SEW-Eurodrive MOVIFIT MC User manual

*29157056_0919*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIFIT®MC
Functional Safety
Edition 09/2019 29157056/EN

SEW-EURODRIVE—Driving the world

Contents
Manual – Functional Safety 3
Contents
1 General information.................................................................................................................. 4
1.1 About this documentation ...............................................................................................4
1.2 Structure of the safety notes ...........................................................................................4
1.3 Rights to claim under limited warranty ............................................................................6
1.4 Content of the documentation.........................................................................................6
1.5 Other applicable documentation .....................................................................................6
1.6 Product names and trademarks......................................................................................6
1.7 Decimal separator in numerical values ...........................................................................6
1.8 Copyright notice ..............................................................................................................6
2 MOVIFIT® MC safety concept................................................................................................... 7
2.1 Functional description .....................................................................................................7
2.2 MOVIFIT® MC block diagram.........................................................................................8
2.3 Restrictions .....................................................................................................................8
2.4 Safety functions ..............................................................................................................9
3 Safety-related conditions....................................................................................................... 11
3.1 Approved devices .........................................................................................................11
3.2 Installation requirements...............................................................................................13
3.3 External safety controller requirements ........................................................................13
3.4 Startup requirements ....................................................................................................15
3.5 Operation requirements ................................................................................................16
4 Hazard caused by drive coasting.......................................................................................... 17
5 Electrical installation.............................................................................................................. 18
5.1 Installation instructions..................................................................................................18
5.2 Safety-related disconnection MOVIFIT® ......................................................................19
6 Service..................................................................................................................................... 23
6.1 Diagnostics for STO......................................................................................................23
6.2 EBOX replacement .......................................................................................................24
7 Technical data......................................................................................................................... 25
7.1 Safety characteristics....................................................................................................25
7.2 Technical data MOVIFIT® MC (safety technology) ......................................................25
Index ........................................................................................................................................ 26
29157056/EN – 09/2019

1General information
About this documentation
Manual – Functional Safety
4
1 General information
1.1 About this documentation
The current version of the documentation is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation, or if you require further
information, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
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1
General information
Structure of the safety notes
Manual – Functional Safety 5
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
Warning of automatic restart
1.2.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
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1General information
Rights to claim under limited warranty
Manual – Functional Safety
6
1.3 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.4 Content of the documentation
This documentation contains additional safety-related information and conditions for
operation in safety-related applications.
1.5 Other applicable documentation
This documentation supplements the operating instructions of the associated product.
Use this document only in connection with the operating instructions.
Always use the latest edition of the documentation and the software.
The SEW‑EURODRIVE website (www.sew‑eurodrive.com) provides a wide selection
of documents for download in various languages. If required, you can also order prin-
ted and bound copies of the documentation from SEW‑EURODRIVE.
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.7 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.8 Copyright notice
©2019SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
29157056/EN – 09/2019

2
MOVIFIT® MC safety concept
Functional description
Manual – Functional Safety 7
2 MOVIFIT® MC safety concept
The described safety technology of the MOVIFIT® device has been developed and
tested in accordance with performance level d to ENISO13849‑1:2015.
This was certified by TÜV Nord. Copies of the TÜV certificate and the corresponding
report are available from SEW‑EURODRIVE on request.
2.1 Functional description
The MC design of the MOVIFIT® acts as a power distributor and communication inter-
face for controlling up to 3 MOVIMOT® drives. MOVIFIT® MC allows for the connection
of an external safety controller (or an external safety relay). If the connected emer-
gency stop device (e.g. emergency off button with latching function) is activated, the
safety controller disconnects the 24V supply voltage that is required for creating a ro-
tating field for the connected MOVIMOT® drive.
The 24V_P supply voltage (safety-related 24 V supply voltage) is connected in the
ABOX at the X29 terminal and fed to the EBOX via a plug strip. The EBOX houses
electronic components, such as a short-circuit protection, voltage monitor, RS485
transceiver and coupler. The safety-related 24V_P supply voltage is routed through a
polarity protection diode at the input of the EBOX. A switch-mode power supply
(SMPS) generates 5 V voltage from the safety-related 24 V voltage for the RS485
transceiver and the coupler. Short-circuit protection of the positive pole of the safety-
related 24 V voltage protects the contactor tracks of the MOVIFIT® and the hybrid
cables connected to the MOVIFIT®. In the ABOX, the safety-related 24V voltage is
distributed to the terminal strips X71, X81, and X91 or the plug connectors X7, X8, and
X9. The terminal strips of plug connectors serve to connect the respective MOVIMOT®
drives. Further, the RS+, RS- signals and the supply system cables L1, L2, L3 are for-
warded to the MOVIMOT® drives.
For the connection between the terminal strips X71, X81, and X91 or the plug con-
nectors X7, X8, and X9 and the MOVIMOT® drives, SEW‑EURODRIVE recommends
prefabricated hybrid cables that have been designed and shielded especially for this
purpose.
The connected MOVIMOT® inverters can de-energize all active elements that are re-
quired for creating pulse trains at the power output stage (IGBT) if the safety-related
24 V supply voltage is disconnected. This ensures that the MOVIMOT® inverter no
longer supplies power to the motor for generating torque.
External connection via a controller that
• Is approved for at least PL d according to ENISO13849-1
• Disconnects with at least PL d according to ENISO13849-1
MOVIFIT® MC devices can be used with:
• Safe Torque Off according to EN61800‑5‑2
• Safe Stop 1 according to EN61800-5-2
• Restart inhibit in accordance with ENISO 14118
• In compliance with performance level d according to ENISO13849-1.
MOVIFIT® MC supports stop categories 0and 1 according to EN60204-1.
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2MOVIFIT® MC safety concept
MOVIFIT® MC block diagram
Manual – Functional Safety
8
2.2 MOVIFIT® MC block diagram
MOVIFIT®
MC block
diagram
The following block diagram shows the MOVIFIT® MC safety concept:
SNT
ABOX EBOX
L1
L2
L3
M
MOVIMOT®
RS+
RS-
X45X7
X71
X8 X81
X9 X91
MOVIMOT®1
MOVIMOT®2
MOVIMOT®3
+24V_P
0V24_P
STO_P
STO_M
X29
24V
[2]
[10]
[9] [8] [7]
[6]
[5]
[4][3]
[1]
27021601858448651
[1] Field
[2] External safety controller (with MOVIFIT® without PROFIsafe option)
[3] Short-circuit protection
[4] 24V_P voltage monitor
[5] Voltage status 24V_P
[6] MOVIFIT® processor
[7] Serial interface
[8] Coupler
[9] Transceiver
[10] SEW‑EURODRIVE hybrid cable
2.3 Restrictions
WARNING
Electric shock due to dangerous voltages in the ABOX. If the safety-related 24 V
voltage is disconnected, MOVIFIT® device remains connected to the line voltage.
Severe or fatal injuries.
• De-energize the new MOVIFIT® device. Observe the minimum switch-off time
after disconnection from the supply system:
–1 minute
• The safety concept is only suitable for performing mechanical work on driven sys-
tem/machine components.
• A system/machine-specific risk assessment must at all costs be carried out by the
system/machine manufacturer and be observed when using the MOVIFIT® MC
device.
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2
MOVIFIT® MC safety concept
Safety functions
Manual – Functional Safety 9
2.4 Safety functions
The following drive-related safety functions can be used:
2.4.1 STO – Safe Torque Off
When the STO function is active, the inverter does not supply any power to the motor.
The drive cannot generate torque. This safety function corresponds to a non-con-
trolled stop according to EN60204-1, stop category 0.
The STO input must be disabled by a suitable external safety controller/safety relay.
The following figure illustrates the STO function:
t
V
t1
9007201225613323
Drive safety function trips
v = Speed
t = Time
t1 = Point of time when STO is triggered
INFORMATION
The motor coasts to a halt or is stopped mechanically.
Controlled standstill is preferred, if possible (see SS1).
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2MOVIFIT® MC safety concept
Safety functions
Manual – Functional Safety
10
2.4.2 SS1(c) – Safe Stop 1
Adhere to the following procedure:
• Decelerate the drive using an appropriate brake ramp specified via setpoint inputs.
• Disconnect the STO input (= triggering the STO function) after a specified safety-
related time delay.
This safety function corresponds to a controlled stop according to EN60204‑1, stop
category 1.
The following figure illustrates the SS1(c) function:
t2 t1
t
V
∆t
9007201225618443
Drive safety function monitoring
Drive safety function trips
v = Speed
t = Time
t1 = Point of time when SS1(c) is activated and the braking action is triggered
t2 = Point of time when STO is triggered
Δt = Safety-related period of time
INFORMATION
• The SS1(c) function does not monitor the stopping of the drive.
• The safety-related period of time Δt allows the drive to come to a stop. In the
event of a fault, the drive does not come to a stop and becomes de-energized at
the time t2 (STO).
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3
Safety-related conditions
Approved devices
Manual – Functional Safety 11
3 Safety-related conditions
The following requirements are mandatory for installation and operation of MOVIFIT®
in safety-related applications according to the safety categories mentioned above. The
conditions are divided into the following sections:
• Approved devices
• Installation requirements
• Requirements for the external safety controller (for digital control for safety-related
disconnection)
• Startup requirements
• Operational requirements
3.1 Approved devices
3.1.1 Nameplates
Nameplate position
The following figure shows the positions of the nameplates on the ABOX:
[1] [2]
7012396683
[1] Nameplate of the complete device (EBOX and ABOX)
[2] Nameplate of the ABOX
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3Safety-related conditions
Approved devices
Manual – Functional Safety
12
Nameplate of complete unit
The following figure provides an example of a nameplate of the complete MOVIFIT®
MC device (EBOX and ABOX):
MOVIFIT
Type:
SO#:
MTM11A000-P10A-00
MTA11A-503-S011-M01-00
01.1785033001.0001.12
N2936
ML01
IND. CONT. EQ.2D06
WHEN USED WITH MOVIMOT DRIVES
01
LISTED
®
6872634379
This overall device nameplate is only available if the EBOX and the ABOX have been
ordered as one unit.
INFORMATION
Only components marked with the FS logo for functional safety may be installed in
safety applications. For combinations of devices without FS logo (consisting of indi-
vidual EBOX and ABOX), the safety function must be described in the documenta-
tion.
FS logo description
The FS logo can be displayed on the complete device nameplate of MOVIFIT® in the
following design:
01
MOVIFIT® MC with STO (without PROFIsafe option)
For MOVIFIT® with FS01 logo, refer to this manual.
3.1.2 Device replacement requirements
Observe the following notes during device replacement:
• In safety-related applications, a defective EBOX may only be replaced by an
EBOX according to the type designation on the nameplate of the complete
MOVIFIT® device.
• If the ABOX is defective in safety-related applications, you have to replace the en-
tire MOVIFIT® device (EBOX and ABOX) with a new MOVIFIT® device with
identical type designation.
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3
Safety-related conditions
Installation requirements
Manual – Functional Safety 13
3.2 Installation requirements
• Safety-related control cables are all cables between safety controller and
MOVIFIT® terminal X29.
• Supply system cables and the safety-related control cables must be routed separ-
ately (Exception: When using genuine hybrid cables by SEW‑EURODRIVE).
• The line length between the safety controller and MOVIFIT® may not exceed
100m.
• To connect the MOVIFIT® device to the motor, SEW‑EURODRIVE recommends
using the specifically designed prefabricated hybrid cable by SEW‑EURODRIVE.
• The wiring technology used must comply with EN60204-1.
• Route the safety-related control cables EMC-compliantly.
– Outside an electrical installation space: Shielded cables must be routed per-
manently (fixed) and protected against external damage, or other equivalent
measures.
– No single conductors must be routed within the installation space.
• Make sure that parasitic voltages cannot be generated in the safety-related control
cables.
• Observe the values specified for safety controllers when designing the safety cir-
cuits.
• Observe the notes in the "MOVIFIT® .." and "MOVIMOT® MM..D" operating instruc-
tions for information on EMC-compliant installation.
• For all 24V supply voltages of the MOVIFIT® device only voltage sources with safe
disconnection (SELV/PELV) according to EN60204‑1 and EN61131‑2 are permit-
ted.
In case of a single fault, the voltage between the outputs or between any output
and grounded parts may not exceed DC 60 V.
• Observe MOVIFIT® and MOVIMOT® MM..D technical specifications.
3.3 External safety controller requirements
The following requirements for the external safety controller for controlling the STO
safety function apply to safety-related disconnection with binary control.
The requirements apply to both a safety controller and a safety relay.
• For safety-related approval to EN ISO 13849‑1, there must be at least one ap-
proval for performance level d according to ENISO13849‑1 and the disconnection
of the safety-related control voltage must be designed for performance level d to
ENISO13849‑1 at least.
• The wiring of the safety controller must be suitable for the required safety class.
Safety circuits with MOVIFIT® require 2-pole disconnection.
• The values specified for the safety controller must be strictly adhered to when
designing the circuit.
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3Safety-related conditions
External safety controller requirements
Manual – Functional Safety
14
• The switching capacity of the control must correspond at least to the maximum
permitted limited output current of the DC 24V voltage supply.
Observe the manufacturer's instructions concerning the permitted contact
loads and fusing that may be required for the safety contacts. If the manu-
facturer provides no specific information, the contacts must be protected
with 0.6 times the nominal value of the maximum contact rating specified by
the manufacturer.
• For wiring with crossfault monitoring, the controller must feature an option for sig-
naling crossfault monitoring and trigger recognition.
• To ensure protection against unintended restart in accordance with ENISO14118,
the safety controller must be configured and connected in such a way that reset-
ting the control device alone does not lead to a restart. A restart may only be car-
ried out after a manual reset of the safety circuit.
• The input for the safety-related DC 24 V voltage supply of the device has an input
capacitance. For detailed information, refer to the "Technical Data "chapter of the
operating instructions of the respective device. This must be taken into account as
load when designing the switching output.
• Other requirements of the safety controller (such as protecting the output contacts
against welding) must be strictly observed. You must also observe the basic cable
routing requirements from chapter "Installation requirements".
• If the safety circuit is disconnected at 2 poles, the test pulses may not be applied
at the same time. The length of a test pulse must not exceed 1ms. The interval
between 2 test pulses must be at least 1 s.
t
< 1 ms > 1 s
high
low
9007199938827659
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3
Safety-related conditions
Startup requirements
Manual – Functional Safety 15
3.3.1 Sample circuit "safety relay"
The following figure shows the disconnection of an external safety relay.
[4]
[3] [1]
[5]
[6]
[2] U
18014400103440907
[1] Safety relay with approval
[2] DC24V voltage supply
[3] Fuses in accordance with the manufacturer's specifications of the safety relay
[4] Safety-related DC24 V voltage supply
[5] Reset button for manual reset
[6] Approved emergency stop actuating device
3.4 Startup requirements
After parameterization and startup, the system startup engineer has to check and doc-
ument the correct performance of the safety functions.
For MOVIFIT® applications with safety-related disconnection of the drive
• In stop category 0 or 1 in accordance with EN60204-1
• Restart inhibit in accordance with ENISO 14118
• In compliance with performance level d according to ENISO13849-1
you must, as a general rule, carry out and document startup checks of the disconnect-
ing device and the correct wiring.
During startup you must include signal detection of the safety-related control voltage in
the function test.
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3Safety-related conditions
Operation requirements
Manual – Functional Safety
16
INFORMATION
The insert labels of the MOVIFIT® EBOXes are assigned to the respective EBOX. If
you take out the labels to mark them, make sure that they are re-inserted in the right
EBOX.
To avoid danger in the application, the user has to check whether the fault response
time of each safety function (when a failure occurs) is shorter than the maximally per-
mitted fault response time of the application. The maximum permitted fault response
time may not be exceeded!
3.5 Operation requirements
• Operation is only permitted within the limits specified in the data sheets. This ap-
plies to the external safety control as well as to MOVIFIT® and MOVIMOT®.
• You must check the safety functions on a regular basis to ensure proper function-
ing. The test intervals should be specified in accordance with the risk assessment.
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4
Hazard caused by drive coasting
Manual – Functional Safety 17
4 Hazard caused by drive coasting
WARNING
Hazard caused by coasting of the drive. Without mechanical brake or if the brake is
faulty, the drive might coast to a halt.
Severe or fatal injuries.
• If coasting to a halt results in application-dependent hazards, take additional pro-
tective measures (for example, guards with locking device), which cover the haz-
ardous area until persons are no longer in danger. As an alternative, you must
equip the drive with a safety brake.
• The additional protective covers must be designed and integrated so that they
meet the requirements determined in the risk assessment of the machine.
• After activating the stop command, access to the machine must remain blocked
until the drive has reached standstill according to the risk. As an alternative, you
must determine the access time or calculate the resulting safety clearance that
must be adhered.
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5Electrical installation
Installation instructions
Manual – Functional Safety
18
5 Electrical installation
5.1 Installation instructions
To guarantee electrical safety and fault-free operation, you must observe the general
installation instructions and the notes in the MOVIFIT® operating instructions.
INFORMATION
• Observe the requirements in chapter "Safety-relevant conditions".
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5
Electrical installation
Safety-related disconnection MOVIFIT®
Manual – Functional Safety 19
5.2 Safety-related disconnection MOVIFIT®
Safety-
related
disconnecti
on
MOVIFIT®
5.2.1 MOVIFIT® MC
Terminals relevant for safety-related disconnection
The following figure shows the connecting terminals of the standard ABOX "MTA...-
S01.-...-00" relevant for safe disconnection of MOVIFIT® MC:
1 2 3 4
11 12 13 14
X1
S3
1
11
1 2 3 4 5
12 13 14 15
11
1 2 3 4 5
12 13 14 15
31 32 33 34 35
21 22 23 24 25
11
1 2 3 4 5 6 7 8
12 13 14 15 16 17 18
31 32 33 34 35 36 37 38
21 22 23 24 25 26 27 28
1
11 12 13 14 15 16
2 3 4 5 6
2 3 4
1 2 3 4
X20
X45 X25
X35
X50
X7
1 2 3 4
X8
X9
1
2
3
4
11
12
13
14
X1
S3
11
1
2
3
4
5
6
7
8
12
13
14
15
16
17
18
31
32
33
34
35
11
1
2
3
4
5
12
13
14
15
31
32
33
34
35
21
22
23
24
25
11
1
2
3
4
5
12
13
14
15
1
36
37
38
21
22
23
24
25
26
27
28
1
11
12
13
14
15
16
2
3
4
5
6
2
3
4
1
2
3
4
X20
X45
X25
X35
X50
X7
1
2
3
4
X8
X9
1 2 3 4 5
X71
1 2 3 4 5
X81
1 2 3 4 5
X91
1
11 12 13 1415 16
2 3 4 5 6
1718
7 8
X29
4094605451
Terminal strip Name Function
X29/5 +24V_P Connection of safety-related 24V supply voltage
+24V supply for MOVIMOT®, (IN)
X29/6 0V24V_P Connection of safety-related 24V supply voltage
0V24 reference potential for MOVIMOT®, (IN)
X29/15 +24V_P Connection of safety-related 24V supply voltage
+24V supply for MOVIMOT®, (OUT)
X29/16 0V24V_P Connection of safety-related 24V supply voltage
0V24 reference potential for MOVIMOT®, (OUT)
X71/1, X71/4
X81/1, X81/4
X91/1, X91/4
0V24_MM Output of safety-related 24V supply voltage
0V24 reference potential MOVIMOT® 1 to 3
X71/5
X81/5
X91/5
+24V_MM Output of safety-related 24V supply voltage
+24V supply voltage MOVIMOT® 1 to 3
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5Electrical installation
Safety-related disconnection MOVIFIT®
Manual – Functional Safety
20
Wiring diagram MOVIFIT® MC for safety-related disconnection
MOVIFIT®-MC
5
6
+24V_P
0V24_P
X29
X1
X7 X8 X9 X71 X81 X91
MOVIMOT®1 MOVIMOT®2 MOVIMOT®3
[1]
[3]
[2]
24V
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
L1 L2 L3
9007203349479819
[1] External safety controller
[2] Line connection
[3] Hybrid cable
29157056/EN – 09/2019