Motrona DS230 Series User guide

Safety Manual
motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. [phone], Fax [phone], [email protected], www.motrona.com
DS230 / DS240 series
Safety monitor for SinCos and incremental encoders / sensors
Product features:
• Monitoring underspeed, overspeed, standstill and direction of rotation
•SIL3 and PLe certification
• Safety functions equivalent to EN61800-5-2 (SS1, SS2, SOS, SLS, SDI, SSM)
• Mounting to 35 mm top hat rail (according to EN 60715)
• USB interface for simple parametrization by the OS 6.0 operator surface
• Optional available display and programming unit BG230 for parametrization and indication
• Inputs for: 2 SinCos encoders
2 RS422 incremental encoders
2 HTL/PNP incremental encoders, proximity switches or control signals
• Outputs: 1 Relay Output 5 … 36 VDC (NO), (safety related)
1 Analog Output 4 … 20 mA, (safety related)
4 Control HTL Outputs, (safety related)
• Signal splitter: 1 SinCos Splitter Output, (safety related)
1 RS422 Splitter Output, (safety related)
Available devices:
DS230: All inputs and outputs as well as signal splitter function
DS236: All inputs and outputs, but without signal splitter function
DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function
DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter

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Version:
Description:
Ds23001a_oi_e.doc/mb/07/14
First edition pre series
Ds23003a_oi_e.doc/sn/ag/06/15
First edition series
Rechtliche Hinweise:
All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH. Any
reproduction, modification, usage or publication in other electronic and printed media as well as in the
internet requires prior written authorization by motrona GmbH.

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Table of Contents
1. Safety Instructions and Responsibility ......................................................... 5
1.1. General Safety Instructions ..................................................................................5
1.2. Use according to the intended purpose................................................................5
1.3. Installation ............................................................................................................6
1.4. Cleaning, Maintenance and Service Notes ..........................................................6
2. Introduction ................................................................................................. 7
3. Available Models ........................................................................................ 8
4. Block Diagrams and Connections................................................................. 9
4.1. DS230 Block Diagram ...........................................................................................9
4.2. DS230 Connections...............................................................................................9
4.3. DS236 Block Diagram .........................................................................................10
4.4. DS236 Connections.............................................................................................10
4.5. DS240 Block Diagram .........................................................................................11
4.6. DS240 Connections.............................................................................................11
4.7. DS246 Block Diagram .........................................................................................12
4.8. DS246 Connections.............................................................................................12
5. Description of Connections.........................................................................13
5.1. Power Supply ......................................................................................................14
5.2. Encoder Supply ...................................................................................................15
5.3. SinCos-Inputs...................................................................................................... 19
5.4. RS422-Inputs.......................................................................................................20
5.5. HTL / Control Inputs............................................................................................ 21
5.6. SinCos-Splitter-Output........................................................................................ 22
5.7. RS422-Splitter-Output.........................................................................................23
5.8. Analog-Output 4 to 20 mA.................................................................................. 24
5.9. Control-Outputs................................................................................................... 25
5.10. Relay-Output .......................................................................................................26
5.11. DIL switch ...........................................................................................................27
5.12. Interface for Display Unit BG230........................................................................ 28
5.13. USB Interface for the OS6.0 Operator Surface...................................................29
5.14. LEDs / Status Indication......................................................................................30

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6. Operational Modes.....................................................................................31
6.1. Operational Modes of DS23x types....................................................................31
6.2. Operational Mode of DS24x types...................................................................... 32
6.3. Achievable Safety Levels of DS23x ....................................................................33
6.4. Achievable Safety Level of DS24x...................................................................... 34
6.5. „Operational Mode“ = 0 (DS23x)........................................................................35
6.6. „Operational Mode“ = 0 (DS24x)........................................................................36
6.7. „Operational Mode“ = 1......................................................................................37
6.8. „Operational Mode“ = 2......................................................................................38
6.9. „Operational Mode“ = 3......................................................................................39
6.10. „Operational Mode“ = 4......................................................................................40
6.11. „Operational Mode“ = 5......................................................................................41
6.12. „Operational Mode“ = 6......................................................................................42
6.13. „Operational Mode“ = 7......................................................................................43
6.14. „Operational Mode“ = 8......................................................................................44
6.15. „Operational Mode“ = 9......................................................................................45
7. Start-Up the Unit ........................................................................................46
7.1. Setup by PC......................................................................................................... 47
7.2. Setup by the Programming Module BG230 ........................................................48
7.3. Parameter / Menu Overview...............................................................................49
7.4. Parameter Description ........................................................................................51
8. Start-Up the Plant.......................................................................................78
8.1. Cabinet installation............................................................................................. 78
8.2. Parametrization................................................................................................... 79
8.3. Preparation before first start-up......................................................................... 84
8.4. Checklist for Parameter Settings ........................................................................85
8.5. Definition of the Directions.................................................................................85
8.6. Sensor Channel Adaption ...................................................................................86
8.7. Completion of Commissioning............................................................................ 88
9. Error Detection ...........................................................................................89
9.1. Error Representation........................................................................................... 89
9.2. Initial Error ..........................................................................................................90
9.3. Runtime Error ......................................................................................................91
9.4. Error Clearing ...................................................................................................... 93
9.5. Error Detection Time...........................................................................................93
10. Parameter List ............................................................................................94
11. Technical Specifications.............................................................................97
11.1. Dimensions .........................................................................................................99
12. Certificate ................................................................................................100

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1.Safety Instructions and Responsibility
1.1. General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and hints
about the installation, function and usage. Non-observance can result in damage and/or impairment
of the functions to the unit or the machine or even in injury to persons using the equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use these
manual. The unit must be installed, connected and put into operation by a qualified electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property and
for consequential damage, due to incorrect handling, installation and operation. Further claims, due
to errors in the operation manual as well as misinterpretations are excluded from liability.
In addition the manufacturer reserves the right to modify the hardware, software or operation
manual at any time and without prior notice. Therefore, there might be minor differences between
the unit and the descriptions in operation manual.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.
1.2. Use according to the intended purpose
The unit is intended exclusively for use in industrial machines, constructions and systems. Non-
conforming usage does not correspond to the provisions and lies within the sole responsibility of the
user. The manufacturer is not liable for damages which are arisen through unsuitable and improper
use. Please note that device may only be installed in proper form and used in a technically perfect
condition in accordance to the technical specifications (see chapter 11). The device is not suitable
for operation in explosion-proof areas or areas which are excluded by the EN 61010-1 standard.

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1.3. Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further
it must be ensured that no danger can arise by touching the disconnected voltage-sources.
Devices which are supplied by AC-voltages, must be connected exclusively by switches, respectively
circuit-breakers with the low voltage network. The switch or circuit-breaker must be placed as near
as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated from
dangerous electrical cables (SELV circuits) by using double resp. increased isolation.
All selected wires and isolations must be conforming to the provided voltage- and temperature-
ranges. Further all country- and application-specific standards, which are relevant for structure, form
and quality of the wires, must be ensured. Indications about the permissible wire cross-sections for
wiring are described in the technical specifications (see chapter 11).
Before first start-up it must be ensured that all connections and wires are firmly seated and secured
in the screw terminals. All (inclusively unused) terminals must be fastened by turning the relevant
screws clockwise up to the stop.
Overvoltage at the connections must be limited to values in accordance to the overvoltage category
II.
For placement, wiring, environmental conditions as well as shielding and earthing/grounding of the
supply lines the general standards of industrial automation industry and the specific shielding
instructions of the manufacturer are valid. Please find all respective hints and rules on
www.motrona.com/download.html --> [General EMC Rules for Wiring, Screening and Earthing].
1.4. Cleaning, Maintenance and Service Notes
To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff or
assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures or
malfunctions the device must be shipped for back to the manufacturer for checking, adjustment or
reparation. Unauthorized opening and repairing can have negative effects or failures to the
protection-measures of the unit.

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2.Introduction
This series of speed monitors is suitable for safety-related monitor tasks e. g. over-speed, under-
speed, standstill and direction of rotation. This SIL3/PLe certified generation of devices was
developed to achieve functional safety by supporting a wide range of sensors and encoders in
different combinations.
Due to its innovative multifunctional inputs these devices are perfectly suitable for the retrofitting of
existing plants and machines which are using “non-safe“ sensors. This offers a great opportunity to
save costs for expensive and certified sensors. Also the costs for new installations and adjustments
can be reduced significantly by using the existing components and wiring.
Typical examples are centrifuges, cranes, wind power or hauling plants.
Special features:
Additionally suitable for a "Set-Up Operation",
e. g. for manual settings at plants with open doors and reduced speed
All models are safety-related and dually certified according to
EN 61508, EN 62061 / SIL3 and EN ISO 13849-1 Cat. 3 / Ple,
even when using “non-safety-related”standard sensors or encoders
Wide input frequency range and fast response time
Very versatile range of possible monitoring functions
Easy setup by PC via USB or by the optional programming module BG230

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3.Available Models
D
S
2
x
x
Unit
D =
Speed Monitor
Application
S =
Safety Applications
Housing
2 =
Housing for DIN rail mounting into a control
cabinet (according to EN 60715)
Inputs
3 =
2 Inputs for SinCos encoders
2 Inputs for incremental RS422 encoders
2 Inputs for HTL/PNP incremental encoders
or HTL/PNP control signals
4 =
1 Input for SinCos encoder with SIL3 / PLe
2 Inputs for HTL/PNP control signals
Outputs
0 =
1 Relay Output
1 Analog Output
4 Control Outputs
1 SinCos Splitter Output
1 RS422 Splitter Output
6 =
1 Relay Output
1 Analog Output
4 HTL Control Outputs

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4.Block Diagrams and Connections
4.1. DS230 Block Diagram
4.2. DS230 Connections

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4.3. DS236 Block Diagram
4.4. DS236 Connections

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4.5. DS240 Block Diagram
4.6. DS240 Connections

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4.7. DS246 Block Diagram
4.8. DS246 Connections

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5.Description of Connections
This chapter describes only the electrical connections and their general function. For a detailed
technical information please refer the chapter 11.
Name
Description see chapter
X1 | RELAY OUT
5.10 Relay-Output
X2 | CONTROL OUT
5.9 Control-Outputs
X3 | 24V IN
5.1 Power Supply
X4 | ANALOG OUT
5.8 Analog-Output 4 to 20 mA
X4 | RS 422 OUT
5.7 RS422-Splitter-Output
X5 | SINCOS OUT
5.6 SinCos-Splitter-Output
X6 | SINCOS IN 1
5.3 SinCos-Inputs
X7 | SINCOS IN 2
5.3 SinCos-Inputs
X8 | RS422 IN 1
5.4 RS422-Inputs
X9 | RS422 IN 2
5.4 RS422-Inputs
X10 | CONTROL IN
5.5 HTL / Control Inputs
X11
5.12 Interface for Display Unit BG230
X12
5.13 USB Interface for the OS6.0 Operator Surface
S1
5.11 DIL switch
ERROR - ON
5.14 LEDs / Status Indication
All outputs perform safe. The connection to the outputs is only safe if the sequential
device is able to detect the fault status of each output.
In order to prevent simultaneous damages to the cables by external influences,
the encoder resp. sensor lines must be kept physically separate from one another.

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5.1. Power Supply
If the unit is connected to a DC power supply network, which supplies further devices or systems, it
must be ensured that no voltages ≥60 V can occur at the terminals X3:1 and X3:2.
If this cannot be ensured, the unit must be supplied by a separate DC power pack, which may not be
connected to further devices or systems.
The requirements for both kinds of power supply are:
Nominal voltage range from 18 …30 VDC
Ripple < 10% @ 24 V
External fuse (2.5 A, medium time lag) required
A separate power pack must cover the following requirements:
The switch-on current of the unit is maximum 2.5 A
The consumption of the unit is maximum 45 W
The 18 … 30 VDC power supply must be connected by the pluggable 2-pin screw terminal [X3].
The power supply input is protected by an internal reverse polarity protection.
pluggable 2-pin screw terminal [X3]
The input must be protected by an external fuse
(type and value see chapter 11.“Technical Specifications”).
A SIL3 certified power supply can be used without any further external
components or protections.

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5.2. Encoder Supply
The unit offers an auxiliary voltage output to power the used encoder resp. sensors.
The power supply of the encoders must be carried out directly from the safety unit
(see chapter 5.2.1) or in use of an external power supply via a relay (see chapter 5.2.2).
Encoder supply: SinCos inputs [X6] [X7]
Encoder supply: RS422 inputs [X8] [X9]
HTL encoders or sensors must also be connected to the encoder supply of the RS422 inputs
The maximum load of encoder supply is 200 mA each channel (Sensor1 and Sensor2).
Supply
SinCos inputs
RS422 inputs
HTL inputs
Sensor1
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
Examples for the connection of encoders and the encoder supply can be found in chapter 6.
When powering up the encoder supply, the maximum input current of the safety unit can be
exceeded due to different encoders. In this case, the encoder supply will not be enabled and an error
appears (see chapter 9).
In case of such problems or if another voltage level is required, the encoder supply can be switched
via a relay by an external voltage source. The relay activation must essentially be performed by the
encoder supply of safety unit (see chapter 5.2.2).
In case of a direct encoder supply it is mandatory to operate the encoders with the
auxiliary voltage from the unit.
An external encoder supply must be done in each case via a relay which is triggered
by the auxiliary voltage of the unit.

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5.2.1. Direct Encoder Supply
The unit provides an auxiliary encoder supply for each sensor channel
(HTL encoders must be supplied by the encoder supply for the RS422 inputs).
The level of the supply voltage is approximate 2 V below the 18 … 30 VDC power supply
at terminal [X3].
The maximum load of encoder supply is 200 mA each channel (Sensor1 and Sensor2).
Supply
SinCos inputs
RS422 inputs
HTL inputs
Sensor1
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
Example of a direct encoder supply
In case of a direct encoder supply it is mandatory to supply the encoders with the
auxiliary voltage from the unit.

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5.2.2. External Encoder Supply
An external encoder supply must be done in each case via a relay which is triggered by the auxiliary
voltage of the unit. This is necessary, because the encoder supply will only be activated after the
safety unit has successfully completed its initialization and self-test.
In case of a relay failure or a failure of the external encoder voltage (switched by the relay), the
operator must ensure that the plant cannot reach a safety-critical state.
Explanation / Solution:
In case of an encoder supply failure the encoder would "rotate", but the unit is incapable to detect
speed or speed differences. In order to detect this error, the operator can use e. g. a control output
of the unit which indicates "standstill" (see Section 7.4.6). A master controller has to compare these
two states (plant "rotate" and control output "standstill"). If the two states differ the master
controller has to trigger an error and the plant has to go to a safe state.
Example of an external encoder supply (1 encoder is switched via 1 relay)
An external encoder supply must be done in each case via a relay which is triggered by
the auxiliary voltage of the unit.
The operator must ensure that the plant cannot reach a safety-critical state, in case of
a failure of the relay or a failure of the external encoder voltage (switched by the relay).

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Continuation “External Encoder Supply”
Example of an external encoder supply (2 encoders are switched via 1 relay)
An external encoder supply must be done in each case via a relay which is triggered by
the auxiliary voltage of the unit.
The operator must ensure that the plant cannot reach a safety-critical state, in case of a
failure of the relay or a failure of the external encoder voltage (switched by the relay).

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5.3. SinCos-Inputs
If the operational mode is set for using SinCos encoders (see chapter 7.4.1 / Parameter 000), the unit
will accept SinCos input signals with 1 Vpp and 2.5 V DC-offset at the 9-pin SUB-D connectors [X6]
and [X7].
It is mandatory to connect up always all existing signal lines (SIN+, SIN-, COS+ and COS-). The
internal SinCos encoder signal monitor verifies the Common Mode range of each signal line and is
capable to detect cable fractures.
An evaluation option for any existing reference signals (REF+ and REF-) is not applicable.
All input lines are already terminated by internal 120 Ohm load resistors.
The SinCos encoder must use the corresponding encoder supply at pin 4 and pin 5 of the connector
(see chapter 5.2).
male SUB-D connector [X6], [X7]

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5.4. RS422-Inputs
(Only DS230 and DS236)
If the operational mode (see chapter 7.4.1 / Parameter 000) is set for RS422 encoder use, the unit
will accept differential input signals from an incremental encoder in RS422 format at the terminal
strips [X8] and [X9]. The RS422 input channels (A and /A resp. B and /B) are internally terminated by
a dynamic terminating circuit (220 pF / 120 ohm).
It is mandatory to connect up all signal lines (A, /A, B and /B).
An evaluation option for any existing zero pulses (or Z / Z) does not exist.
The RS422 encoder must use the encoder supply at pin 1 and 2 of the respective terminal
(see chapter 5.2).
pluggable 7-pin screw terminal [X8], [X9]