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

SEW-EURODRIVE—Driving the world

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.

Manual – MOVIGEAR® B Functional Safety 11
3
Approved units
Safety Conditions
3 Safety Conditions
The requirement for safe operation is that the safety functions of MOVIGEAR®are prop-
erly integrated into an application-specific higher-level safety function. A system/ma-
chine-specific risk assessment must be carried out through the system/machine manu-
facturer and taken into account for the use of the drive system with MOVIGEAR®.
The system/machine manufacturer and the operator are responsible for compliance of
the system/machine with applicable safety regulations.
The following requirements are mandatory when installing and operating MOVIGEAR®
units in safety-related applications.
The requirements are divided into:
• Approved units
• Requirements on the installation
• Requirements on external safety controllers and safety relays
• Requirements on startup
• Requirements on operation
3.1 Approved units
Only the following unit variants of MOVIGEAR®are permitted for safety-related applica-
tions.
Permitted application options:
• GIO12A
• GIO13A
• GIO12B
• GIO13B
Type code
example
MG F A S 2- DSM SNI B/XX
Explana-
tion
Product
series
Gear
unit
type
Shaft
variant
Housing
mounting
type
Size Motor
type
Installation
technology
Ver-
sion
Op-
tions
Permitted
variants
MG F A
T
•
S
T
2
4
DSM SNI
DSC
DAC
DBC
B/ECR
/ET
/XT
/DSP
/IV
/EBW
/WA
/HA
/CA

12 Manual – MOVIGEAR® B Functional Safety
3Installation requirements
Safety Conditions
3.2 Installation requirements
• Power lines and STO control lines have to be routed in separate cables.
• The length of the cable from the safety controller to MOVIGEAR®must not exceed
100 m.
• The wiring technology used must comply with EN60204-1.
• The STO control lines must be routed according to EMC guidelines and as follows:
– Outside an electrical installation space: Shielded cables must be routed perma-
nently (fixed) and protected against external damage, or equivalent measures
have to be taken.
– Inside an electrical installation space: Individual conductors can be routed.
– Adhere to the regulations in force for the application.
• MOVIGEAR®does not detect short circuits in the supply line. Ensure that parasitic
voltages cannot be generated in the STO control lines.
• Observe the values specified for safety components when designing the safety cir-
cuits.
• The STO signal may not be used for feedback.
• Observe the notes in the MOVIGEAR®operating instructions for EMC-compliant in-
stallation.
It is important that the shielding of the STO control line is connected to the housing
at both ends.
• Only use grounded voltage sources with safe disconnection (PELV) according to
VDE 0100 and EN 60204-1 for all signal interfaces (SBus, binary inputs, binary out-
put, etc.) of MOVIGEAR®and all SBus stations.
In case of a single fault, the voltage between the outputs or between any output and
grounded parts must not exceed DC 60 V.
• When planning the installation, observe the technical data of MOVIGEAR®.
• Do not use the DC 24 V output of MOVIGEAR®for safety-related applications with
MOVIGEAR®.

Manual – MOVIGEAR® B Functional Safety 13
3
Installation requirements
Safety Conditions
• For safety-related applications with MOVIGEAR®, you have to remove the jumpers
labeled "Caution, remove jumper for safety operation", se following figures (jumpers
are not installed in unit variants with STO plug connectors X5502 and X5503):
WARNING
No safe disconnection of the MOVIGEAR®drive unit.
Severe or fatal injuries.
• Do not use the 24 V output for safety-related applications with MOVIGEAR®drive
units.
• You may only jumper the STO input with 24 V when the MOVIGEAR®drive unit
need not fulfill any safety function.
MOVIGEAR®DBC-B and DAC-B
Remove the jumpers between STO input (terminals 1/2) and 24 V output (terminals 6/7):
3152002955
MOVIGEAR®DSC-B and SNI-B
Remove the jumpers between STO input (terminals 1/2) and 24 V output (terminals 5/15):
3152004875
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
1.
2.
3.
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
1.
2.
3.
CAUTION
remove jumper
for safety operation

14 Manual – MOVIGEAR® B Functional Safety
3External safety controller requirements
Safety Conditions
3.3 External safety controller requirements
A safety relay can be used as an alternative to a safety controller. The following require-
ments apply analogously.
• The safety controller and all other safety-related subsystems must be approved and
tested for at least that safety class which is required in the overall system for the re-
spective, application-related safety function.
The following table shows an example of the required safety class of the safety con-
troller:
• The wiring of the safety controller must be suitable for the required safety class, (see
manufacturer documentation). The STO input of MOVIGEAR®requires 2-pole dis-
connection (P-M switching).
• The values specified for the safety controller must be strictly adhered to when de-
signing the circuit.
• The switching capacity of the safety relays or the relay outputs of the safety controller
must correspond at least to the maximally permitted, limited output current of the
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 manufacturer 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.
• To ensure protection against unintended restart in accordance with EN 1037, the
safe control system must be designed and connected in such a way that resetting the
control device alone does not lead to a restart. A restart may only be carried out after
a manual reset of the safety circuit.
Application Safety controller requirements
Performance level e according to
EN ISO 13849-1.
Performance level e according to
EN ISO 13849-1.
SIL 3 according to EN 61508
SIL 3 according to EN 62061 Performance level e according to
EN ISO 13849-1.
SIL 3 according to EN 61508

Manual – MOVIGEAR® B Functional Safety 15
3
External safety controller requirements
Safety Conditions
• Note the following for two-pole disconnection of MOVIGEAR®with tested, safe out-
puts:
– When disconnected, the switch-on test pulses may never occur at the plus and
minus output at the same time.
– When connected, the switch-off test pulses may not be longer than 1 ms. The next
pulse blanking cannot reoccur earlier than after 20 ms.
3.3.1 Sample circuit "safety relay"
The following figure shows the basic connection of an external safety relay (according
to the requirements listed above) to MOVIGEAR®.
The information in the respective manufacturer's data sheets must be observed for con-
nection.
9007201720642187
<1 ms >20 ms
t
High: no STO
Low: STO active
2466502411
[1] Safety relay with approval [4] STO signal
[2] DC 24 V voltage supply [5] Reset button for manual reset
[3] Fuses in accordance with the manufacturer's
specifications of the safety relay
[6] Permitted emergency stop actuating device
[4]
[3] [1]
[5]
[6]
[2] U

16 Manual – MOVIGEAR® B Functional Safety
3Startup requirements
Safety Conditions
3.4 Startup requirements
• To validate the implemented safety functions, they must be documented and
checked after successful startup (validation).
Observe the limitations for safety functions in chapter "Limitations" for the validation
of the safety functions. Non-safety-relevant parts and components that affect the re-
sult of the validation test must be deactivated, if necessary.
• For using MOVIGEAR®in safety-relevant applications, it is essential that you per-
form and record startup checks for the disconnecting device and correct wiring.
3.5 Operation requirements
• Operation is only allowed within the limits specified in the data sheets. This principle
applies to the external safety controller as well as to MOVIGEAR®and approved op-
tions.
• The built-in diagnostic function is limited in case of a permanently enabled or perma-
nently disabled STO input. Only when the STO signal is activated ("Low" to "High"),
extended diagnostic functions are performed. This means that the STO input must
be switched at least once in three months while the supply system is connected to
achieve a complete test coverage. Follow this test procedure:
• To achieve complete test coverage after a unit reset (e.g. after connecting the supply
system), the test transition (STO active →not active) can only be started min.
10 seconds later. The unit must (already) be signaling "ready for operation" or "STO
– safe torque off" and may not be in error state.
• A detected hardware fault in the internal switch-off channels for STO will lead to a
locking error state of MOVIGEAR®. When the error is reset (e.g. by switching the
power supply off and back on), a complete internal diagnostics test run must be per-
formed according to the above test procedure. If the error re-occurs, replace the unit
or contact SEW Service (for detailed information about possible error states, refer to
the respective MOVIGEAR®operating instructions).
2467673483
max. 3 months >500 ms >500 ms
High: no STO
Low: STO active
internal
diagnostics
internal
diagnostics
t

Manual – MOVIGEAR® B Functional Safety 17
4
Technical Data
4 Technical Data
The table below shows the technical data for MOVIGEAR®relating to the integrated
safety technology. The technical data and approvals in the respective MOVIGEAR®op-
erating instructions must be observed in addition.
Technical data of the STO input Min. Typical Max. Unit
Input voltage range −32430VDC
Input impedance 1000 Ohm
Switch-on/switch-off threshold 11 V
Input voltage for ON status (STO) 15 V
Input voltage for OFF status (STO) 5 V
Permitted leakage current of the external
safety controller
0 2mA
Required current for STO-IN supply 30 mA
Time from disconnecting the safety voltage
until the deactivation of the rotating field
420ms
Time from connecting the safety voltage until
the deactivation of the rotating field
220 300 ms
Test interval for STO function: See test proce-
dure in chapter "Operation requirements"
3Months
Safety characteristics
Approved safety classes SIL 3 according to IEC 61800-5-2
Performance level e according to EN ISO 13849-1.
Probability of a dangerous failure per hour
(= PFH value)
1.9 × 10−91/h
Service life 20 years, after which the component must be replaced
with a new one.
Safe condition Safe torque off (STO)
P
i
f
kVA
Hz
n

18 Manual – MOVIGEAR® B Functional Safety
5Unit variants with DynaStop®
Appendix
5 Appendix
5.1 Unit variants with DynaStop®
The optional DynaStop®function is not safety-related. It is not part of the safety func-
tions described in chapter "Integrated Safety Technology / Safety functions".
5.1.1 Using the DynaStop®function in connection with the STO function
To use the DynaStop®function in connection with the STO function, we recommend
control in line with SS1(c).
In connection with electronic variants DAC, DSC, and SNI, the parameter "8584.0
– Brake function" must be set to "1" for this purpose.
The following table shows the behavior of the DynaStop®function depending on the pa-
rameter setting:
WARNING
The electrodynamic deceleration function DynaStop®does not allow for a definite stop
at a position.
Severe or fatal injuries.
• Do not use the electrodynamic deceleration function for hoists.
•DynaStop
®may only be used for inclining tracks after a risk assessment.
Index Parameter/ setting Meaning
Electronic variant
DAC, DSC, SNI:
Electronic variant
DBC:
8584.0 Brake function
0 = OFF
The drive decelerates along the
set ramp. When the drive reaches
speed "0", DynaStop®is not acti-
vated.
The drive decelerates along the
set ramp. When the speed is "0",
DynaStop®is activated.
Brake function
1 = ON
The drive decelerates along the set ramp. When the speed is "0",
DynaStop®is activated.
9833.20 Activation of
DynaStop®for STO
0 = NO
The DynaStop®status remains unchanged when STO is triggered.
Activation of
DynaStop®for STO
1 = ON
DynaStop®is activated when STO is triggered.
Necessary setting in connection with electronic variants DAC, DSC, SNI
Recommended setting

Manual – MOVIGEAR® B Functional Safety 19
5
Unit variants with DynaStop®
Appendix
The following figure shows the use of the DynaStop®function in connection with the
STO function:
9007201718955403
[1] Parameter setting "8584.0 – Brake function": 1 = ON
(All variants)
[2] Factory setting of parameter "8584.0 – Brake function": 0 = OFF
(in connection with electronic variants DAC, DSC, SNI)
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
Deceleration
ramp
Speed
Drive enable
signal
Control signal
STO
DynaStop
®
active
inactive
t
t
1
tt
2
[1] [2]

20 Manual – MOVIGEAR® B Functional Safety
5Unit variants with DynaStop®
Appendix
5.1.2 Behavior when STO is activated before standstill
If STO is activated before the motor has come to a standstill, the DynaStop®function
behaves as set in parameter "9833.20 – Activation of DynaStop®for STO":
Parameter "9833.20 – Activation of DynaStop®for STO": 1 = Yes
• DynaStop®is activated when STO is triggered.
Parameter "9833.20 – Activation of DynaStop®for STO": 0 = No
(Factory setting / recommended setting)
The DynaStop®status remains unchanged when STO is triggered.
• Depending on the application, the motor coasts to a halt or even accelerates.
• The deceleration distance is not defined.
NOTICE
Depending on the setting in parameter "9833.20", the DynaStop®function can be ac-
tivated outside the permitted operating range.
This can cause a high torque load / high motor currents, which may damage the drive
unit and the application.
Possible damage to property
• Use the factory settings or recommended settings.