SEW-Eurodrive EMS User manual

240_10030005/EN
Drive Technology \ Drive Automation \ System Integration \ Services
Edition
*240-27779165/EN-02/22*
Operating manual [27779165/EN]
Control technology
EMS modular controls
02/2022

Table of contents
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Operating manual [27779165/EN] - EMS modular controls
Table of contents
1 Document history ................................................................................................................ 4
2 Abbreviations....................................................................................................................... 5
3 General ................................................................................................................................. 6
3.1 About these instructions ........................................................................................... 6
3.2 Symbols.................................................................................................................... 7
3.3 Copyright protection ................................................................................................. 9
3.4 Disclaimer................................................................................................................. 9
3.5 Customer service ..................................................................................................... 9
3.6 Warranty ................................................................................................................... 10
3.6.1 Warranty terms and conditions ................................................................. 10
4 Safety instructions .............................................................................................................. 11
4.1 Safety ....................................................................................................................... 11
4.2 Intended use & obvious misuse ............................................................................... 12
4.2.1 Intended use ............................................................................................. 12
4.2.2 Foreseeable misuse.................................................................................. 12
4.3 General risks ............................................................................................................ 13
4.3.1 Danger from electrical energy................................................................... 14
4.4 Responsibilities of the operating company............................................................... 15
4.5 Personnel requirements ........................................................................................... 16
4.5.1 Qualifications............................................................................................. 16
4.6 Personal protective equipment................................................................................. 17
4.7 Safety devices .......................................................................................................... 19
4.8 Conduct in case of danger or accident..................................................................... 20
4.9 Signage .................................................................................................................... 21
5 Notes about hazardous substances .................................................................................. 22
6 Applicable documents ........................................................................................................ 23
7 Applied guidelines, ordinances and standards................................................................24
8 Technical data ...................................................................................................................... 26
9 System description.............................................................................................................. 29
9.1 Basic system ............................................................................................................ 29
9.2 Preferred variant 1: Rail bus CAN + SMGM, without safety function ....................... 30
9.3 Preferred variant 2: Rail bus CAN, STO via power rail............................................. 31
9.4 Preferred variant 3: SMGM, STO via PROFIsafe..................................................... 32
10 Safety functions (only for controls with integrated safety technology)......................... 33
10.1 Overview .................................................................................................................. 33
10.2 Safety function description ....................................................................................... 34
10.2.1 STO (safe torque off) ................................................................................ 34
10.2.2 SLS (safely limited speed) ........................................................................ 36
11 Dimensions .......................................................................................................................... 37

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12 Overview...............................................................................................................................38
12.1 Complete overview................................................................................................... 38
12.2 Overview: Front ........................................................................................................ 39
12.3 Overview: Bottom ..................................................................................................... 41
13 Connections......................................................................................................................... 42
13.1 Connections: Bottom ................................................................................................ 42
13.1.1 Connection: X1.......................................................................................... 42
13.1.2 Connection: X2.1 ... X2.4 .......................................................................... 43
13.1.3 Connection: X3.......................................................................................... 44
13.1.4 Connection: X4.......................................................................................... 45
13.1.5 Connection: X5.......................................................................................... 46
13.2 Connections: Front ................................................................................................... 47
13.2.1 Overview: SysBus types ........................................................................... 47
13.2.2 SysBus module: IM.1 ................................................................................ 48
13.2.3 SysBus module: IO.1 ................................................................................ 52
13.2.4 SysBus module: IO.2 ................................................................................ 57
14 Circuits: Power outputs ...................................................................................................... 66
15 Frequency converter ........................................................................................................... 67
16 Communication.................................................................................................................... 68
16.1 Railbus CAN............................................................................................................. 69
16.1.1 Basics........................................................................................................ 69
16.1.2 Interface Description ................................................................................. 70
16.2 SMGM ...................................................................................................................... 72
16.2.1 Basics........................................................................................................ 72
16.2.2 Interface Description ................................................................................. 73
17 Type code ............................................................................................................................. 81
18 Type plate ............................................................................................................................. 82
19 Order overview & scope...................................................................................................... 83
20 Commissioning.................................................................................................................... 84
20.1 Safety notes ............................................................................................................. 84
20.1.1 Mechanical installation.............................................................................. 84
20.1.2 Electrical installation.................................................................................. 85
20.1.3 EMC .......................................................................................................... 86
20.1.4 Operating modes....................................................................................... 87
20.2 Installation ................................................................................................................ 88
20.2.1 Fastening the control................................................................................. 88
20.2.2 Connections .............................................................................................. 90
20.2.3 Housing PE connection (control bottom)................................................... 91
20.3 Condition after the installation .................................................................................. 92
20.4 First commissioning.................................................................................................. 93
20.5 Switching on sequence ............................................................................................ 94
20.6 Operation..................................................................................................................95
20.7 Decommissioning ..................................................................................................... 96

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21 Malfunctions......................................................................................................................... 97
21.1 Safety notes ............................................................................................................. 97
21.2 Procedure in the event of malfunction...................................................................... 98
21.3 Error messages ........................................................................................................ 99
21.4 Return/repair ............................................................................................................ 100
22 Maintenance......................................................................................................................... 101
22.1 Safety information about repairs .............................................................................. 102
23 Transport and storage......................................................................................................... 103
23.1 Safety instructions for transport and storage............................................................ 103
23.2 Transport inspection ................................................................................................. 103
24 Disassembly and disposal.................................................................................................. 104
24.1 Preparation for disassembly..................................................................................... 104
24.1.1 Disassembly.............................................................................................. 104
24.2 Disposal.................................................................................................................... 105
Index ..................................................................................................................................... 107

Document history
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Document history
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1 Document history
Part number Version Issue Description/changes
27779165/EN 1.01 11/2021 First issue
27779165/EN 1.02 02/2022 Part number of this document added; New connector X5: Informa-
tion added
----

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Abbreviations
Abbreviations 2
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2 Abbreviations
Designation Definition
DIN Digital IN (digital input)
DOUT Digital OUT (digital output)
EMS (electric monorail
system)
Application: Electric monorail system
EI Field bus: Ethernet/IP
EMC Electromagnetic compatibility
ESD Electrostatic discharge
FC Frequency converter
HF High frequency
HW Communication type: Half wave
IEN Industrial Ethernet
PCB Communication type: Rail bus, PowerCAN
PN Field bus: PROFINET
RS485 Serial interface: RS485 standard
SMGM Communication type: SMGM
SSI Serial interface: RS422 standard
ASL Above sea level
XIN Fixed assignment of the contact as a digital input
XIO Contact switchable digital input/output

General
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General
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3 General
3.1 About these instructions
These operating instructions enable the safe and efficient handling of our SEW prod-
ucts. This document is an integral part of the installation and must be kept accessible to
operating and maintenance personnel in the immediate vicinity. The basic requirement
for safe working is compliance with all specified safety instructions and instructions. This
documentation does not give instructions for operating the plant/machine in which our
system is integrated. In addition, the local accident prevention regulations and general
safety regulations for the use of the system apply. Illustrations serve basic understand-
ing and may deviate from the actual version.

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General
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3.2 Symbols
The safety information in these instructions is identified by symbols. Safety information
is introduced by signal words, which highlight the extent of the hazard. The different
types of warning and safety instructions and their design are explained in the following.
⚠
DANGER
Cause of danger
Consequence of non-compliance
• Measure to avoid it
⚠
WARNING
Cause of danger
Consequence of non-compliance
• Measure to avoid it
⚠
CAUTION
Cause of danger
Consequence of non-compliance
• Measure to avoid it
NOTICE
Cause of danger
Consequence of non-compliance
• Measure to avoid it
INFORMATION
Cause of danger
Consequence of non-compliance
• Measure to avoid it
⚠DANGER! Residual voltage from charged capacitors!Severe injury. Do not touch any
live product parts or power connections.
⚠WARNING! Residual voltage from charged capacitors!Severe injury. Do not touch
any live product parts or power connections.
⚠CAUTION! Residual voltage from charged capacitors!Severe injury. Do not touch
any live product parts or power connections.
NOTICE! Residual voltage from charged capacitors!Severe injury. Do not touch any live
product parts or power connections.
INFORMATION! Residual voltage from charged capacitors!Severe injury. Do not touch
any live product parts or power connections.

General
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General
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Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice
text Notice text Notice text Notice text Notice text Notice text Notice text Notice text No-
tice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text

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General
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3.3 Copyright protection
The contents of these instructions are copyright protected. Their use is permitted as part
of operating the system. A usage that goes beyond the above, is not permitted without
written approval by the manufacturer. Transferring these instructions to third parties, re-
productions of any kind and form - including extracts - as well as utilizing and/or com-
municating the content are not permitted without the manufacturer's written consent,
except for internal purposes.
3.4 Disclaimer
All information and instructions in this documentation have been compiled taking into ac-
count the applicable standards and regulations, state of the art and our many years of
knowledge and experience.
The manufacturer assumes no liability for damage due to:
• Failure to observe the technical documentation
• Improper use
• Use of unskilled personnel
• Unauthorized modifications and technical changes
• Use of unauthorized spare parts or accessories
The actual scope of delivery may deviate from the explanations and illustrations de-
scribed here in the case of special designs, use of additional order options or latest tech-
nical changes.
Obligations agreed in the delivery contract, general terms and conditions as well as the
manufacturer's delivery conditions and legal obligations applicable at the time of the
conclusion of the contract apply.
We reserve the right to make technical changes to improve usability and for further de-
velopment.
3.5 Customer service
SEW-EURODRIVE GmbH & Co KG
Ernst-Blickle-Str. 42
Tel: [phone]
Fax: [phone]
D - 76646 Bruchsal
E-Mail: [e-mail]
Web: www.sew-eurodrive.com
Country of origin: Germany

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3.6 Warranty
3.6.1 Warranty terms and conditions
All information and instructions in this documentation have been compiled taking into ac-
count the applicable standards and regulations, state of the art and our many years of
knowledge and experience.
The warranty period and scope are determined by your contractual conditions and the
general delivery conditions of SEW-EURODRIVE GmbH & Co KG.
The general warranty and delivery conditions can be viewed on our website. www.sew-
eurodrive.com
⚠
WARNING
No liability for changes, modifications or accessories!
Accidents and serious injuries
• Modifications or changes to the delivered product are only permitted after consulta-
tion with the manufacturer. Original spare parts and accessories approved by the
manufacturer ensure safety. Use of other parts invalidates any liability on the part of
the manufacturer.
• Always consult the manufacturer!
The guarantee is void if one or more of the situations listed below occur!
• If the product is changed without SEW's consent.
• If the user himself carries out assembly or repairs within the warranty period or has
them carried out by third parties.
• If the product was incorrectly handled or maintained.
• If no SEW approved original parts have been used.
• If this documentation and its contents are not observed.

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Safety instructions
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4 Safety instructions
4.1 Safety
This section provides an overview of all important for protecting people as well as safe
handling and fault-free operation. Further task-related safety instructions are contained
in the sections about individual life phases.
⚠
DANGER
Danger if the safety instructions are not observed
Death or serious injuries
• Safety regulations must be strictly observed!

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4.2 Intended use & obvious misuse
4.2.1 Intended use
The controls described in this document are designed exclusively for use in industrial
environments in automation systems such as EMS, sorters, push skids and similar ap-
plications.
The control is approved only for industrial environments in terms of electromagnetic
compatibility (EMC).
The control supply voltage depends on respective project planning and is typically in the
following areas:
• AC: 3/PE/PEN: 360 ... 440 V at 45 ... 55 Hz
• AC: 3/PE/PEN: 432 ... 528 V at 54 ... 66 Hz
The number and performance of the motors that can be connected depends on the con-
trol configuration.
A large number of sensors and actuators can be connected to the control, depending on
the equipment. Sensors and actuators are supplied with 24 VDC.
Communication type depends on the control configuration.
EMS modular controls are only approved for indoor use in industrial environments.
Control operation in EX areas is not permitted.
For proper operation, all information in this manual must be observed.
Information/requirements for compliance with EMC specifications in these instructions
must be fully met.
The system in which the control is installed must meet all requirements of the Machinery
Directive (2006/42/EC) or equivalent on-site requirements before starting normal oper-
ation. For proper documentation, the system builder must create a comprehensive op-
erating manual for the complete system.
Any use that goes beyond the intended use, or any other type of use, modification or
changes not approved by SEW are considered misuse and are prohibited. In the event
of misuse, the manufacturer's warranty is void.
4.2.2 Foreseeable misuse
Any use that goes beyond the intended use, or any other type of use, modification or
changes not approved by SEW are considered misuse and are prohibited.
Any application outside the specifications given in this documentation is prohibited.
In the event of misuse, the manufacturer's warranty is void.

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4.3 General risks
In the following section, residual risks are specified that can arise from the product even
if it is used as intended. In order to reduce the risk of personal injury and property dam-
age and avoid dangerous situations, safety instructions listed in other sections of this
manual must be observed.
The system must not be changed improperly!
⚠
WARNING
Danger from incorrect replacement and dismantling!
Accidents and serious injuries
• Before starting any dismantling work, safety instructions must be observed.

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4.3.1 Danger from electrical energy
Carry out the following safety work in accordance with VDE 0105-100 (this work must
be carried out by a qualified electrician, see section ""Personnel requirements" (
16)").
Unlocking
Required isolating distances must be established.
Secure against restart
During work, a prohibition sign must be attached reliably on switching handles or drives
of switches, control units, pressure and sensing devices, safety parts, circuit breakers
that have been used to unlock a system part or that can be used to connect electricity.
If this is not possible, then the clearly associated prohibition sign must be nearby. In the
case of manually operated switches, existing interlocking devices must be used to pre-
vent them from being switched on again.
Determine that electricity is disconnected
Absence of voltage is to be determined at or as close as possible to the work site at all
poles. Absence of voltage must be checked with a voltage tester immediately before and
after use.
Grounding and short circuiting
Parts on which work will be performed at the work place must first be grounded and then
short circuited. Grounding and short-circuiting must be visible from the workplace. De-
viating from the above, it is permitted to ground and short-circuit near the work place if
this is required due to local conditions or for safety reasons. Devices for grounding and
short-circuiting must always first be connected with the grounding system or the ground
electrode and afterwards with the parts to be grounded. Grounding and short circuiting
may be waived in certain low-voltage systems (see VDE 0100-100).
Cover and block adjacent parts that are connected to electricity
Before starting work, check whether it is feasible to disconnect adjacent parts
from electricity.
⚠
DANGER
Electric current hazard!
Death or serious injuries
• No live parts may be touched!
• It must be ensured that components are not live (switch off the voltage) or, if this is
not possible, cover the parts with insulating material.
• Live parts must be secured against unauthorized approach.

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4.4 Responsibilities of the operating company
Provider definition
The provider can be found in the order confirmation and has the following obligations:
Provider obligations
The plant system is used in the commercial sector. The system provider is therefore sub-
ject to the statutory obligations relating to occupational safety. In addition to the safety
instructions in this manual, the safety, accident prevention and environmental regula-
tions applicable to system use must be observed. The following is especially applicable:
• The provider ensures protection against electric shock (protection against direct
contact).
• The provider must inform himself about the applicable occupational health and safe-
ty regulations and determine additional hazards in risk assessment resulting from
special working conditions at the system location. He must implement these in the
form of instructions for operating the system.
• During the entire system service life, the provider must check whether the operating
instructions he has created correspond to the current status of the regulations and,
if necessary, adapt them.
• The provider must clearly regulate and define who is responsible for installation, op-
eration, maintenance and cleaning.
• The provider must ensure that all employees who work with the system have read
and understood the operating instructions. In addition, he must train the staff at reg-
ular intervals and inform them of dangers.
Furthermore, the provider is responsible for ensuring the system is always in a
technically perfect condition, therefore the following applies:
• The provider must ensure that maintenance intervals described in this documenta-
tion are followed.
• Controls and safety devices created by him for operating the system must be
checked for functional reliability and completeness.
• The provider must ensure installation and assembly in accordance with EN 60204.
• The provider must ensure that all components are disconnected from the power sup-
ply in the event of an EMERGENCY STOP. In particular, the power rail installed in
parallel.

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4.5 Personnel requirements
4.5.1 Qualifications
Tasks described in these instructions represent different requirements for qualifying the
person who looks after them.
⚠
DANGER
Danger if persons are inadequately qualified
Death or serious injuries
• Have all work performed only by persons qualified for the task.
• Inadequately qualified persons should be kept away from the work area.
Operator
The operator was briefed by the provider about the tasks assigned to him and the pos-
sible dangers in the case of inappropriate behavior. The operator may only perform
tasks that go beyond normal operation if this is specified in the instructions and the pro-
vider has expressly entrusted him with them.
Qualified electrician (see VDE 0105-100)
Due to their technical training, knowledge and experience, as well as knowledge of the
relevant standards and regulations, the qualified electrician is able to work on electrical
systems as well as recognize and avoid possible dangers independently. The electrician
is specially trained for the work environment in which he works and knows the relevant
standards and regulations.
Qualified personnel
Based on their technical education, knowledge and experience as well as knowledge of
relevant regulations, qualified personnel are in a position to perform the work assigned
to them as well as identify and prevent possible hazards independently.
Instructed persons
Instructed persons were trained by the provider about the tasks assigned to them and
possible hazards in case of incorrect behavior. In addition, these persons must have
read and understood these safety regulations and must adhere to them afterwards.
If required, this may have to be confirmed by the customer/user with a signature.

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4.6 Personal protective equipment
Each person assigned for work at or in the proximity of the system (support personnel)
must – depending on the type and application area of work to be done – wear personal
protective clothes/protective equipment. Personal protective equipment is used to pro-
tect people from adverse effects on health and safety at work. The provider is responsi-
ble for ensuring that the protective equipment is worn.
Personal protective equipment is described below:
Safety shoes
Safety shoes are used to protect against heavy falling parts and slipping on slippery sur-
faces.
Protective goggles
Goggles are used to protect against flying chips and splashing acids.
Hard hat
Helmets are used to protect against falling and flying parts and materials.
Gloves
To protect the hands from friction, abrasions, punctures or deep injuries, as well as from
contact with hot surfaces.
Protective work clothes
Protective work clothing is tight-fitting and tear-resistant, with tight sleeves and without
protruding parts. It is primarily used to protect against being caught by moving machine
parts, but must not restrict freedom of movement. Rings, chains or other jewelry may not
be worn. If you have long hair, it must be covered (cap, hat, hairnet or similar). Safety
harnesses, face and hearing protection according to DGUV regulation 112-189.
Ear protection
To protect against serious and permanent hearing damage.

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Respiratory protection
To protect against serious and permanent diseases of the respiratory tract.