SEW-Eurodrive DR Series Operating instructions

*30590876_0923*
Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Operating
Instructions
Safety Brakes
DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
Functional Safety
Edition 09/2023 30590876/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 About this documentation ...............................................................................................5
1.2 Other applicable documentation .....................................................................................5
1.3 Structure of the safety notes ...........................................................................................6
1.3.1 Meaning of signal words ................................................................................ 6
1.3.2 Structure of section-related safety notes........................................................ 6
1.3.3 Meaning of the hazard symbols ..................................................................... 6
1.3.4 Structure of embedded safety notes .............................................................. 6
1.4 Rights to claim under limited warranty ............................................................................7
1.5 Product names and trademarks......................................................................................7
1.6 Copyright notice ..............................................................................................................7
1.7 Content of the documentation.........................................................................................7
2 Safety notes .............................................................................................................................. 8
2.1 Preliminary information ...................................................................................................8
2.2 Designated use ...............................................................................................................8
2.2.1 Safety brakes ................................................................................................. 9
2.3 Inspection/maintenance................................................................................................10
3 Functional safety (FS) ............................................................................................................ 11
3.1 Functionally safe motor options ....................................................................................11
3.1.1 General ........................................................................................................ 11
3.1.2 Safety brakes ............................................................................................... 12
3.2 FS mark ........................................................................................................................12
3.3 Retraceability ................................................................................................................13
3.4 Underlying standards ....................................................................................................13
3.5 TÜV certification............................................................................................................13
3.6 Safety functions of the safety brake..............................................................................14
3.7 Brake test......................................................................................................................15
3.8 Motor combinations.......................................................................................................16
3.8.1 Safety brake ................................................................................................. 16
3.9 Acceptance ...................................................................................................................18
4 Motor structure ....................................................................................................................... 19
4.1 Nameplates...................................................................................................................19
4.1.1 Motor ............................................................................................................ 19
4.1.2 Safety brake ................................................................................................. 19
5 Mechanical installation .......................................................................................................... 20
5.1 General information ......................................................................................................20
5.2 Manual brake release ...................................................................................................20
6 Electrical installation.............................................................................................................. 21
6.1 Temperature sensor /TF ...............................................................................................21
6.2 Brake control.................................................................................................................21
6.3 Permitted brake controls ...............................................................................................21
7 Inspection/maintenance......................................................................................................... 22
30590876/EN – 09/2023

Table of Contents
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
4
7.1 Inspection and maintenance intervals...........................................................................22
7.1.1 Safety brake ................................................................................................. 22
7.2 Preliminary work for motor and brake maintenance .....................................................23
7.2.1 General information...................................................................................... 23
7.2.2 Wear parts.................................................................................................... 23
7.2.3 Order information for operating supplies and auxiliary material for
maintenance................................................................................................. 25
7.2.4 Drive with encoder/safety encoder............................................................... 25
7.3 Inspection of (E)DR..71 – 225, (E)DRN../DRU../DR2..63 – 225 brakemotors ..............26
7.3.1 Setting the working air gap of brakes BE05–BE32 .................................... 26
7.3.2 Measuring the wear of BE03 brakes ............................................................ 27
7.4 Brake replacement........................................................................................................28
7.5 Diagnostic unit /DUE and /DUB for function and wear monitoring................................28
7.5.1 Option /DUB ................................................................................................. 28
7.5.2 Option /DUE ................................................................................................. 28
7.5.3 DIP switch setting values for option /DUE.................................................... 29
8 Technical data......................................................................................................................... 30
8.1 Safety brakes ................................................................................................................30
8.1.1 Braking work until maintenance ................................................................... 30
8.1.2 Working air gap ............................................................................................ 31
8.1.3 Safety characteristics ................................................................................... 32
8.1.4 Combination of safety brake and brake control............................................ 33
9 Checklists................................................................................................................................ 35
9.1 Checklist for BE03 brake assembly ..............................................................................35
9.2 Checklist for BE05–32 brake assembly ......................................................................36
Index ........................................................................................................................................ 38
30590876/EN – 09/2023

1
General information
About this documentation
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 5
1 General information
1.1 About this documentation
The documentation at hand 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 Other applicable documentation
This addendum to the operating instructions contains special information on safety
brakes of the DR.., DRN.., DRU.., DR2.., EDR.., and EDRN.. motor series.
The corresponding documentation applies for all other components. Observe in partic-
ular the following documentation:
• "AC Motors" operating instructions
• "Explosion-Protected AC Motors" (ATEX or IECEx) operating instructions
• "Project Planning for BE.. Brakes" manual
• Addendum to the Operating Instructions "Built-in Encoders, Add-on Encoders, and
Safety Encoders"
30590876/EN – 09/2023

1General information
Structure of the safety notes
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
6
1.3 Structure of the safety notes
1.3.1 Meaning of signal words
The following table shows the graduation and meaning of the signal words in the
safety notes.
Signal word Meaning Consequences if not observed
DANGER Imminent danger Death or severe injuries
WARNING Possibly dangerous situation Death or severe injuries
CAUTION Possibly 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.
1.3.2 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.
1.3.3 Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
1.3.4 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous step.
This is the formal structure of an embedded safety note:
 SIGNAL WORD! Type and source of danger. Possible consequence(s) if disre-
garded. Measure(s) to prevent danger.
30590876/EN – 09/2023

1
General information
Rights to claim under limited warranty
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 7
1.4 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.
1.5 Product names and trademarks
The product names mentioned in this documentation are trademarks or registered
trademarks of the respective titleholders.
1.6 Copyright notice
©2023SEW‑EURODRIVE. All rights reserved. Copyright law prohibits the unautho-
rized reproduction, modification, distribution and use of this document – in whole or in
part.
1.7 Content of the documentation
This documentation contains additional safety-related information and conditions for
operation in safety-related applications.
30590876/EN – 09/2023

2Safety notes
Preliminary information
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
8
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 in-
tegrity level "SIL") of a system's safety functions, the system manufacturer must
perform an overall evaluation. This document contains the product-related specifi-
cations 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.
30590876/EN – 09/2023

2
Safety notes
Designated use
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 9
2.2.1 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).
30590876/EN – 09/2023

2Safety notes
Inspection/maintenance
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
10
2.3 Inspection/maintenance
The users can perform work themselves on a drive with functionally safe motor op-
tions (can be identified by the FS logo on the motor nameplate).
Any work on the safety encoder and/or the safety brake is carried out at your own risk.
The user is responsible and liable for the proper performance of the work described in
the corresponding documentation.
The user has to ensure the traceability of the work performed with regard to the func-
tional safety. In the event of proven compliance with the work described in the docu-
mentation, the characteristics regarding functional safety described by the manufactur-
er are maintained.
Use only genuine spare parts in accordance with the valid spare parts list.
30590876/EN – 09/2023

3
Functional safety (FS)
Functionally safe motor options
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 11
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.
30590876/EN – 09/2023

3Functional safety (FS)
FS mark
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
12
3.1.2 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.
3.2 FS mark
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 makes it possible to uniquely
identify an available functional safety 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 for 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.
30590876/EN – 09/2023

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 the safety brakes is based on the following standards and
safety classes:
IEC62061
IEC61508
IEC61800‑5‑2 ISO13849
BE.. – – X
Performance Levele (PLe) safety class can be achieved if a functionally safe motor
option is suitably integrated into a safety system. The requirements (e.g. on the sys-
tem architecture, required diagnostics, and failure probabilities) are to be implemented
according to the normative specifications and to the documentation in hand. If the
safety system with safety brakes is to be evaluated in accordance with SIL, the neces-
sary 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.
30590876/EN – 09/2023

3Functional safety (FS)
Safety functions of the safety brake
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
14
3.6 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 (Safe Brake Control) and STO (Safe Torque Off) 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.
30590876/EN – 09/2023

3
Functional safety (FS)
Brake test
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 15
3.7 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.
INFORMATION
SEW‑EURODRIVE offers various types of brake tests. With these brake tests, safety
functions up to Performance Levele can be implemented with brakes in horizontal
and vertical applications.
30590876/EN – 09/2023

3Functional safety (FS)
Motor combinations
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
16
3.8 Motor combinations
3.8.1 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../
DR2.. 56 63 71 80 90 100 112
132S
132M
132L
160
180
200
225
250
280 315
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
BE32 X X
BE60 X X
BE62 X X
BE120 X X
BE122 X X
XCombination available
Optionally available as safety brake
30590876/EN – 09/2023

3
Functional safety (FS)
Motor combinations
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 17
Braking torque graduations
Depending on the brake requirements, various braking torque graduations are avail-
able to suit different brake sizes.
The following table shows the available graduations:
Brake (MBmax) BE03
(3.4Nm)
BE05
(5Nm)
BE1
(10Nm)
BE2
(20Nm)
BE5
(55Nm)
BE11
(110Nm)
BE20
(200Nm)
Available
graduations for
MB
0.9 X
1.3 X
1.7 X
1.8 X
2.1 X
2.5 X
2.7 X
3.4 X
3.5 X
5XXX
7X X
10 X X
14 X X
20 XXX
28 X X
40 XXX
55 XXX
80 X X
110 X X
150 X
200 X
Brake (MBmax) BE30
(300Nm)
BE32
(600Nm)
Available
graduations
for MB
75 X
100 X X
150 X X
200 X X
300 X X
400 X
500 X
600 X
XAvailable
XNot available for BE.. safety brake.
INFORMATION
Please not that for the BE.. safety brake, some of the reduced braking torque gradu-
ations are not available in combination with the manual brake release option. Contact
SEW‑EURODRIVE, if necessary.
30590876/EN – 09/2023

3Functional safety (FS)
Acceptance
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
18
3.9 Acceptance
The system manufacturer has to perform an overall evaluation for determining the
safety of a machine.
The effectiveness of each risk minimization must be checked. It must also be checked
if the required safety integrity is reached for each implemented safety function.
To validate the safety integrity level you can use the "SISTEMA" calculation tool from
the Institut für Arbeitsschutz (Institute for Occupational Safety and Health of the Ger-
man Social Accident Insurance).
30590876/EN – 09/2023

4
Motor structure
Nameplates
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors 19
4 Motor structure
4.1 Nameplates
4.1.1 Motor
The following figure shows an example motor nameplate with FS logo:
η100%
87.8%
76646 Bruchsal/Germany
η75%
88.3%
η50%
87.3%
RF87 DRN100L4/BE5HR/TF/EK8S
01.41027997609.0001.21
Made in Germany
Inverter duty VPWM 3 ~IEC60034
Hz 50 r/min 1456/52 V 230/400Δ/Y
kW 3 S1 A 11.2/6.4 IE3
Cos φ 0.76
Th.Kl. 130(B)
IP 54
Jahr 2021
i 27.88
kg 106.076
CLP 220 Miner.Öl/2.3 l
188 578 2
°C -20..40
Vbr 400 AC
Nm 55 IM M1 Nm 40
BST0.7S
11
[1]
[2]
36067931403
[1] Motor serial number
[2] FS logo for functional safety
4.1.2 Safety brake
The following figure shows an example self-adhesive label of a safety brake with FS
mark:
BE20
MN: 12345678901234
Use only with SEW-Rectifier
ID: 0001.123456789012.160112
[1]
[2]
[3]
[4] [5]
9007203740398475
[1] Identification number of the brake:
• 0001.: Plant
• 123456789012.: Serial number of the brake
• 160112: Date of production (DDMMYY)
[2] Assembly order number
[3] Brake and brake size
[4] Data matrix
[5] FS mark
The design as a safety brake is marked on the motor nameplate, see chapter "FS
mark".
30590876/EN – 09/2023

5Mechanical installation
General information
Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors
20
5 Mechanical installation
5.1 General information
INFORMATION
Note that greases and oils must not be allowed on the mechanical connections of the
safety components during assembly or operation.
5.2 Manual brake release
If the manual brake release was ordered, the manual brake release is installed and set
at the factory.
INFORMATION
The brake option manual brake release/HF is not permitted and must not be retrofit-
ted.
The manual brake release/HR must not be retrofitted, see corresponding operating
instructions.
30590876/EN – 09/2023