SEW-Eurodrive DR Series Operating instructions

*27777383_1221*
Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Operating
Instructions
Safety Encoders and Safety Brakes
DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
Functional Safety
Edition 12/2021 27777383/EN


SEW-EURODRIVE—Driving the world

Table of contents
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 3
Table of contents
1 General information.................................................................................................................. 5
1.1 How to use this documentation.......................................................................................5
1.2 Content of the documentation.........................................................................................5
1.3 Other applicable documentation .....................................................................................5
2 Safety notes .............................................................................................................................. 6
2.1 Preliminary information ...................................................................................................6
2.2 Designated use ...............................................................................................................6
2.3 Inspection/maintenance..................................................................................................9
3 Functional safety (FS) ............................................................................................................ 10
3.1 Functionally safe motor options ....................................................................................10
3.2 FS mark ........................................................................................................................12
3.3 Retraceability ................................................................................................................13
3.4 Underlying standards ....................................................................................................13
3.5 TÜV certification............................................................................................................13
3.6 Safety functions ............................................................................................................14
3.7 Initializing the safety encoder........................................................................................15
3.8 Requirements for the follow-up electronics...................................................................16
3.9 Brake test......................................................................................................................18
3.10 Motor combinations.......................................................................................................19
3.11 Acceptance ...................................................................................................................23
4 Motor structure ....................................................................................................................... 24
4.1 Nameplates...................................................................................................................24
5 Mechanical installation .......................................................................................................... 26
5.1 General information ......................................................................................................26
5.2 Manual brake release ...................................................................................................26
6 Electrical installation.............................................................................................................. 27
6.1 General information ......................................................................................................27
6.2 Temperature sensor /TF ...............................................................................................27
6.3 Brake control.................................................................................................................28
6.4 Permitted brake controls ...............................................................................................28
7 Inspection/maintenance......................................................................................................... 29
7.1 Inspection and maintenance intervals...........................................................................29
7.2 Removing/installing the encoder...................................................................................31
7.3 Measuring wobbling ......................................................................................................33
7.4 Preliminary work for motor and brake maintenance .....................................................35
7.5 Inspection of (E)DR..71 – 225, (E)DRN../DRU../DR2..63 – 225 brakemotors ..............36
7.6 Brake replacement........................................................................................................39
7.7 Diagnostic unit /DUE and /DUB for function and wear monitoring................................39
8 Technical data......................................................................................................................... 41
8.1 Safety encoders ............................................................................................................41
8.2 Safety brakes ................................................................................................................44
27777383/EN – 12/2021

Table of contents
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
4
9 Checklists................................................................................................................................ 50
9.1 Checklist for encoder assembly ....................................................................................50
9.2 Checklist for BE03 brake assembly ..............................................................................52
9.3 Checklist for BE05–32 brake assembly ......................................................................53
Index ........................................................................................................................................ 55
10 Glossary .................................................................................................................................. 56
27777383/EN – 12/2021

1
General information
How to use this documentation
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 5
1 General information
1.1 How to use this documentation
This addendum to the operating instructions contains special information on function-
ally safe motor options (safety encoder and safety brake) of the DR.., DRN.., DRU..,
DR2.., EDR.., and EDRN.. motor series.
In addition to the addendum to the operating instructions at hand, the following operat-
ing instructions apply for motors with safety encoders and/or safety brakes:
•AC motors with safety encoder and/or safety brake
– Operating instructions "DR..71–315, DRN63–315, DR2..56–80 AC Motors"
– Operating instructions "DR.. 56 – 315 AC Motors"
•Explosion-protected AC motors with safety encoder and/or safety brake
– Operating instructions "Explosion-Protected EDR..71 – 315 AC Motors,
EDRN63 – 315 – ATEX" or operating instructions "Explosion-Protected
EDR..71 – 315 AC Motors, EDRN63–315 – IECEx"
This documentation is an integral part of the product and contains important informa-
tion on operation and service. The documentation is intended for all employees who
assemble, install, start up, and service this 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.
Make sure you always use the latest documentation and software version.
1.2 Content of the documentation
This documentation contains additional safety-related information and conditions for
operation in safety-related applications.
1.3 Other applicable documentation
The following documentations and documents are to be observed as well:
• Addendum to the operating instructions "Built-in Encoders and Add-on Encoders -
DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC motors - Integrated, Tapered Shaft,
Spread Shaft, Plug-in Shaft, Hollow Shaft, Encoder Mounting Adapters"
• Manual "Project Planning for BE.. Brake – DR.., DRN.., DRU.., DR2.., EDR..,
EDRN.. AC Motors – Standard Brake/Safety Brake"
• Catalog "DR.. AC Motors"
• Catalog "DRN – DR2.. AC Motors"
27777383/EN – 12/2021

2Safety notes
Preliminary information
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
6
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Designated use
• DR.., DRN.., DRU.., DR2.., EDR.., and EDRN.. motors with functionally safe motor
options are intended for industrial systems.
• When installed in machines, start of the designated operation is prohibited until it is
determined that the machine complies with the local laws and directives. The Ma-
chinery Directive 2006/42/EC is valid for the respective area of application.
• In order to determine the safety integrity (performance level PL and/or safety inte-
grity level SIL) of a system's safety functions, the system manufacturer must per-
form an overall evaluation. This document contains the product-related specifica-
tions necessary for the evaluation.
• Operation of DR.., DRN.., DRU.., DR2.., EDR.., and EDRN.. motors with function-
ally safe motor options on third-party inverters is permitted.
• Before starting the designated use, make sure that the system complies with the
specifications of this documentation, and in particular the technical data.
27777383/EN – 12/2021

2
Safety notes
Designated use
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 7
2.2.1 Safety encoders
• The safety encoders described in this documentation are intended for use with
DR.., DRN.., DRU.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount
them on other motors.
• When using a safety encoder in combination with a BE.. brake, the brake may only
be used as a holding brake. Braking during operation is not permitted. The desig-
nated use of the brake is to activate the brake at standstill (brake application
speed < 20 min-1). Emergency stops from higher motor speeds are permitted.
SEW‑EURODRIVE recommends stopping the drive with stop category1 in accor-
dance with EN60204-1.
• Operation of the safety encoders is permitted at ambient temperatures of -30°C to
+60°C.
• The safety encoders are rated for the following installation altitudes:
– ES7S, AS7W, AS7Y: 4000m above sea level
– EG7S, AG7W, AG7Y: 4000m above sea level
– EK8S, AK8W, AK8Y: 4000m above sea level
– EI7C FS: 3800m above sea level
Installation altitudes that deviate from these and derating of the drives or frequency
inverters must be noted.
• For AS7W, AG7W, AS7Y, AG7Y, AK8Y and AK8W safety encoders, the incre-
mental interface is part of the PL d/SIL 2 approval.
• For AS7W, AG7W, AS7Y, AG7Y, AK8Y and AK8W safety encoders, the absolute
interface is not part of the PL d/SIL 2 approval. The multi-turn absolute interface
may not be used solely for implementing safety functions.
• SEW‑EURODRIVE recommends activating the monitoring functions lag error,
speed, and encoder monitoring when configuring the inverter.
• The safety encoders described in this documentation are not capable of indepen-
dently bringing about a safe state in the machine.
• In the event of a failure or malfunction of the safety encoder, injury and damage to
the system or operating equipment must be prevented by means of suitable mea-
sures taken in the overall system.
• Protection against unintentional or automatic restarting of the machine must be en-
sured in the overall system, if necessary.
• The safety encoders described in this documentation are intended to be used in
functional safety and are mounted on the drive. Fault exclusion in compliance with
EN 61800‑5‑2 can be assumed on the mounting of the safety encoder.
• Motors with a safety encoder are not suitable for operation in areas with increased
vibration stress of level 1 (vibration level 1).
27777383/EN – 12/2021

2Safety notes
Designated use
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
8
2.2.2 Safety brakes
• The safety brakes described in this documentation are intended for use with DR..,
DRN.., DRU.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them
on other motors.
• When using an AC motor in combination with a BE.. safety brake, the safety brake
may be used only as a holding brake. The designated use is to activate the brake
at an idle state (brake application speed<20min-1). Emergency stops from higher
motor speeds are permitted.
SEW‑EURODRIVE recommends stopping the drive with stop category1 in accor-
dance with EN60204‑1.
• The BE.. safety brake may only be used at an ambient temperature of
-20°Cto+40°C.
• The BE.. safety brake is rated for an installation altitude of up to 1000m above sea
level.
• The number of emergency stop braking operations must be limited to avoid over-
loading the safety brake and gear unit. The maximum number of emergency stop
braking operations is configured during project planning.
• There must be a pause between 2 emergency stop braking operations to prevent
overheating of the friction system. The required length of the pause is configured
for the safety brake during project planning.
• When dimensioning the BE.. safety brake, observe the valid project planning spe-
cifications and the resulting application limits of SEW‑EURODRIVE. If the applica-
tion requirements or technical properties of the BE.. safety brake change, project
planning and a check of the application limits must be performed again.
• It is not permitted to retrofit the BE.. safety brake or to replace an existing BE..
brake with a BE.. safety brake.
• The BE.. safety brake must not be exposed to the following substances/conditions:
– Oils
– Acids
– Gases
– Vapors
– Radiation
• Motors with a BE.. safety brake are not suitable for operation in areas with in-
creased vibration stress of level 1 (vibration level1).
27777383/EN – 12/2021

2
Safety notes
Inspection/maintenance
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 9
2.3 Inspection/maintenance
Work on a drive with functionally safe motor options – indicated by the FS logo on the
motor nameplate – can be performed by the operator.
Any work on the safety encoder and/or the safety brake is carried out at your own risk.
The operator is responsible and liable for the proper fulfillment of the work described
in the relevant documentation.
The operator has to ensure the traceability of the performed work regarding functional
safety. In case of proven compliance with the work described in the operating instruc-
tions, the characteristics regarding functional safety described by the manufacturer are
maintained.
Use only genuine spare parts in accordance with the valid parts list for maintenance
purposes.
27777383/EN – 12/2021

3Functional safety (FS)
Functionally safe motor options
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
10
3 Functional safety (FS)
3.1 Functionally safe motor options
Drives from SEW‑EURODRIVE are also optionally available with functionally safe mo-
tor options. These options are intended for implementation of safety functions in
safety-relevant applications.
SEW‑EURODRIVE assumes responsibility for the delivered drive in terms of compli-
ance of the functionally safe motor options with the functional safety regulations.
Safety-relevant connecting elements are marked as follows:
• Safety encoder: Retaining ring or adhesive label
• Safety brake: Locking compound
The markings are tamper-proof. If these markings are damaged, there is a deviation
from the delivery state.
3.1.1 General
When implementing safety functions in machines, it is necessary to evaluate in partic-
ular whether the used components are suitable for performing a specific safety func-
tion. When using functionally safe motor options from SEW‑EURODRIVE, the follow-
ing safety-related requirements, e.g. in accordance with ISO 13849 – parts 1 and 2,
are already taken into account:
• Application of basic safety principles
• Application of proven safety principles
• Specifications on failure probability (B10D, MTTFD, or PFHD)
• Common Cause Failure (CCF)
• Determination of the category (Cat.)
• Production monitoring with 100% final inspection
• Retraceability by the unique motor assignment
• Notice of influences and ambient conditions
• Compliance with normative requirements regarding documentation
As an advantage for the machine designer, SEW‑EURODRIVE has already fulfilled
these safety-relevant requirements for functionally safe motor options. In the overall
analysis of safety technology, the machine designer can rely on the manufacturer's
confirmation, e.g. based on the product documentation or the German Technical In-
spection Association (TÜV) certificate. The internal effort required for evaluation and
documentation is reduced considerably.
If other components (standard components) are used for implementing safety func-
tions, the machine designer has to evaluate the safety-related requirements.
27777383/EN – 12/2021

3
Functional safety (FS)
Functionally safe motor options
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 11
3.1.2 Safety encoders
Safety encoders from SEW‑EURODRIVE are characterized by their exceptional reli-
ability as well as electronic and mechanical load capacity.
Safety encoders allow you to improve the safety of your machines by implementing
safety functions in relation to their speed, direction of rotation, idle state, relative posi-
tion or absolute position. The safety encoder provides the safety-relevant signals in
the intelligent interaction of sensor, control and actuator.
The safety function requires a reliable mechanical connection between encoder and
motor. At SEW‑EURODRIVE, this connection is dimensioned in such a way that fault
exclusion is achieved.
The safety encoders cannot trigger a safe state at the machine autonomously. There-
fore, they have to be monitored in the overall system. In case the encoder or the fol-
low-up electronics detects a fault, a fault response is initiated in the overall system,
such as safe state.
3.1.3 Safety brakes
Safety brakes from SEW‑EURODRIVE are characterized by their exceptional reliabil-
ity as well as electronic and mechanical load capacity.
Safety brakes allow you to increase the safety in your machines by implementing
safety functions for deceleration and stopping. The safety brake represents the safety-
relevant actuator in the intelligent interaction of sensor, control, and actuator.
The safety brakes cannot trigger a safe state at the machine autonomously. The
brakes must be augmented in the overall system with suitable brake control and mon-
itored by means of a brake test, if necessary. The overall system triggers a suitable
error response, e.g. the safe state, on request.
27777383/EN – 12/2021

3Functional safety (FS)
FS mark
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
12
3.2 FS mark
Motors from SEW‑EURODRIVE are optionally available with functionally safe motor
options. These are designed for implementing safety functions.
The documentation designates the respective functional safety design explicitly as
safety encoder plus "type designation" or safety brake plus "type designation".
SEW‑EURODRIVE labels a functionally safe motor option at the drive with an FS logo
and a 2-digit number on the motor nameplate. The number is a code that indicates
which components in the drive are safety-related. This allows to uniquely identify an
available functionally safe motor option via the motor nameplate.
FS logo Available functionally safe motor option
Decentralized in-
verters
Safety brake Safety encoder
01
X
02
X
04
X
07
X X
11
X X
If the FS logo, e.g. with the code "FS 11" is present on the motor nameplate, the com-
bination of safety encoder and safety brake is available at the motor. Drives can also
be equipped with two encoders, e.g. built-in encoder and add-on encoder. In such
cases, the FS logo for the safety encoder always relates to the add-on encoder. If an
FS logo is available, adhere to the information specified in the corresponding docu-
mentation.
27777383/EN – 12/2021

3
Functional safety (FS)
Retraceability
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 13
3.3 Retraceability
Functionally safe motor options can be retraced by SEW‑EURODRIVE with the motor
serial number and thus have a unique assignment to the motor.
If the SEW‑EURODRIVE service replaces a safety encoder or a safety brake, the re-
traceability is ensured.
If you replace a functionally safe motor option on your own, you revoke this assign-
ment. To continue the assignment, document the replacement yourself.
3.4 Underlying standards
The safety assessment of safe motor options is based on the following standards and
safety classes:
Safety encoder
IEC61508
(SIL2)
IEC 62061
(SILCL2)
IEC 61800‑5‑2 ISO13849
(PLd)
ES7S
EG7S X X – X
AS7W
AG7W X X – X
AS7Y
AG7Y X X – X
EK8S
AK8W
AK8Y
X X – X
EI7C FS – – X X
Safety brake
IEC61508
(SIL2)
IEC62061
(SILCL2)
IEC61800‑5‑2 ISO13849
(Cat.1)
BE.. – – – X
Safety class SIL3 or PLe can be achieved if a suitable functionally safe motor option
is integrated into a safety system. The requirements (e.g. on the system architecture,
required diagnostics and failure probabilities) are to be implemented according to the
normative specifications and to the document in hand. If the safety system is to be
evaluated in accordance with SIL, the necessary verification must be provided by the
customer.
3.5 TÜV certification
The following certificate is available for the described safety brakes:
• Certificate of TÜVNORDSystems GmbH & Co. KG
A copy of the TÜV certificate can be obtained from SEW-EURODRIVE.
27777383/EN – 12/2021

3Functional safety (FS)
Safety functions
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
14
3.6 Safety functions
3.6.1 Safety functions of the safety encoder
INFORMATION
For AK8W, AS7W, AG7W, AK8Y, AS7Y and AG7Y encoders, the multi-turn absolute
interface is not part of the PL d/SIL 2 approval. The absolute interface may not be
used solely for implementing safety functions.
Safety encoders can be used to implement the following safety functions in compli-
ance with IEC 61800-5-2 with respect to speed, direction of rotation, idle state, and re-
lative position:
En-
coder
SS11) SS21) SOS1) SLA1) SLS1) SDI1) SLI1) SSR1) SAR1) SSM1)
ES7SXXXXXXXXXX
EG7SXXXXXXXXXX
AS7WXXXXXXXXXX
AG7WXXXXXXXXXX
AS7YXXXXXXXXXX
AG7YXXXXXXXXXX
EK8SXXXXXXXXXX
AK8WXXXXXXXXXX
AK8YXXXXXXXXXX
EI7C FS X – – – X X – – – –
1) You will find the exact meaning in the glossary.
Safety encoders can be used to implement the following safety functions in compli-
ance with IEC61800-5-2 with respect to the absolute position:
Encoder SCA1) SLP1)
ES7S2) X X
EG7S2) X X
AS7W2) X X
AG7W2) X X
AS7Y2) X X
AG7Y2) X X
EK8S2) X X
AK8W2) X X
AK8Y2) X X
EI7C FS – –
1) You will find the exact meaning in the glossary.
2) The safety function is dependent on the follow-up electronics.
27777383/EN – 12/2021

3
Functional safety (FS)
Initializing the safety encoder
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 15
3.6.2 Safety functions of the safety brake
The implementation of a safety function with brakes requires that the brake be applied
on request. The safety function is activated when the brake is applied. The brake coil
has to be de-energized and the energy stored in the brake coil reduced.
By adding a safety brake to a safe overall system, the following safety functions can
be implemented:
• SBA (Safe Brake Actuation)
• SBH (Safe Brake Hold)
INFORMATION
Safety functions SBA and SBH are defined by SEW‑EURODRIVE based on the stan-
dard EN61800‑5-2.
The implementation of the SBA and SBH safety functions additionally require the
safety functions SBC and STO in the overall system. For safety-related requests of
the brake, SBC and STO ensure that the brake applies and that the drive does not
generate a torque against the applied brake.
The SBC and STO safety functions are not part of the brake and have to be addition-
ally implemented in the overall safety system. The performance level (PL) of the SBC
and STO safety functions must at least meet the required performance level (PLr) of
the application.
SEW‑EURODRIVE recommends to stop the drive using the stop category1 accord-
ing to EN60204‑1 prior to activating the SBC and STO safety functions.
3.7 Initializing the safety encoder
Switch the safety encoder off and on again at least once a year in accordance with
ENISO61800‑5-2.
27777383/EN – 12/2021

3Functional safety (FS)
Requirements for the follow-up electronics
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
16
3.8 Requirements for the follow-up electronics
Where safety encoders are used for safety-related reasons, follow-up electronics are
needed to monitor the signals of the rotary encoder and check their validity. When a
malfunction is detected, a fault response (e.g. the safe state) must be triggered in the
overall system.
The follow-up electronics in the overall system have to meet the following require-
ments:
3.8.1 Add-on encoders: ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y
Designation Requirement
Safety requirements ≥ SIL 2
Diagnostic coverage (DC) ≥ 90%
Error presumptions According to IEC61800-5-2:2016, table
D.8
Monitoring of the phasor length "r"
r a b= +
2 2
with
a = A – A for cosine signals and
b = B – B for sine signals
Safe state Phasor length "r" outside of the range
350mV ≤ r ≤ 700mV
Terminating resistance between A and A
or B and B
120Ω ±10%
A
A120
Ω
a
B
B120
Ω
b
Terminating resistance between A, A, B,
B to the supply voltage and reference
ground
> 1kΩ
Scanning frequency At least twice as high as the frequency
maximally occurring in the application at
the encoder signal outputs (Nyquist cri-
terion)
If the safety encoders are operated with prefabricated encoder cables from
SEW‑EURODRIVE at follow-up electronics from SEW‑EURODRIVE, these previously
mentioned requirements have been met.
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3
Functional safety (FS)
Requirements for the follow-up electronics
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 17
3.8.2 Add-on encoders: EK8S, AK8W, AK8Y
Designation Requirement
Safety requirements ≥ SIL 2
Diagnostic coverage (DC) ≥ 90%
Error presumptions According to IEC61800-5-2:2016, table
D.8
Monitoring of the phasor length "r"
r a b= +
2 2
with
a = A – A for cosine signals and
b = B – B for sine signals
Safe state Phasor length "r" outside of the range
350mV ≤ r ≤ 700mV
Terminating resistance between A and A
or B and B
120Ω ±10%
A
A120
Ω
a
B
B120
Ω
b
Terminating resistance between A, A, B,
B to the supply voltage and reference
ground
> 1kΩ
Scanning frequency For the frequency maximally occurring in
the application at the encoder signal out-
puts, the following sampling frequency
must be met:
• minimum 8times with synchronous
sampling
• minimum 5times with asynchronous
sampling
The risk of an undetected fault at the safety encoder is increased if the sampling fre-
quency is not adhered to. If you cannot adhere to the required sampling frequency
when using the follow-up electronics, contact the manufacturer of the follow-up elec-
tronics to clarify any additional diagnostics.
If the safety encoders are operated with prefabricated encoder cables from
SEW‑EURODRIVE at follow-up electronics from SEW‑EURODRIVE, these previously
mentioned requirements have been met.
3.8.3 Built-in encoders: EI7C FS
The built-in encoder EI7C FS is intended for operation with functionally safe encoder
evaluation units from SEW‑EURODRIVE, e.g. safety option S12 or safety card
MOVISAFE® CS..A. Operating the encoder with encoder evaluation units from other
manufacturers is not permitted.
27777383/EN – 12/2021

3Functional safety (FS)
Brake test
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
18
3.9 Brake test
In applications with brakes, the braking torque represents an important criterion for the
functional and performance capability of the brake. If the braking torque is reduced or
lost, the functionality of the application, the safety of the machine, and/or personal
safety can be limited. To check the functional and performance capability of a brake,
you can integrate a brake test into the overall system.
Especially for safety-related applications in which the brake performs a safety function,
a brake test for the brake may be required by one or more standards, e.g. by
ISO13849-1. The brake test is not an independent safety function but supplements a
higher-level safety system for brake testing which is required by the standards. The
overall system must meet the diagnostic coverage (DC) required by the standards.
A brake test provides you with information about the functional and performance cap-
ability of the brake. Potential faults or functional limitations can be detected at an early
stage, allowing the necessary maintenance and repair work to be initiated. In a brake
system with multiple brakes, each brake must be tested separately. This ensures that
the safety function is maintained even if one brake fails.
The functional and performance capability of a brake can be adversely affected by a
multitude of potential faults. To summarize, the potential faults can appear in one of
the following fault patterns:
Fault pattern Effect of fault
Brake remains applied Safe state
Brake remains open Dangerous state
Insufficient braking torque Dangerous state
Brake does not release fully Dangerous state
CAUTION
Undesired movements of the machine during a brake test due to damaged brake or
brake control.
Injury to persons and damage to property.
• During the implementation and performance of a brake test, ensure that the
safety of persons and the machine is guaranteed.
27777383/EN – 12/2021

3
Functional safety (FS)
Motor combinations
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 19
3.10 Motor combinations
3.10.1 Safety encoders
The safety encoders described below are intended for use with DR.., DRN.., DRU..,
DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors.
Safety encoders on DR.., DRN.., DRU.., DR2.. AC motors
INFORMATION
A built-in encoder with an add-on encoder, designed as a safety encoder, can also be
combined at the drive, e.g. encoder EI7C + safety encoder EK8S. Only the add-on
encoder can be selected as the safety encoder in such combinations. The FS logo on
the motor nameplate will then relate to the add-on encoder as the safety encoder.
Motors Encoder Part number
without with
connection cover
DR..71 – DR..132
DRN80–DRN132S
ES7S 13642715 13642898
AS7W 13643878 13643916
AS7Y 13643851 13643908
DR..160–DR..280
DRN132M–DRN280
EG7S 13642782 13642952
AG7W1) 13643886 13643924
AG7Y1) 13643894 13643932
1) For motor design with brake/safety brake, the AG7W/AG7Y encoders are available up to size DR../
DRN225.
Motors En-
coder1)
Part number
DR2..71–DR2..315
DRU..71–DRU..315
DRN..71–DRN..315
EK8S 21018464
AK8W 21018502
AK8Y 21018499
1) Size DRN../DRU..255 or DR2.180 or larger only permitted with insulation coupling /IK
Motors Encoder Part number
DR..71–DR..132
DRN..71–DRN..315
DRU..71 – DRU..315
DR2..71–DR2..315
EI7C FS Ordering with part number not possible
27777383/EN – 12/2021

3Functional safety (FS)
Motor combinations
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
20
Safety encoders on EDR.., EDRN.. explosion-protected AC motors
Motors En-
coders
Part number
without with
connection cover
EDR..71–EDR..132
EDRN80–EDRN132S
ES7S 13642715 13642898
AS7W 13643878 13643916
AS7Y 13643851 13643908
EDR..160–EDR..280
EDRN132M–EDRN280
EG7S 13642782 13642952
AG7W1) 13643886 13643924
AG7Y1) 13643894 13643932
1) For motor design with brake/safety brake, the AG7W/AG7Y encoders are available up to size EDR../
EDRN225.
Motors En-
coder1)
Part number
EDRN71–EDRN315 EK8S 21018464
AK8W 21018502
AK8Y 21018499
1) Size EDRN225 or larger only permitted with insulation coupling /IK.
3.10.2 Safety brake
Motor combinations with BE.. brake
Different brake sizes and braking torque steps are available for the various motor
series.
The following tables show the possible combinations of motor and brakes as well as
the available braking torque steps:
(E)DR.. – – 71 80 – 90
100
112
132 160 180 200 225
250
280 315
(E)DRN../DRU.. – 63 71 80 90 100 112
132S
132M
132L
160
180
200
225
250
280 315
DR2.. 56 63 71 80 90 100 112
132S
132M
132L
160
180
200
225 – –
BE02 X
BE03 X X
BE05 XXX
BE1 X X X X
BE2 X X X
BE5 X X X
BE11 X X
BE20 X X
BE30 X X
27777383/EN – 12/2021