations for environmentally friendly disposal of electronic components must be observed.
Safety Function Performance Test: The implemented safety function must undergo a regular and documented performance test by a specialist during the machine's use. The EMCA should be checked at least once per year.
Cooling: Before cleaning or maintenance work, the drive must be allowed to cool down to room temperature to prevent burns from hot housing surfaces and to avoid gas formation and ignition if cleaning agents contact hot surfaces.
Safety During Maintenance: Before starting any mounting, installation, or maintenance work, power supplies must be switched off and secured against accidental reactivation. Removal of the enable signal at the EMCA is not sufficient.
Rotating Parts: Due to the rapidly rotating motor shaft with high torque, contact must be avoided to prevent burn injuries and abrasions. Clothing, jewelry, and hair must not be caught by the rotating shaft. Personnel with long hair must wear hair nets.