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

Ds230_03a_oi_e.doc / Jun-15 Page 2 / 100
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.

Ds230_03a_oi_e.doc / Jun-15 Page 3 / 100
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

Ds230_03a_oi_e.doc / Jun-15 Page 4 / 100
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

Ds230_03a_oi_e.doc / Jun-15 Page 5 / 100
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.

Ds230_03a_oi_e.doc / Jun-15 Page 6 / 100
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.

Ds230_03a_oi_e.doc / Jun-15 Page 7 / 100
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

Ds230_03a_oi_e.doc / Jun-15 Page 8 / 100
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

Ds230_03a_oi_e.doc / Jun-15 Page 9 / 100
4.Block Diagrams and Connections
4.1. DS230 Block Diagram
4.2. DS230 Connections

Ds230_03a_oi_e.doc / Jun-15 Page 10 / 100
4.3. DS236 Block Diagram
4.4. DS236 Connections