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Teknic EF-785 Installation Manual Download Page 89

A

PPENDIX 

G:

 

C

ONNECTOR 

R

EFERENCE

 

1- AC Line 1 

2- Chassis Ground 

3- AC Line 2 

1. AC line 1 

2. Protective Earth

3. AC Line 2

6. RV- 

5. Regen 

4. RV+ 

8. +24VDC (Ckt 1) 

7. 24VDC Return (Ckt 1)

4. 24VDC Return (Ckts 2 and 3)

1. Main AC Hazard Power (Line 1) 

2. Main AC Hazard Power (Line 2)

9. AC Control Power (Line 2)

6. AC Control Power (Line 1) 

3.  Protective Earth 

5. +24VDC (Ckts 2 and 3) 

2. +75VDC 

1. Return 

1. AC Line 1 

2. Chassis Ground 

3.  AC Line 2 

1. AC Line 1 

2. Protective Earth

3. AC Line 2

6. RV- 

5. Regen 

4. RV+ 

8. DC Motor Power + 

7. DC Motor Power +

4. DC Motor Power Return

1. Main AC Hazard Power (Line 1) 

2. Main AC Hazard Power (Line 2 )

9. No Connection 

6. No Connection 

3. Protective Earth 

5. DC Motor Power Return 

2. +75VDC 

1. Return 

J5: 24VDC Power Distribution

10

20-14

20-14

12

AWG

AMP/640309-3

AMP/350547-3

AMP/640309-3

AMP/350552-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480706-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

J4: AC Motor Drive Power - Load

10

20-14

20-14

12

AWG

AMP/640309-3

AMP/350547-3

AMP/640309-3

AMP/350552-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480704-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

J2: Misc. Hazardous AC Out

10

20-14

20-14

12

AWG

AMP/640309-3

AMP/350547-3

AMP/640309-3

AMP/350552-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480700-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

J8A, J8B: DC Motor Power - Load

10

20-14

20-14

12

AWG

AMP/640309-3

AMP/350547-3

AMP/640309-3

AMP/350552-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480698-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

P2: Incoming AC Power

10

20-14

20-14

12

AWG

AMP/640310-3

AMP/350550-3

AMP/640310-3

AMP/350551-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480700-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

P3: AC Motor Drive Power - Main

10

20-14

20-14

12

AWG

AMP/640310-3

AMP/350550-3

AMP/640310-3

AMP/350551-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480704-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

P6: 48-90VDC Power Supply Distribution

10

20-14

20-14

12

AWG

AMP/640310-3

AMP/350550-3

AMP/640310-3

AMP/350551-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480706-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

P7A, P7B: DC Motor Power - Main 

10

20-14

20-14

12

AWG

AMP/640310-3

AMP/350550-3

AMP/640310-3

AMP/350551-3

Terminal PN

Insul Dia.

.200" Max.
.200" Max.
.060-.130
.130-.200

Crimp Tool (manual)

Crimp Die

Mating Connector

AMP/1-480698-0

AMP/69710-1 (w/o die)
AMP/69710-1 (w/o die)
AMP/91500-1
AMP/91508-1

AMP/58380-1

AMP/58380-2

NA
NA

 

 

 

 

e F - 7 8 5

 

I

N S T A L L A T I O N  

M

A N U A L

 

87

 

 

T

EKNIC

,

 

I

NC

 

 

F

AX 

(585)784-7460

   

V

OICE 

(585)784-7454 

Summary of Contents for EF-785

Page 1: ...EF 785 POWER DISTRIBUTION AND SAFETY CONTROL CENTER VERSION 1 42 AUGUST 26 2005 INSTALLATION GUIDE TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...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 con...

Page 4: ...ea 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 ...

Page 5: ...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...

Page 6: ...tection 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 includ...

Page 7: ...or Pwr 90VDC Max P7A P7B DC Servo Supply 24VDC Supply Hazardous AC Out J2 J5 P6 P11 A B 24VDC Ckt 3 SA USB P15 P16 115V DC AC 48 90VDC Power Supply 2 max DC AC 24VDC Power Supply 2 max DC Motor Drives 4 circuits total 24VDC Devices 6 circuits total Guardlocks AC Motor Drives L o a d A r e a M a i n A r e a M a i n A r e a L o a d A r e a Interlocks or Guardlocks AC power to Control PC AC power to ...

Page 8: ...nd 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 Pow...

Page 9: ...rdlocks 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 AUTOMATIC SAFETY SYSTEM CHECKOUT 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 electro...

Page 10: ...ons 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 Appen...

Page 11: ...n 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 Additionally we ve researched tested and recommended a number of critical components including switches interlocks and guard locks eF 785 INSTALLATION MANUAL 9 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 12: ...u can use interlock switches without locks on guards in the Main area of your machine when a The hazards are such that the EN 954 1 assessment concludes that they require a level B 1 or 2 safety control system or b when the guards are clearly marked as containing hazards behind them and the guard can only be opened with a tool or key Guard locks must be used if the hazards are such that the EN 954...

Page 13: ... processing area A segmented machine is one that is designed to allow an operator to safely load or unload raw or finished product in one Load area while main processing activities continue undisturbed in another Main area under separate power and safety control Main Area The main functional area of an automated machine The Main Area is typically where the core processing work of the machine is pe...

Page 14: ... a segmented machine defined on the previous page that offers several advantages in terms of safety and throughput to your end user In this section we will describe the available power control options for the eF 785 illustrating each with a small schematic diagram Below is a brief table summarizing the available options and the appropriate code to use when ordering Main Area Load Area Option Code ...

Page 15: ...or Drives To Main Area DC Motor Drives To Load Area DC Motor Drives AC DC AA Configuration Door locks Simplified power flow schematic AA AD The AD model supports AC and DC powered motor drives in the Main Area and DC powered motor drives in the Load Area Example part number EF 785 ADxx xxx x J2 P3 P7B P7A J8B J8A P6 Main Load Safety Control 48 90VDC Supply CB1 P2 Interlock switches E Stop switches...

Page 16: ...s E Stop switches To general hazardous loads To Main Area AC Motor Drives To Main Area DC Motor Drives AC DC AN Configuration Door locks see text Simplified power flow schematic AN DD The DD configuration supports DC powered motor drives in the Main area and DC powered motor drives in the Load area Example part number EF 785 DDxx xxx x J2 P7B P7A J8B J8A P6 Main Load Safety Control 48 90VDC Supply...

Page 17: ... need EMI FILTERING OPTIONS The eF 785 offers two available EMI filtering options two stage D and four stage Q TWO STAGE DUAL FILTERING 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 power contr...

Page 18: ... If your design does not include the ControlPoint hub with 40VDC network power supply order your eF 785 with an X in the indicated position With or without ControlPoint options the eF 785 provides excellent power distribution and safety control functionality POWER OFF DELAY OPTIONS MAIN The eF 785 offers you some options as to how quickly hazardous power is removed from the Main Area of your machi...

Page 19: ...utdown enabled Post E Stop Enable bypassed D Host Soft Shutdown disabled Post E Stop Enable required E Host Soft Shutdown enabled Post E Stop Enable required SOFT SHUTDOWN FEATURE The soft shutdown feature allows you to power off your machine by shutting down the host computer This feature is user configurable by installing or removing an internal hardware jumper See the appendix for details Examp...

Page 20: ... the machine s On Enable button in order for the machine to resume normal operations Note The operator should always follow safe machine operating procedures and return to a safe operating position prior to any machine restart If operation were to immediately resume after an E Stop button was restored to the run position an undesirable potentially dangerous operational condition could occur Always...

Page 21: ... 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 EXAMPLE EF 785 PART NUMBER Example Part Number EF 785 AAQC FFE 2 0 1 AA AC and DC drives in Main and Load Areas Q Quad EMI Filtering installed C CP network hub and 40 VDC netw...

Page 22: ...olPoint Network Hub Options C CP network hub and 40VDC supply included X Power and Safety functions only 4 Power off Delay options Main Area N None Power is turned off with no delay F Fast Power is turned off within 150 ms S Slow Power is turned off within 450 ms 5 Power off Delay options Load Area N None Power is turned off with no delay F Fast Power is turned off within 150 ms S Slow Power is tu...

Page 23: ...t TM 24VDC Safety F7 F8 F10 F9 DC Servo Main 15A Max DC Servo Option 15A Max CB2 CB3 Status 24VDC Ckt 2 10A Max 24VDC 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...

Page 24: ...reaker 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 F e 785 20 20 F6 24VDC Ckt 3 10A Max 40VDC ControlPoint TM 24VDC Safety F7 F8 F10 F9 DC Servo Main 15A Max DC Servo Option 15A Max CB2 CB3 Status 24VDC Ckt 2 10A Max 24VDC Ckt 1 10A Max SAFETY ALARM Do not operate o...

Page 25: ...ten the bottom of a machine offers the coolest ambient air temperatures RACK SLIDES 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 eF 785 INSTALLATION MANUAL 23 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 26: ...Ckt 3 Net Out Net In RED BLK P2 IEEE 1284 Host Port J17 24VDC POWER SUPPLY CONNECTOR J5 24VDC OUTPUTS P9A B P10A B P11A B 24VDC Distribution Connectors SELECTING THE POWER SUPPLIES Your 24VDC power distribution requirements will help you determine which power supply or supplies and wiring harness to select You can integrate 1 or 2 supplies depending on your machine s specific requirements There ar...

Page 27: ...er This means that power to the 24VDC supplies is on only when hazardous power in the Main area of the machine is on Main AC Power is removed after a safety event E Stop has occurred Although 24V is not considered hazardous when fused at or below 10A it is often desirable to have some or all of it turn off when a safety event occurs e g in order to turn off solenoid valves such that pneumatics wil...

Page 28: ...ax front panel fuses rear panel connectors AC Control Power Single 24VDC supply configuration A B A single 24VDC power supply that is on only when Main AC Hazard Power is on Power to these circuits would be cut in the event of an E Stop or interlock breech See figure B below 24VDC P11 B P11 A P10 B P10 A P9 B P9 A J5 F10 F9 F8 CKT 3 CKT 2 CKT 1 10A max 10A max 10A max front panel fuses rear panel ...

Page 29: ...urations C and D Design Note Use 14 AWG wire with a temperature rating of 90 C or greater or 12AWGwhen fabricating AC wiring to any connected 24V power supply 12 AWG or larger wire if it has insulation rated at or above 70 degrees C Note Your 24VDC supplies should have an internal fuse or other current limiting device to protect against catastrophic failure of the supply itself this is typical of ...

Page 30: ...its own pros and cons The following is a brief description of each wiring method Daisy chained 24VDC power from the eF 785 is connected to the first load in the chain power from the first load is connected to the second load and so on This is the simplest wiring topology available but does not have the redundancy and lower resistance that the Daisy chained loop topology offers Daisy chained wiring...

Page 31: ...er control circuits to reduce noise The central star distribution method will prevent ground loops in the machine from occurring 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 eF 785 INSTALLATION MANUAL 29 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 32: ... drives Also since servo and stepper motor drives have high peak current demands the supply should support a high peak current rating above the continuous RMS rating Teknic manufactures a bulk DC supply of this type part number SSt EMF75 The SSt EMF75 is a bulk DC power supply featuring a large 47 000 µF output capacitor bank that also offers a resistive power clamp for regenerated drive power A c...

Page 33: ... Safety Gnd 3 4 5 6 7 8 EF 785 DC Power Supply Return V Return V N C 9 V V N C Connecting a DC power supply for the 48 90V motor drives The connector that mates to P6 is a Tyco Electronics AMP MATE N LOK Style connector part number 1 480706 0 and female crimp sockets part number 350550 3 CONNECTING THE LOADS DC MOTOR DRIVES P7A P7B J8A J8B The eF 785 can manage power for any DC powered stepper or ...

Page 34: ...ors although they are keyed differently from P7A and P7B see below P7B P7A J8B J8A P6 Main Load Safety Control 48 90VDC Supply Main AC Power F6 15A max F7 15A max DC motor power distribution and fusing for AN and DN configurations Switched and over current protected DC servo power is available at the rear panel connectors P7A B Main Area and J8A B Load Area for distribution into the machine Note A...

Page 35: ...r machine you can take advantage of our unique dual power connector design to create a power distribution daisy chain that offers reduced complexity lower cost and superior noise immunity for your servo power distribution system By daisy chaining your Teknic drives see below no extra terminal blocks distribution panels or fuses are required and because the DC bus power is isolated from all of the ...

Page 36: ...esistance is reduced and subsequently the I2R power loss in the cabling is reduced This parallel power path provides improved machine performance and reliability As with the daisy chained wiring method described previously the drive s power circuits should be isolated from the machine chassis and any control circuits connected to them eF 785 Main Option SSt Servo Drives Daisy chained loop wiring t...

Page 37: ...eF 785 Main Option DC Servo or Stepper Motor Drives Terminal Block Central star wiring topology eF 785 INSTALLATION MANUAL 35 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 38: ...on control circuits that are provided on most AC powered motor drives For specific details on wiring AC motor drives see the diagram under the Wiring Configuration section below 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 lo...

Page 39: ...AC 1 AC DC BUS DC BUS P3 P4 P8 RED BLK 2 3 AC 1 AC DC BUS DC BUS P3 P4 P8 RED BLK PROTECTIVE EARTH GROUND 2 CONDUCTOR CABLE SHOWN BELDEN 9314 14 AWG 300V SHIELDED WITH DRAIN WIRE Up to 8 SSt 6000 3100 Servo Drives Total combined total for Main and Load areas not to exceed 8 5 2 3 2 3 1 3 2 5 4 6 LIV E N E U T R A L R E G E N R V R V 4 PROTECTIVE EARTH GROUND P E eFoundation P3 or J4 AC Servo Main ...

Page 40: ...Ext DC Motor Supply 48 90VDC 24VDC Supplies J5 P6 USB P15 P16 Main DC Motor Pwr 90VDC Max P7A P7B P18 40V 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 P11 A B 24VDC Ckt 3 Net Out Net In RED BLK P2 IEEE 1284 Host Port J17 MISC HAZARDOUS AC OUT J2 Hazardous AC Out Connector Fabricate all wiring from this connector with 14AWG wire with a...

Page 41: ...C Power components The line cord should be a 12AWG 2 05mm cable with international color codes Recommended cordage is Alpha 1918 International Configurations 1601312 or Olflex 1600119 Refer to the Appendix for a drawing of a line cord assembly with a recommended cord grip The eF 785 can be extended to control 3 phase power while maintaining safety compliance Contact Teknic for details or see the 3...

Page 42: ...ect switch even when power is supplied via a plug EN 60204 1 section 5 3 4 states that the recommended height for locating the disconnect is from 0 6 m 23 63 inches to 1 7 m 66 92 inches above the floor Altech KU340N switch is an economical option for this switch and is pictured below with the Altech OKA 0 V Y R handle A typical positive disconnect lock out switch Altech KU340N switch with Altech ...

Page 43: ...r to the host 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 Example Warning Label The fuses for these outlets are also located on the rear panel of the eF 785 see fuse holders F1 and F2 in above illust...

Page 44: ...t 3 meters in length USB CONNECTIONS P15 P16 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 42 VERSION 1 42 AUGUST 26 2005 ...

Page 45: ...st Power JB Host Power P3 Main AC Motor Power Load AC Motor Power J4 SA F1 F2 Host Pwr 8A Max P12 Safety Harness Hazardous AC Out J2 P14 P13 Safety Control Ext DC Motor Supply 48 90VDC 24VDC Supplies J5 P6 USB P15 P16 Main DC Motor Pwr 90VDC Max P7A P7B P18 40V 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 P11 A B 24VDC Ckt 3 Net Out N...

Page 46: ...ol 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 Since this Soft Shutdown event is essentially the same thing as manually press...

Page 47: ...to EN 60204 1 section 10 7 4 and EN 418 section 4 4 3 Mounting the E Stop switches The E Stop switches must be mounted in readily accessible ergonomic locations and be within close reach of the operator s normal operating position refer to EN 60204 1 sections 10 1 2 10 7 1 and EN 418 section 4 4 2 The E Stop switches must be mounted so that they are not less than 0 6 m above the servicing level of...

Page 48: ...consists of 3 separate parts Euchner GP1 538HA M interlock switch with 2 NC force guided contacts Euchner 059 440 metal hinged latch actuator key Euchner M20CGP cable entry gland nut Suggested Euchner Interlock Switch GUARD LOCKS Guard lock selection considerations The switch must be a DPST type switch with normally closed and positively guided contacts refer to EN 1088 EN292 1 section 3 22 5 and ...

Page 49: ...rd locks Suggested Guard lock consists of 3 separate parts Euchner TP3 2131A024M guard locking interlock switch with 2 NC force guided contacts spring lock and solenoid unlock Euchner 059 440 metal hinged latch actuator key Euchner M20CGP cable entry gland nut Suggested Euchner Guard lock eF 785 INSTALLATION MANUAL 47 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 50: ... harness typically daisy chains through each switch and a separate cable is used to power the interlock solenoids Main Area Interlock Switch Main Area E Stop Switch Main Main Main Main Main guard Main guard Main guard Main guard Load Load Load Load Load guard Load guard Load guard Load guard 1 3 2 4 Main Area Interlock Solenoid Main Area E Stop and Interlock Switch Loop P12 13 14 15 16 9 11 12 10 ...

Page 51: ...in Area Interlock Switch Main Area E Stop Switch Main Main Main Main Main guard Main guard Main guard Main guard Load Load Load Load Load guard Load guard Load guard Load guard 1 3 2 4 Main Area Interlock Solenoid Main Area E Stop and Interlock Switch Loop P12 13 14 15 16 9 11 12 10 8 7 6 5 Load Area Interlock Solenoid Load Area Interlock Switch Loop Load Area Interlock Switch Note This symbol ind...

Page 52: ...s Load Hazard Control Load Hazard Control Main Hazard Control Main Hazard Control Load Hazard Monitor SW A Load Hazard Monitor SW B 24VDC External Buzzer Machine ON Light 24VDC AC Applied Light 24VDC To optional external Main Area contactor To optional external Load Area contactor Auxiliary Safety Connector P13 with sample schematic Usually only jumpers Jmp1 Jmp2 are required Auxiliary Safety Conn...

Page 53: ...able at connectors P12 P13 and P14 is less than the power budget shown in the table below Exceeding this power budget will cause CB2 to trip eF 785 Model Total Allowable External Component Power Draw IMAX mA DN 38 5 Watts 1604 DD 30 2 Watts 1258 AN 30 2 Watts 1258 AD 30 2 Watts 1258 AA 22 0 Watts 916 Allowable power available from the safety supply If the eF 785 is to be powered from a low AC line...

Page 54: ...et plugs ControlPoint network power is supplied by the eF 785 s internal 40VDC power supply and distributed by the Cat 5 cable The diagram below shows an example network of ControlPoint devices hosted by the eF 785 Host PC Computer I S C 1 7 0 0 TG 540 I S C 1 0 0 0 TG 540 IOC 540 IEX 808 8 8 2 2 2 2 2 2 2 2 10 DigiLogTM 6 IEX 808 8 8 Up to 4 IEX 808s can be connected to an IOC 540 0 1 E Stop Swit...

Page 55: ...nly be performed while the machine is idle i e no hazardous power being requested in any area s of the machine RECOVERING AFTER AN E STOP EVENT After any of the machine s E Stop buttons have been actuated i e the switch has been pressed down and latched any unsafe or hazardous conditions in the machine must be cleared Once the machine operator has closed any open guards gates and returned to a saf...

Page 56: ...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 54 VERSION 1 42 AUGUST 26 2005 ...

Page 57: ... 3 10A Max 40VDC ControlPointTM 24VDC Safety F7 F8 F10 F9 DC Servo Main 15A Max DC Servo Option 15A Max CB2 CB3 Status 24VDC Ckt 2 10A Max 24VDC Ckt 1 10A Max Front panel fuses and circuit breakers FUSE CIRCUIT PROTECTED REAR PANEL CONNECTOR I MAX MFG PART F6 Main DC Motor Power P7A B 15 Bussmann MDA 15 F7 Option DC Motor Power J8A B 15 Bussmann MDA 15 F8 24VDC Ckt 1 P9A B 10 Bussmann MDA 10 F9 24...

Page 58: ...56 VERSION 1 42 AUGUST 26 2005 Load AC Motor Power P12 Safety Harness 115V F1 F2 Host Pwr 8A Max AC Control Power rear panel fuses F1 and F2 ...

Page 59: ...tor 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 The NC contact must be guaranteed to be open if any of the NO contacts weld closed per EN 60947 5 1 Annex L These contacts provide feedback to the eF 785 that the hazardous power has been removed from the ...

Page 60: ...irective and the EN standards that support it have become the de facto world standard suite for machinery safety because as standards go these are well thought out comprehensive and conservative Even if you don t intend to sell equipment in Europe meeting the CE Machinery Directive requirements is a well understood way to keep the machine operators safe and may put your company in a more legally d...

Page 61: ...ificant rework and delay of product launch when the test lab discovers insufficient compliance If you re lucky enough to pass a machinery safety compliance inspection despite having errors and or omissions then of course there is a real liability issue Clearly taking shortcuts is not advisable Light at the end of a short tunnel Fortunately the eF 785 is pre engineered to remove nearly all of this ...

Page 62: ...e machine 5 All interlocks with guard locking must have their unlock solenoid under the direct control of the eF 785 using the separate and specific outputs for the Main and Load areas 6 The machine s moveable guards must employ interlock switches with guard locking wherever the operator enters the hazard area of the machine at a medium frequency e g a typical Load Unload Area guard 7 The machine ...

Page 63: ...se circuits are not accessible as per EN 61010 1 within the machine These devices must require that a tool is used to access any hazardous circuits or hazardous mechanical elements The cables which supply power to devices within the machine from JA and JB and pins 6 9 on J5 should be clearly marked with the shock hazard international symbol There should be marking on cables and components powered ...

Page 64: ...l the guidelines described herein meet the following EN standards EN 954 1 EN 60204 1 EN 61010 1 SEMI S8 SEMI S2 These guidelines are no substitute for a proper evaluation of risks and a careful review of the appropriateness of the safety system In fact meeting the EN standards and the Machinery Directive may be insufficient to protect personnel and property The user of the eF 785 must perform a c...

Page 65: ...W 20A in three fused circuits 40VDC output 150 W 3 6A internal supply for ControlPoint devices overload protected EMI filtering Consistent with meeting EN61326 Regeneration load capacity 150W RMS Cooling Fan cooled Safety Control Functions Support for one or two area control Load Unload Area and Main Area fully monitored and EN954 compliant to Cegory 3 Supports E stop switches door interlock switc...

Page 66: ...APPENDIX C CABLE DIAGRAMS 48 90VDC LOAD AREA TO SST J8A J8B 64 VERSION 1 42 AUGUST 26 2005 ...

Page 67: ...48 90VDC MAIN AREA TO SST P7A P7B eF 785 INSTALLATION MANUAL 65 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 68: ...48 90VDC LOAD AREA TO ISC J8A J8B 66 VERSION 1 42 AUGUST 26 2005 ...

Page 69: ...48 90 VDC MAIN AREA TO ISC SST ISC P7A P7B eF 785 INSTALLATION MANUAL 67 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 70: ...AC SERVO POWER CABLE LOAD AREA J4 68 VERSION 1 42 AUGUST 26 2005 ...

Page 71: ...AC SERVO POWER CABLE MAIN AREA P3 eF 785 INSTALLATION MANUAL 69 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 72: ...SST 6000 3000 DC POWER JUMPER CABLE 70 VERSION 1 42 AUGUST 26 2005 ...

Page 73: ...SST 6000 3000 AC INPUT CABLE eF 785 INSTALLATION MANUAL 71 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 74: ...SINGLE 24VDC SUPPLY CABLE J5 72 VERSION 1 42 AUGUST 26 2005 ...

Page 75: ...DUAL 24VDC SUPPLY CABLE J5 eF 785 INSTALLATION MANUAL 73 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 76: ...70 90VDC SUPPLY CABLE SST EMF75 P6 74 VERSION 1 42 AUGUST 26 2005 ...

Page 77: ...24VDC DIST CABLE IOC APC P9 P11 eF 785 INSTALLATION MANUAL 75 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 78: ...40VDC POWER TAP DISTRIBUTION CABLE P18 76 VERSION 1 42 AUGUST 26 2005 ...

Page 79: ...FRONT PANEL HARNESS POWER ENABLE CIRCUITS P14 eF 785 INSTALLATION MANUAL 77 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 80: ...INTEGRATION TESTING CHEATER PLUG SAFETY CONTROL CKTS P12 78 VERSION 1 42 AUGUST 26 2005 ...

Page 81: ...EXTENSION CHEATER PLUG P13 eF 785 INSTALLATION MANUAL 79 TEKNIC INC FAX 585 784 7460 VOICE 585 784 7454 ...

Page 82: ...INPUT POWER CABLE J2 80 VERSION 1 42 AUGUST 26 2005 ...

Page 83: ...led hazardous power can become available as soon as the E Stop button is reset to its normal operating position See the Supplementary Options section for more details CHANGING THE JUMPER SETTINGS Step 1 Remove all power from the eF 785 Step 2 Remove the top access panel Refer to diagram below F6 24VDC Ckt 3 10A Max 40VDC ControlPointTM 24VDC Safety F7 F8 F10 F9 DC Servo Main 15A Max DC Servo Optio...

Page 84: ...ard next to the rear panel of the eF 785 Refer to the photo illustration below JP9 JP8 JP7 JP7 JP9 JP8 JP7 Jumper locations for JP7 JP8 and JP9 Step 4 Set jumpers Refer to the table below Feature Enabled Disabled Host Soft Shutdown JP7 open JP7 installed Post E Stop Enable JP8 JP9 open JP8 JP9 installed Jumper Configuration Table ...

Page 85: ...nd 10A supply feeding 24VDC Circuit 1 power supply off when machine is shut off 1 2 5 3 9 6 7 8 4 PE PE Wired for power supply off during a safety event only Wired for power supply off when machine is shut off Belden 9314 14 AWG 2 cond 300V shielded 24VDC OUTPUT 24VDC OUTPUT AC IN AC IN Belden 9314 10 Amp External 24 VDC Power Supply 20 Amp External 24 VDC Power Supply AC LINE 1 AC LINE 2 24VDC CK...

Page 86: ...A supply feeding 24VDC Circuits 1 2 3 power supply off during a safety event 1 2 5 3 9 6 7 8 4 PE Wired for power supply off when machine is shut off AC IN 24VDC OUTPUT Belden 9314 20 Amp External 24 VDC Power Supply AC LINE 1 AC LINE 2 24VDC CKTS 2 AND 3 24VDC RETURN CKTS 2 AND 3 24VDC CKT 1 PE AC LINE 2 AC LINE 1 24VDC RETURN CKT 1 14 AWG twisted pair 14 AWG twisted pair eF 785 MAIN HAZARD POWER...

Page 87: ...echanical control circuit devices BS EN 61010 1 2001 IEC 31010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements BS EN 953 1998 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards BS EN 954 1 1997 Safety of machinery Safety related parts of control systems Part 1 General...

Page 88: ...f machinery Safety distances to prevent danger zones being reached by the upper limbs BS EN 811 1997 Safety of machinery Safety distances to prevent danger zones being reached by the lower limbs 86 VERSION 1 42 AUGUST 26 2005 ...

Page 89: ...710 1 w o die AMP 69710 1 w o die AMP 91500 1 AMP 91508 1 AMP 58380 1 AMP 58380 2 NA NA J8A J8B DC Motor Power Load 10 20 14 20 14 12 AWG AMP 640309 3 AMP 350547 3 AMP 640309 3 AMP 350552 3 Terminal PN Insul Dia 200 Max 200 Max 060 130 130 200 Crimp Tool manual Crimp Die Mating Connector AMP 1 480698 0 AMP 69710 1 w o die AMP 69710 1 w o die AMP 91500 1 AMP 91508 1 AMP 58380 1 AMP 58380 2 NA NA P2...

Page 90: ...erminal PN Insul Dia 051 122 Crimp Tool manual Crimp Die Mating Connector Molex 39 01 2160 Molex 11 01 0197 NA P13 Safety Extension 24 18 AWG Molex 39 00 0039 Terminal PN Insul Dia 051 122 Crimp Tool manual Crimp Die Mating Connector Molex 39 01 2180 Molex 11 01 0197 NA P14 Power Enable 24 18 AWG Molex 39 00 0039 Terminal PN Insul Dia 051 122 Crimp Tool manual Crimp Die Mating Connector Molex 39 0...

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