SEW-Eurodrive MOVIGEAR B User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Manual
Mechatronic Drive System
MOVIGEAR
®
B
Functional Safety
Edition 10/2012 19374410 / EN

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Manual – MOVIGEAR® B Functional Safety 3
Contents
Contents
1 General Information ............................................................................................ 4
1.1 How to use this documentation................................................................... 4
1.2 Underlying standards .................................................................................. 4
1.3 Structure of the safety notes ....................................................................... 4
1.4 Rights to claim under limited warranty ........................................................ 5
1.5 Exclusion of liability..................................................................................... 5
1.6 Content of the documentation..................................................................... 5
1.7 Other applicable documentation ................................................................. 5
1.8 Copyright..................................................................................................... 5
1.9 Product names and trademarks.................................................................. 5
2 Integrated Safety Technology............................................................................ 6
2.1 Safe condition ............................................................................................. 6
2.2 Safety concept ............................................................................................ 6
2.3 Safety functions .......................................................................................... 8
2.4 Restrictions ............................................................................................... 10
3 Safety Conditions.............................................................................................. 11
3.1 Approved units .......................................................................................... 11
3.2 Installation requirements........................................................................... 12
3.3 External safety controller requirements .................................................... 14
3.4 Startup requirements ................................................................................ 16
3.5 Operation requirements ............................................................................ 16
4 Technical Data................................................................................................... 17
5 Appendix............................................................................................................ 18
5.1 Unit variants with DynaStop®.................................................................... 18
5.2 Connection variants .................................................................................. 22
5.3 Connection of an external safety relay for STO ........................................ 28
5.4 Connection of an external safety controller for STO ................................. 32
Index................................................................................................................... 36

4Manual – MOVIGEAR® B Functional Safety
1How to use this documentation
General Information
1 General Information
1.1 How to use this documentation
This documentation is an integral part of the product and contains important information
on operation and service. The documentation is intended for all employees who perform
assembly, installation, startup and service work on the product.
The documentation must be kept accessible and legible. Ensure that persons responsi-
ble for the system and its operation, as well as persons who work independently on the
unit, have read through the entire documentation and have understood it. If you are un-
clear about any of the information in this documentation or require further information,
please contact SEW-EURODRIVE.
1.2 Underlying standards
The safety assessment of the unit is based on the following standards and safety
classes:
1.3 Structure of the safety notes
1.3.1 Meaning of the signal words
The following table shows the grading and meaning of the signal words for safety notes,
notes on potential risks of damage to property, and other notes.
1.3.2 Structure of the section-related safety notes
Section-related safety notes do not apply to a specific action, but to several actions per-
taining to one subject. The used symbols indicate either a general or a specific hazard.
This is the formal structure of a section-related safety note:
Underlying standards
Safety class / underlying standard • Performance level (PL) according to EN ISO 13849-1:2008
• Safety Integrity Level (SIL) according to EN 61800-5-2:2007
Signal word Meaning Consequences if disregarded
DANGER Imminent danger 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 drive system or its envi-
ronment
INFORMATION Useful information or tip: Simpli-
fies the handling of the drive
system.
SIGNAL WORD
Nature and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to avoid the danger.

Manual – MOVIGEAR® B Functional Safety 5
1
Rights to claim under limited warranty
General Information
1.3.3 Structure of the embedded safety notes
Embedded safety notes are directly integrated in the instructions just before the descrip-
tion of the dangerous action.
This is the formal structure of an embedded safety note:
•SIGNAL WORD Nature and source of danger.
Possible consequence(s) if disregarded.
– Measure(s) to avoid the danger.
1.4 Rights to claim under limited warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the instructions in the documentation. Read the documen-
tation before you start working with the unit.
1.5 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation and to achieve the specified product characteristics and performance fea-
tures. SEW-EURODRIVE assumes no liability for injury to persons or damage to equip-
ment or property resulting from non-observance of these operating instructions. In such
cases, any liability for defects is excluded.
1.6 Content of the documentation
This documentation contains additional safety-relevant information and conditions for
use in safety-related applications.
1.7 Other applicable documentation
This document supplements the operating instructions and limits the application notes
according to the following information. Use this document only together with the operat-
ing instructions.
1.8 Copyright
© 2012 – SEW-EURODRIVE. All rights reserved.
Copyright law prohibits the unauthorized reproduction, modification, distribution, and
use of this instruction manual, in whole or in part.
1.9 Product names and trademarks
All brands and product names in this documentation are trademarks or registered trade-
marks of their respective titleholders.

6Manual – MOVIGEAR® B Functional Safety
2Safe condition
Integrated Safety Technology
2 Integrated Safety Technology
The safety technology of MOVIGEAR®described below has been developed and tested
in accordance with the following safety requirements:
• SIL 3 according to EN 61800-5-2:2007
• PL e according to EN ISO 13849-1:2008
This was certified by TÜV Nord. Copies of the TÜV certificate and the corresponding re-
port are available from SEW-EURODRIVE on request.
2.1 Safe condition
For safety-related operation of MOVIGEAR®, safe torque off is defined as safe condition
(see STO safety function). The safety concept is based on this.
2.2 Safety concept
• The MOVIGEAR®drive unit can be connected to an external safety controller or
safety relay. This disconnects the safety-related STO input via 2-pole 24 V switching
signal (P-M switching) when a connected control device (e.g. emergency stop button
with latching function) is activated. This activates the STO function (safe disconnec-
tion) of MOVIGEAR®.
• An internal, dual-channel structure with diagnostics prevents the generation of pulse
trains at the power output stage (IGBT). On the one hand, the internal supply voltage
for controlling the upper and lower IGBTs is disconnected, and on the other hand the
controlling pulse patterns are short-circuited. This means that the output stage can
no longer supply power to the motor for generating torque.
• Instead of galvanic separation of the drive from the supply system by means of con-
tactors or switches, the disconnection of the STO input described here safely pre-
vents the control of the power semiconductors in the output stage. The rotary-field
generation for the respective motor is deactivated even though the line voltage is still
present.

Manual – MOVIGEAR® B Functional Safety 7
2
Safety concept
Integrated Safety Technology
2.2.1 Schematic representation "Safety concept for MOVIGEAR®"
The following figure shows a schematic representation of the safety concept for
MOVIGEAR®:
2463070859
[1] Safety controller/safety relay external
[2] Connection "STO+"
[3] Connection "STO-"
[4] Motor phase
[5] Motor
24V
Safety M
UZ-
UZ+
[1]
[2]
[3]
[4]
[5]
μC
HV
SNT SNT

8Manual – MOVIGEAR® B Functional Safety
2Safety functions
Integrated Safety Technology
2.3 Safety functions
The following drive-related safety functions can be used:
•STO (safe torque off according to IEC 61800-5-2) by disconnecting the STO input.
If the STO function is activated, the frequency inverter no longer supplies power to
the motor for generating torque. This safety function corresponds to a non-controlled
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 shows the STO function:
2463228171
v Velocity
tTime
t1Time at which STO is triggered
Disconnection range
v
t
t1

Manual – MOVIGEAR® B Functional Safety 9
2
Safety functions
Integrated Safety Technology
•SS1(c) (safe stop 1, function variant c according to IEC 61800-5-2) by means of suit-
able external control (e.g. safety relay with delayed disconnection)
The following sequence is mandatory:
– Decelerate the drive using an appropriate brake ramp specified via setpoints.
– 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:
2463226251
v Velocity
tTime
t1Point of time when the brake ramp is initiated
t2Point of time when STO is triggered
∆t Time between initiating the brake ramp and STO
Safe time delay range
Disconnection range
v
t
t1tt
2

10 Manual – MOVIGEAR® B Functional Safety
2Restrictions
Integrated Safety Technology
2.4 Restrictions
• MOVIGEAR®has no mechanical brake. This means coasting of the drive depends
on the application (subject to friction and mass moment of inertia of the system). In
case of regenerative loads, the drive can even accelerate. This must be taken into
account in a risk assessment of the system/machine. Additional safety measures
might have to be implemented (e.g. safety brake system).
→MOVIGEAR®cannot be used without an additional brake system for application-
specific safety functions that require active deceleration (braking) of the dangerous
movement.
• When using the SS1(c) function as described in chapter "Safety functions", the brake
ramp of the drive is not monitored with respect to safety. In case of a fault, the drive
might not be decelerated after the delay time, or it might be accelerated in the worst
case. In this case, the STO function (see chapter "Safety functions") is only activated
after the set time delay has elapsed. The resulting danger must be taken into account
in the risk assessment of the system/machine. Additional safety measures might
have to be implemented.
WARNING
The safety concept is only suitable for performing mechanical work on the system/ma-
chine components.
If the STO signal is disconnected, the supply system voltage is still present at the
MOVIGEAR®DC link.
Severe or fatal injuries from electric shock.
• Before working on the electric part of the drive system, disconnect it from the sup-
ply system using an appropriate external disconnecting device and secure it
against unintentional reconnection to the power supply.