Braun E16x442 Operation instructions

\BETRANL\E16x442e I E16x442 Rev: 00 26.11.2014Page 1 of 73
D 71334 Waiblingen-Hegnach
Esslinger Str. 26
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.braun-tacho.de
Quality certified according ISO 9001
Monitor A
Monitor B
Monitor C
E1691
P
E
E1665
1
2
3
4
Trip
SP3
RPM
P
E
E1665
1
2
3
4
Trip
SP3
RPM
P
E
E1665
1
2
3
4
Trip
SP3
RPM
Monitor A
Monitor B
Monitor C
SIL2/IEC61508
SIL2/IEC61508
SIL2/IEC61508
Test Interface
Original Manual
of
Protection-System E16x442
with
Overspeed Protection
and
Voters for external Trip Release Conditions
IEC61508;SIL2 and API670 compliant
Figure 1: E16x442 System Front View

I E16x442 Rev: 00 Page 2 of 73
Contents Page
1. General Informations ................................................................................................4
1.1. List of Figures..............................................................................................................4
1.2. List of Abbreviations....................................................................................................5
1.3. System Applications and Explanation ....................................................................7
1.4. Key Features of System E16x442.............................................................................7
1.5. Ordering Key for Systems E16x442.abc.................................................................8
1.6. Safety Data..................................................................................................................9
1.6.1. Safety Data IEC61508; SIL2 .......................................................................................9
1.7. External Tests .............................................................................................................9
1.7.1. External tests during normal operation by PLC or operator ........................................9
1.7.2. Test of 2oo3 solenoid valve block...............................................................................9
2. System Structure and I/Os......................................................................................10
2.1. System Structure.......................................................................................................10
2.1.1. Speed Sensors..........................................................................................................10
2.1.2. System Components.................................................................................................10
2.1.3. System Design..........................................................................................................10
2.1.4. System Structure Diagrams ......................................................................................11
2.1.5. System Wiring Diagrams...........................................................................................13
2.1.6. Connection of Sensors to the Speed Signal Inputs...................................................15
2.1.7. Position of Terminal Blocks with Version E16E442...................................................16
2.1.8. Position of Terminal Blocks with version E16A442 ..................................................17
2.2. Inputs of the System .................................................................................................18
2.2.1. Speed Signal Inputs..................................................................................................18
2.2.2. Direction Signal Inputs (F/R : Forward/Reverse).......................................................18
2.2.3. Input Reset of Alarms................................................................................................18
2.2.4. This chapter is left blank intentionally .......................................................................18
2.2.5. This chapter is left blank intentionally .......................................................................18
2.2.6. Inputs Test I, Test II, Test III......................................................................................19
2.2.7. Inputs Starter (Override of SP2)................................................................................19
2.2.8. Inputs SP1B valid......................................................................................................19
2.2.9. This chapter is left blank intentionally .......................................................................19
2.2.10. Inputs for Voter 1.......................................................................................................19
2.2.11. Inputs for Voters 2 … 6 .............................................................................................19
2.3. Outputs of the System...............................................................................................20
2.3.1. Output System Warning Alarm..................................................................................20
2.3.2. Speed Signal Repeater Outputs................................................................................20
2.3.3. Outputs Monitor Warning Alarm................................................................................20
2.3.4. Outputs Speed Alarm SP3........................................................................................20
2.3.5. Analog Outputs for measured speed (Option)...........................................................21
2.3.6. Outputs Direction Detection ......................................................................................21
2.3.7. Speed Trip Logic Output (2oo3 voted) ......................................................................21
2.3.8. Output Trip-Line IV, V, VI..........................................................................................21
2.3.9. Outputs Trip-Line I, II, III...........................................................................................21
2.3.10. Logic Outputs LO1 through LO6 (voted 2oo3) ..........................................................21
2.3.11. Trip Status of Monitors .............................................................................................22
2.4. Power Supply............................................................................................................23
2.5. Data Interface............................................................................................................23
2.5.1. Profibus Interface for Status and Diagnostics of the System ....................................23
2.5.2. RS232 Interface with Interface Software IS-RS232-E16 (for OEM only)...................23
2.5.3. RS232 Interface with Interface Software IS-RS232-E16-L2 (for End User)..............23
3. Technical Specifications ........................................................................................24
3.1. Technical Data of Inputs ...........................................................................................24
3.1.1. Technical Data of Speed Signal Inputs.....................................................................24
3.1.1.1. Hall Sensor Inputs.....................................................................................................24
3.1.1.2. Eddy Current Sensor Inputs resp. MPU Inputs .........................................................24
3.1.2. Technical Data of Direction Inputs ............................................................................24
3.1.3. Technical Data of Binary Inputs (excluding Voter 1) .................................................24

I E16x442 Rev: 00 Page 3 of 73
3.1.4. Technical Data of Binary Inputs of Voter 1................................................................24
3.2. Technical Data of Outputs.........................................................................................25
3.2.1. Technical Data of Sensor Signal Repeater Outputs..................................................25
3.2.2. Technical Data of Analog Outputs.............................................................................25
3.2.3. Technical Data of Opto-Relay Outputs......................................................................25
3.2.4. Technical Data of Logic Outputs...............................................................................25
3.2.5. Technical Data of Trip-Lines IV, V, VI.......................................................................26
3.2.6. Technical Data of Trip-Lines I, II, III ..........................................................................26
3.3. Technical Data of Power Supply ...............................................................................27
3.4. Installation Conditions...............................................................................................27
3.5. Protection Grade.......................................................................................................27
3.6. Connectors................................................................................................................27
3.7. Conformity to Standards............................................................................................27
3.8. Dimensions of system E16A442 ...............................................................................28
3.9. Dimensions of system E16E442 ...............................................................................29
3.10. Dimensions and Features of E16G442 Enclosure ....................................................30
3.11. Weight of E16x442....................................................................................................30
4. Safety Notes for Installation and Operation..........................................................31
4.1. Safety Notes for Installation ......................................................................................31
4.1.1. General Instructions..................................................................................................31
4.1.2. EMI............................................................................................................................31
4.2. Safety Notes for Operation........................................................................................31
4.2.1. Safety Notes for Commissioning...............................................................................31
5. Description of Monitor E1665.................................................................................32
5.1. Display and Frontside Operational Elements............................................................32
5.1.1. Front View of Monitor E1665.....................................................................................32
5.1.2. Status-LEDs..............................................................................................................32
5.1.3. Display during Test Procedures ................................................................................32
5.1.4. Values accessible during normal operation ..............................................................33
5.1.5. Special Display Mode 1.............................................................................................34
5.1.6. Special Display Mode 2.............................................................................................34
5.1.7. Frontside Reset of Alarms and Event Codes ............................................................34
5.1.8. Data Interface............................................................................................................34
5.2. Functions of Monitor 1667......................................................................................35
5.2.1. Speed Measurement.................................................................................................35
5.2.2. Functions for Overspeed Protection..........................................................................35
5.2.3. Functions for External Trip by Voters........................................................................35
5.2.4. Selftest of Monitor .....................................................................................................35
6. Description of Test Interface E1691 ......................................................................36
7. Programming of the Monitors................................................................................37
7.1. Programming of the Monitors via Front Keyboard.....................................................37
7.2. Programming of the Modules via RS232-Interface ...................................................38
7.3. Default Values...........................................................................................................38
8. Parameters of Monitor E1665.................................................................................39
8.1. Summary of parameters and their default values......................................................39
8.2. Description of Parameters and their Settings of Monitor E1665 ...............................43
9. This chapter is left blank intentionally ..................................................................71
10. Event codes and Troubleshooting ........................................................................71
10.1. Event Codes on display of E1665 .............................................................................71
10.2. Troubleshooting if display of Monitor reads E.0.4.x.x...............................................72
11. Revision notes.........................................................................................................73

I E16x442 Rev: 00 Page 4 of 73
1. General Informations
1.1. List of Figures
Figure 1: E16x442 System Front View 1
Figure 2: E16x442 System Structure Diagram 1 of 2 11
Figure 3: E16x442 System Structure Diagram 2 of 2 12
Figure 4: E16x442 System Wiring Diagram 1 of 3 13
Figure 5: E16x442 System Wiring Diagram 2 of 3 14
Figure 6: E16x442 System Wiring Diagram 3 of 3 15
Figure 7: Position of terminal blocks with version E16E442 16
Figure 8: Position of terminal blocks with version E16A442 17
Figure 9: Dimensions of System E16A442 28
Figure 10: Dimensions of System E16E442 29
Figure 11: Dimensions of E16G442 Enclosure 30
Figure 12: Front view of Monitor E1665 32
Figure 13: SP1 as a variable of the acceleration 51

I E16x442 Rev: 00 Page 5 of 73
1.2. List of Abbreviations
Abbreviation
Meaning
altern.
alternative
API
Technical standards of the "American Petroleum Institute"
A5S
BRAUN GmbH Sensor series
AWG/kcmil
Code number according to the "American Wire Gauge" System
approx.
approximately
CCF
Common Cause Failure
CPU
Central Processing Unit
DCavg
Diagnostic Coverage average
DIN
Deutsches Institut für Normung (German Institute for Standardization)
dN/dt
Change of speed per time unit (Acceleration)
EEPROM
Electrically Erasable Programmable Read-Only Memory
EMV
Electro magnetic compatibility
EN
European Norm
F/R
Forward/Reverse (Forward/Backward)
HE
Height units
HFT
Hardware Failure Tolerance
IEC
International Electrotechnical Commission
incl.
inclusive
IPxx
Ingress Protection Number xx according to DIN EN 60529
ISO
International Organization for Standardization
LED
Light Emitting Diode
LOx
Logic Output x
max.
maximum
min.
minimum
MPU
Magnetic Pick Up
MTTFd
Mean Time To Failure dangerous
n
Short term for Speed
NEMAx
National Electrical Manufacturers Association Number x
PFDavg
Probability of Failure on Demand average
PELV
Protective Extra Low Voltage
RAM
Random Access Memory
RPM
Revolutions Per Minute
sec
second
SELV
Safety Extra Low Voltage
SFF
Safe Failure Fraction
SILx
Safety Integrity Level x
SPx
SetPoint x
SPVx
SetPoint Voter x
SP1var
SetPoint 1 variable
TE
Width unit
TMR
Triple Modular Redundant
Tproof
Proof Test Interval
UL/cUL
Acc. US Underwriter Laboratories resp. Canadian Underwriter Laboratories standards
Vdc
Volt direct current
Vpp
Volt peak-to-peak
resp.
respective
to be continued on next page

I E16x442 Rev: 00 Page 6 of 73
Abbreviation
Meaning
1oo2
1 out of 2 voting logic
1oo3
1 out of 3 voting logic
2oo2
2 out of 2 voting logic
2oo3
2 out of 3 voting logic

I E16x442 Rev: 00 Page 7 of 73
1.3. System Applications and Explanation
Protection of rotating machinery such as turbines, expanders, compressors and motors with
safety requirements SIL2/ IEC61508 and/or API 670 versus Overspeed and other Critical Con-
ditions.
The E16x442 system incorporates one Test interface type E1691 and three Monitors (chan-
nels) A, B and C of type E1665 for the evaluation of speed signals and external trip signals.
The logic blocks for the evaluation of the external trip signals are named "Voter".
The logic results of the three channels are connected internally to form three 2oo3 trip circuits
I, II and III which are named "Trip-Lines".
The Trip-Lines can be connected to a 1oo2 or 2oo3 solenoid valve block.
A released trip status can be latched, this function is named "Trip-Lock".
Trip is released by shut down of the Trip Circuits (Trip-Lines) to the solenoid valve block if:
2oo3 monitors detect Overspeed condition
2oo3 sensor signals are detected as faulty by monitors
2oo3 monitors detect External Trip-Condition by their voters (1oo2, 2oo2, 2oo3 or 3oo3
logic selectable)
1.4. Key Features of System E16x442
Trip Release Function is SIL2/IEC61508 compliant as stand alone unit (without external
testing by DCS or by operator).
Total Response Time to Trip Condition : < 15 milliseconds
Maximum Safety at Maximum Availability by :
TMR (Triple Modular Redundancy) with three monitors E1665.
Triple speed measurement and evaluation by each monitor.
Variable overspeed setpoint depending on acceleration.
Monitoring versus Lowspeed as protection versus incorrect mounting or malfunction of
speed sensors.
Permanent monitoring of speed sensors.
Evaluation of external Trip-Condition signals by voters in each monitor. Response to sig-
nals selectable for each voter individually (logic function, low/high: trip, response time).
Each Trip Line (trip circuit) in 2oo3 technique.
Trip Lines I, II, III, IV, V, VI are formed by safety relays with force guided contact sets.
Trip-Line-Monitoring with Trip-Lock Function (selectable)
The outputs of the Trip Lines I, II and III are permanently monitored. If the Trip-Lock Func-
tion is engaged, a trip condition is detected and locked if 2oo3 trip lines are in trip condi-
tion.
By the (selectable) Trip-Lock Function a released trip is latched

I E16x442 Rev: 00 Page 8 of 73
Additional features of the E16x442-System:
Remote test of solenoid valve block by test signals from DCS possible
Display in each module for measured values and diagnostics
Alarm outputs via opto-relays to DCS
Free extra alarm from each monitor
Up to 6 speed setpoints with 2oo3 logic outputs (if voters are not required)
Sensor signal repeater outputs, free floating and push/pull
Optional Analog Output (to represent the speed) 0/4..20 mamps for each monitor
Direction alarm (only with sensors type A5S with direction output)
Parameters may be set by front keys (protected by code-digit) or by
RS232-Interface (password protected)
1.5. Ordering Key for Systems E16x442.abc
E16x442.abc
c = 1 : Speed Signal Inputs and power supply for A5S sensors
c = 2 : Speed Signal Inputs and power supply for Eddy Current Sensors
c = 3 : Speed Signal Inputs for MPU (magnetic pick up)
b = 1 : 1 Voter in each Monitor for external trip release condition
b = 2 : 6 Voters in each Monitor for external trip release conditions
a = 0 : without Analog Output (to represent the speed)
a = 1 : 1 Analog Output in each Monitor A, B, C
a = 2 : 1 Analog Output rated SIL2 in each Monitor A, B, C
x = A : Surface Mount Version
x = E : 19-Inch Rack File
x = G : Nema 4 Version with front window (surface mount)
Example:
E16A442.021 : Surface Mount Version, without Analog Output, with 6 Voters,
Speed Signal Inputs for A5S sensors
E16A442.112 : Surface Mount Version, with Analog Output, with 1 Voter,
Speed Signal Inputs for eddy current sensors or MPU
E16A442.013 : Surface Mount Version, with 1 Voter,
Speed Signal Inputs for MPU

I E16x442 Rev: 00 Page 9 of 73
1.6. Safety Data
1.6.1. Safety Data IEC61508; SIL2
System Type B; HFT = 1; Architecture 2oo3, Service Time 20 years
PFDavg = 1,81*10-4 at T1 (Proof Check Interval) = 20 years
1.7. External Tests
1.7.1. External tests during normal operation by PLC or operator
The trip release ability of a 2oo3 solenoid valve block can be verified by external.
1.7.2. Test of 2oo3 solenoid valve block
Test can only be performed if the Monitors are not in trip status.
The test is performed for each trip-line separately by control signals Test of
Trip-Line I, II, III. The response of the 2oo3 solenoid valve block must be checked by the PLC
resp. the operator.
Note:
Test of two or three trip-lines at the same time will release trip of the machine.

I E16x442 Rev: 00 Page 10 of 73
2. System Structure and I/Os
2.1. System Structure
The structure of the system is shown in chapter 2.1.4. (figures 2 and 3).
The wiring of the system is shown in chapter 2.1.5. (figures 4, 5 and 6).
The indexes ”see 2.x.x” in these figures refer to the corresponding chapters 2.x.x. which de-
scribe the according functions.
2.1.1. Speed Sensors
With versions E16x442.xx1:
Three A5S Differential-Hall-effect sensors, with integrated signal amplifier are placed at the
machine shaft.
The Differential Hall-effect sensors A5S are not susceptible to uniform external magnetic
fields. Air gap variations between machine and sensor do not create false signals.
With versions E16x442.xx2:
Three Speed signals from Eddy Current Sensors or from MPUs are evaluated.
With versions E16x442.xx3:
Three Speed signals from MPU Sensors are evaluated.
2.1.2. System Components
The system comprises three Monitors E1665 for speed monitoring and for monitoring of the
external trip conditions and one Test Interface E1691 to process the trip-line test signals and
the trip status signals between Monitors and the PLC.
The Monitors and the Test Interface are connected via a backplane. The backplane does not
hold any active components.
2.1.3. System Design
The system is available as
19-Inch Rack File, 3HE 84TE (E16E442) or
for surface mounting (E16A442) or
as NEMA4 version (E16G442).