Teknic EF-785 Manual de usuario

F-785

OWER

ISTRIBUTION AND

AFETY

ONTROL

ENTER

ERSION

1.42

UGUST

26,

2005

NSTALLATION

UIDE

EKNIC

(585)784-7460

OICE

(585)784-7454

HIS PAGE INTENTIONALLY LEFT BLANK

F-785

VERVIEW

......................................................3

eF-785 Benefits.............................................................................. 6

EF-785 Safety Features ..................................................................7

Segmented Machine Support.............................................7

Guard-lock Control ............................................................7

Automatic Safety System Checkout ...................................7

Controlled Stopping Function (ControlPoint™ Only) ..... 8

Integration Steps at a Glance........................................................ 8

NTEGRATION

TEPS

................................................10

Step 1: Complete a risk assessment and select guard-locks or

interlocks for guarded areas.........................................................10

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............................................................................. 22

Rack Slides ...................................................................... 23

Step 4: Set up the 24VDC Power Distribution............................ 24

Selecting the Power Supplies .......................................... 24

Connecting 24VDC Power supplies (J5)......................... 24

Connecting 24VDC loads (P9-P11) ..................................27

Step 5: Set up DC Motor Power Distribution 48-90VDC .......... 30

Selecting the Power Supplies .......................................... 30

Connecting DC Motor Power Supplies (P6) ................... 30

Connecting the Loads (DC Motor Drives) (P7A, P7B, J8A,

J8B)........................................................................................31

Step 6: Connect AC Powered Motor Drives (P3, J4) .................. 36

Wiring Configurations..................................................................37

Step 7: Connecting other miscellaneous AC loads (J2).............. 38

Step 8: Connect Incoming AC Power.......................................... 39

Incoming Power (P2) ...................................................... 39

Add a Power Disconnect Switch (if required)................. 39

Step 9: Connect the embedded control computer .......................41

CPU, Display and Peripheral Power (JA, JB)..................41

Host Control Connections................................................41

Step 10: Mount and connect the Power/Enable Switch(es)....... 43

Power/Enable Circuits (P14) .......................................... 43

Step 11: Mount and connect the safety control components...... 45

Selecting External Safety Devices ................................... 45

Safety harness for non-segmented machine (P12) ......... 48

Safety harness for segmented machine (P12)................. 49

Auxiliary Safety Connector (p13).................................... 50

Step 12: Optional: Connect ControlPoint™ Components.......... 52

Where does ControlPoint™ technology fit in? ............... 52

UNNING A

ACHINE WITH THE E

F-785 ..................53

Powering up......................................................................53

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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 ........................................ 55

AC Control Power Circuit Protection .............................. 55

XTENDING THE

YSTEM

.........................................57

Controlling External Hazardous Energy ..................................... 57

Example: 3-Phase Power Control................................................ 57

PPENDIX

EETING THE

ACHINERY

IRECTIVE FOR

COMPLIANCE

............................58

What is the Machinery Directive (And why is it important even

outside of the EU) ........................................................................58

PPENDIX

PECIFICATIONS

.................................63

PPENDIX

ABLE

IAGRAMS

...............................64

48–90VDC Load Area to SSt (J8A, J8B) ....................................64

48–90VDC Main Area to SSt (P7A, P7B) ....................................65

48–90VDC Load Area to ISC (J8A, J8B)....................................66

48–90 VDC Main Area to ISC / SSt-ISC (P7A, P7B) ..................67

AC Servo Power Cable, Load Area (J4) .......................................68

AC Servo Power Cable, Main Area (P3).......................................69

SSt-6000, 3000 DC Power Jumper Cable ..................................70

SSt-6000, 3000 AC Input Cable ................................................. 71

Single 24VDC Supply Cable (J5) .................................................72

Dual 24VDC Supply Cable (J5)....................................................73

70 – 90VDC Supply Cable – SSt-EMF75 (P6) ............................74

24VDC Dist. Cable/IOC-APC (P9-P11)...................................... 75

40VDC Power Tap Distribution Cable (P18)...............................76

Front Panel Harness power/enable circuits (P14) ...................... 77

Integration & Testing Cheater Plug safety control ckts (P12).....78

Extension Cheater Plug (P13)......................................................79

Input Power Cable (J2)............................................................... 80

PPENDIX

IELD

ODIFIABLE

PTIONS

..............81

Changing the Jumper Settings .................................................... 81

PPENDIX

24VDC

UPPLY

IRING

.....................83

PPENDIX

AFETY

TANDARDS

EFERENCE

.....85

Safety standards Referenced in this manual...................85

Miscellaneous safety standards .......................................85

PPENDIX

ONNECTOR

EFERENCE

.................87

Cable Stock.................................................................................. 88

ERSION

1.42

UGUST

26,

2005

F-785

VERVIEW

The eF-785 is Teknic’s patented power distribution and safety control

center, for use in OEM automated machinery. The “eF” designation

stands for “Electrical Foundation”, an appropriate description as the eF-

785 consolidates nearly all of the required safety, power management

and distribution functions required in an automated machine into one

easy-to-integrate box.

VDC

Ckt. 3

10A Max. 40

VDC

ControlPoint

VDC

Safety

F7 F8 F10F9

DC Servo Main

15A Max.

DC Servo Option

15A Max.

CB2 CB3

Status

VDC

Ckt. 2

10A Max.

VDC

Ckt. 1

10A Max.

SAFETY ALARM

Do not operate or service

machine if sounding

eFoundation- Power Distribution & Safety Control Center

CB1, UL489 Rated Input Breaker

10,000A Interrupting

When installed according to the

accompanying instructions this unit meets:

- UL 61010-1 2nd Edition

- EN 61010

- EN 60204

- EN 954-1 (Class 2)

- Semi S2

- EN 61326

Teknic, Inc.

785

CUS

eF-785 Power Distribution and Safety Center (front panel pictured)

Experienced machine designers know that successfully complying

with the myriad of complicated, often ambiguous compliance standards,

means spending laborious hours working on the electrical distribution,

control, and safety circuits before compliance testing can even begin.

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. Though these functions do

not, typically, provide the OEM with a huge differential advantage, the

eF-785, properly implemented, will reduce your engineering burden,

assure that safety and compliance standards are met with a minimum of

hassle, and speed your product to market.

Time after time our field engineers have come back to report a

product rollout hampered or delayed by oversights and last minute

testing and rework of these critical circuits. As a direct result of these

observations, Teknic set out to build a better solution for our OEM

customers. The eF-785 is that solution. It’s the all-in-one answer to your

machine’s power distribution, safety and control requirements. It’s

economical, easy to integrate, and can greatly improve your machine

production time. Why reinvent the wheel when you can join a growing

number of customers who call the eF-785 Compliance in a Box™.

eF-785

NSTALLATION

ANUAL

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ERSION

1.42

UGUST

26,

2005

VDC

Ckt. 3

10A Max. 40

VDC

ControlPoint

VDC

Safety

F7 F8 F10F9

DC Servo Main

15A Max.

DC Servo Option

15A Max.

CB2 CB3

Status

VDC

Ckt. 2

10A Max.

VDC

Ckt. 1

10A Max.

SAFETY ALARM

Do not operate or service

machine if sounding

eFoundation- Power Distribution & Safety Control Center

CB1, UL489 Rated Input Breaker

10,000A Interrupting

When installed according to the

accompanying instructions this unit meets:

- UL 508

- EN 61010

- EN 60204

- EN 954-1 (Class 2)

- Semi S2

- EN 50081-2

- EN 50082-2

Teknic, Inc.

785

2020

Control Computer

Door Interlocks

(with or without locks)

Controlled / Protected Power Distribution

On/Off

Reset

Disconnect

Switch

EMO

Switch

24VDC Dist.

(6 Circuits)

Hazardous AC

AC Servo Dist.

(2 Circuits)

DC Servo Dist.

(4 Circuits)

Power

Supplies

ACControl

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

Over-current protection

Safety guard lock control/interlocks

Regenerated power dissipation

Conducted EMI filtering

In fact, creating a complete machine power system based on the eF-

785 requires only a comparatively small amount of work. And, if you

follow the installation instructions in this manual, your machine’s power

control system will meet US, European and world standards for electrical

and machine safety, including EN 954-1, EN 60204, EN 61010 and

Semiconductor safety standards SEMI S8 and S2.

The eF-785 can easily manage the power control requirements of a

“two-area” (segmented) machine. This type of machine features a Main

Area and an operator accessible Load/Unload Area, each under separate

control. The eF-785 allows a machine operator to safely disable

hazardous power to the Load/Unload Area while the Main Area of the

machine continues core processing operations. Your customers will

appreciate the greater machine throughput this affords them.

The eF-785’s power-disconnect and safety control is fully compliant

with EN-954-1 (required for compliance with the CE Machinery

Directive). This hazardous power-disconnect is fully single fault tolerant

to component and machine wiring faults and is monitored to detect any

single fault. You won’t need any additional safety control components

(safety relays or controllers) when using the eF-785.

Host Power

Main AC

Motor Power Load AC

Motor Power

F1, F2

Host Pwr. 8A Max

P14

P13

P12

Safety Harness Safety Control Ext.

IEEE-1284 Host Port

J17

P18

40V Net Out Net In

RED BLK

100-125/200-240

VAC~ 20A, 50-60Hz

P9 A,B

24VDC

Ckt. 1

P10 A,B

24VDC

Ckt. 2

J8A J8B

Option DC Motor Pwr.

90VDC Max.

Main DC Motor Pwr.

90VDC Max.

P7A P7B

DC Servo

Supply

24VDC

Supply

Hazardous

AC Out

J2 J5 P6

P11 A,B

24VDC

Ckt. 3

USB

P15 P16

115V

48-90VDC

Power Supply

(2 max)

24VDC

Power Supply

(2 max)

DC Motor Drives (4 circuits total)

24VDC Devices (6 circuits total)

Guardlocks

AC Motor Drives

Load Area

Main Area

Load Area

Interlocks or Guardlocks

AC power

to Control PC

AC power

to Control PC

E-Stop

AC Power

to miscellaneous

(hazardous) devices

Power/Enable

AC Power Source

Control PC

Main Area

(2 circuits)

Load Area

(2 circuits)

Hooking up the eF-785

eF-785

NSTALLATION

ANUAL

EKNIC

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OICE

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ERSION

1.42

UGUST

26,

2005

...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. Learn how to do this in the

Extending the System section of the manual.

Another handy feature, the Soft Shutdown, allows the operator to

power up the control computer from the machine’s front panel On/Off

switch and automatically shut off power to the machine after the control

computer has completed its shutdown process.

24 VDC

Fault-Tolerant

Hazardous Power

Control

Control Computer

Disconnect

Feedback

Contactor

Control

Command

& Monitoring

Control

Data

Control System

Power

Safety

Control

Power

AC Power to

Hazardous Loads

24VDC Power to

Non-Hazardous

Sensors,

Actuators, Valves

Lamps, etc.

48-90VDC Power

to Hazardous

Loads

Main

Breaker

Regeneration and

Power Dump Loads

Front Panel

Power Control

Over-current

Annunciation

Safety Fault

Alarm

Servo or Stepper Motors

Connected to Mechanical

Hazards

eF-785

Power Hub &

Safety Manager

Optional

ControlPoint

Network Hub

E-Stop

Switch(es)

Guard Interlock

Switch(es)

Guard Solenoid

Lock{s)

AC Power

Distribution Hub

24 VDC

On-Off Control

Safety Supply

Safety Control

Expansion Signals

EMI

FiItering

Hazardous Power

Disconnect and Clamp

Motor

Drive

Motor

Drive

External Power

Supplies

Motor

Drive

Preemptive

E-stop signal

48-90 VDC

AC Power

DC Power

Control Signals

Optional ControlPoint Network

Control

INT

Power

Sequencing &

Monitoring

Main

Disconnect

DC Power

Distribution Hub with

Over-current

Protection

Safety and Compliance highlights in the eF-785

F-785

ENEFITS

zSignificantly reduces electrical system design, integration and

debug effort, reducing time to market

zEases wiring requirements, lowering total machine costs

zIntegrates numerous functions in one compact enclosure,

supporting a smaller machine footprint

zSpeeds compliance inspection and testing of a machine for:

oEMC (electromagnetic compatibility),

oMachine Safety (mechanical hazards)

oElectrical Safety (shock and fire hazards)

zSignificantly reduces the risk of failure during machine testing,

making your product launch more predictable

zFeatures a monitoring function to help pinpoint wiring errors in

the safety control system during integration and assembly

zAllows for controlled motor stopping during an Emergency Stop,

minimizing wear and tear on the machine

zVirtually eliminates intermittent connections within e-stop

switches and contactors via proprietary wiring

EF-785

AFETY

EATURES

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

machine continues to process material, samples, etc, allowing an

operator to feed and retrieve material from the machine while it

continues to do useful work. This can result in a significant,

demonstrable throughput advantage on many automated machines.

UARD

LOCK

ONTROL

The eF-785 has specific outputs that control any installed guard-locks

that open guard doors when hazardous power is removed from a given

machine area. These guard-locks are controlled by user software and

electromagnetic logic control. To open guardlocks, two things must

occur: 1) the user software must issue an “open guardlock” request and 2)

removal of hazardous power must be confirmed by the electromagnetic

logic control.

UTOMATIC

AFETY

YSTEM

HECKOUT

The monitoring systems within the eF-785 perform several functions:

they monitor the e-stop and interlock switches (and wiring) for faults,

continuously check the contactors for the proper electromagnetic status

of the hazardous power and guard-lock power. In the event that the

monitoring system detects any errors during operation, it reinforces the

removal of power (which is enforced by the electromagnetic logic control)

and reports the errors to the host computer.

The eF-785 has two important safety diagnostic functions. One

function forces the user to perform a safety test of the e-stop and

interlock switches at each power-up cycle. Periodic checking of these

switches is required by EN 954-1 and this mechanism makes the

procedure automatic. This function removes the requirement for writing

and enforcing periodic inspection procedures and attaching placards or

writing custom software to instruct operators. This function can be

disabled during machine development.

The eF-785 firmware also maintains data on the complete state of the

safety control system just before and after a fault is detected. This

information can help pinpoint the fault to a few possible failures,

speeding up root cause identification.

eF-785

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ONTROLLED

TOPPING

UNCTION

ONTROL

OINT

™

NLY

)

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.

This, combined with the eF-785 ’s hazardous power disconnect delay

function, forces the axes to a smooth controlled stop (in the fraction of

the second before power removal) during an E-Stop, interlock open and

most other safety shutdown events. This typically saves the material in

process, reduces wear and tear on the machine, and generally increases

the perceived quality of the machine by the customer.

NTEGRATION

TEPS AT A

LANCE

Create a complete power & safety system for your machine

using the eF-785 by following these simple steps:

1. Complete a risk assessment of your machine hazards, and then

select guard-locks or interlocks for guarded areas.

2. Select the eF-785 configuration options that fit your machine

requirements.

3. Mount the eF-785.

4. Select and connect the external 24VDC power supplies and devices

to the eF-785. Example cables are shown in Appendix C of this

manual.

5. Select and connect the external DC motor power supplies and DC

motors to the eF-785. Example cables are shown in Appendix C of

this manual.

6. Connect AC powered servo drives. Example cables are shown in

Appendix C of this manual.

7. Connect any other AC loads.

8. Connect incoming AC power, and if required, an incoming power

disconnect switch.

9. Connect the embedded control computer to the eF-785 using off-

the-shelf cables (modular power cord, USB cable, IEEE-1284

cable).

10. Mount the machine’s on-off switch(es) and connect them to the eF-

785. An example cable including recommended switches is shown

in Appendix C of this manual.

11. Mount the safety system components (e-stop switches, interlock

switches and/or guard locks) and connect them to the eF-785. You

will find recommended devices for all of these components in this

manual.

12. Optional: Connect Teknic ControlPoint™ motion and I/O

components via standard Category 5 patch cables.

This manual contains all of the instructions you’ll need to complete each

of these tasks quickly with a minimum of research, while meeting all of

the required safety standards.

ERSION

1.42

UGUST

26,

2005

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