SEW-Eurodrive Movidrive MDX60B User manual

*27778037_0122*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIDRIVE® MDX60B/61B Functional Safety
Edition 01/2022 27778037/EN

SEW-EURODRIVE—Driving the world

Contents
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 3
Contents
1 General information.................................................................................................................. 5
1.1 About this documentation ...............................................................................................5
1.2 Underlying standards ......................................................................................................5
1.3 Structure of the safety notes ...........................................................................................5
1.3.1 Meaning of signal words ................................................................................ 5
1.3.2 Structure of section-related safety notes........................................................ 6
1.3.3 Structure of embedded safety notes .............................................................. 6
1.4 Rights to claim under limited warranty ............................................................................6
1.5 Decimal separator in numerical values ...........................................................................6
1.6 Copyright notice ..............................................................................................................7
1.7 Document content...........................................................................................................7
1.8 Other applicable documentation .....................................................................................7
2 Integrated safety technology................................................................................................... 8
2.1 General ...........................................................................................................................8
2.2 Safe condition .................................................................................................................8
2.3 Safety concept ................................................................................................................8
2.4 Schematic representation "Safety concept for MOVIDRIVE®B" ...................................9
2.5 Safety subfunctions.......................................................................................................10
2.6 Restrictions ...................................................................................................................11
3 Safety requirements ............................................................................................................... 12
3.1 Requirements................................................................................................................12
3.2 Approved devices .........................................................................................................12
3.2.1 MOVIDRIVE® MDX60B/61B for a connection voltage of 3 × AC 380 – 500V...
12
3.2.2 MOVIDRIVE® MDX61B for a connection voltage of AC 230V .................... 13
3.3 Requirements on the installation...................................................................................14
3.4 Requirements on the external safety controller ............................................................16
3.5 Requirements on startup...............................................................................................17
3.6 Requirements on operation...........................................................................................17
4 Connection variants ............................................................................................................... 18
4.1 General information ......................................................................................................18
4.1.1 Terminal X17 on the MOVIDRIVE® MDX60B/61B ....................................... 18
4.2 Requirements................................................................................................................19
4.2.1 Use of safety relays...................................................................................... 19
4.2.2 Using safety controllers................................................................................ 19
4.3 Disconnection of a single drive .....................................................................................20
4.3.1 STO according to PL d (EN ISO 13849-1) ................................................... 20
4.3.2 SS1-t in accordance with PL d (ENISO13849-1) ....................................... 22
4.4 Disconnection of group drives.......................................................................................25
4.4.1 Requirements............................................................................................... 25
4.4.2 Implementing group disconnection with a safety relay................................. 26
4.4.3 STO according to PL d (EN ISO13849-1) ................................................... 27
5 Technical data......................................................................................................................... 29
27778037/EN – 01/2022

Contents
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
4
5.1 Safety characteristics....................................................................................................29
5.2 Electronics data X17: Signal terminal block for STO safety contact .............................29
Index ........................................................................................................................................ 31
27778037/EN – 01/2022

1
General information
About this documentation
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 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 Underlying standards
The safety assessment of the device is based on the following standards and safety
classes:
Underlying standards
Safety class/underlying
standards
• Performance Level (PL) in accordance with
ENISO13849‑1
Observe the versions of the applicable standards as specified on the declaration of
conformity or on the TÜV certificate.
1.3 Structure of the safety notes
1.3.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
27778037/EN – 01/2022

1General information
Rights to claim under limited warranty
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
6
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.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of dangerous electrical voltage
1.3.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
 SIGNAL WORD! Type and source of hazard. Possible consequence(s) if disre-
garded. Measure(s) to prevent the hazard.
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 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
27778037/EN – 01/2022

1
General information
Copyright notice
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 7
1.6 Copyright notice
©2022SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
1.7 Document content
This documentation contains conditions and amendments for MOVIDRIVE®
MDX60B/61B in safety-related applications.
The system comprises a drive inverter with AC motor and safety-tested external dis-
connecting device.
1.8 Other applicable documentation
This documentation supplements the operating instructions of MOVIDRIVE®
MDX60B/61B and limits the application notes in accordance with the following infor-
mation. It may only be used in conjunction with the MOVIDRIVE® MDX60B/61B oper-
ating instructions.
27778037/EN – 01/2022

2Integrated safety technology
General
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
8
2 Integrated safety technology
2.1 General
The safety technology of MOVIDRIVE®MDX60B/61B described below has been de-
veloped and tested in accordance with the following safety requirements:
• PL d according to ENISO13849-1
This was certified by TÜV Nord. Copies of the TÜV certificate can be obtained from
SEW‑EURODRIVE.
2.2 Safe condition
For safety-related operation of MOVIDRIVE®MDX60B/61B, safe torque off is defined
as a safe state (see STO safety function). The safety concept is based on this defini-
tion.
2.3 Safety concept
• In the event of danger, any potential risk related to a machine must be eliminated
as quickly as possible. Idle state with restart prevention is generally the safe state
for preventing dangerous movements.
• The MOVIDRIVE® MDX60B/61B drive inverter is characterized by the option to
connect an external safety relay. The safety relay disconnects all active elements
(disconnection of the safety-related 24V power supply of the output stage control)
that generate the pulse trains to the power output stage (IGBT) when a connected
command device (e.g. an emergency stop button with latching function) is activa-
ted.
• Disconnecting the safety-related 24 V supply voltage ensures that the supply
voltages required for operating the inverter and consequently for generating a rota-
ting field of pulse patterns (which allow the generation of a rotating field) are safely
interrupted, preventing automatic restart.
• Instead of galvanic separation of the drive from the power supply by means of re-
lays or switches, the disconnection of the 24V supply described here safely pre-
vents the control of the power semiconductors in the drive inverter. This process
disconnects the rotating field generation for the respective motor. The individual
motor cannot develop any torque in this state even though the line voltage is still
present.
27778037/EN – 01/2022

2
Integrated safety technology
Schematic representation of the "safety concept for MOVIDRIVE B"
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 9
2.4 Schematic representation "Safety concept for MOVIDRIVE®B"
Schematic
representat
ion of the
"safety
concept for
MOVIDRIVE
B"
S24V
S0V24
M
Uz-
Uz+
24V
SNT
S0V24 SVI24
L1 L2 L3
GND
[1]
[2]
[3]
[4]
9007201052003595
[1] Safety-related DC24V voltage supply
[2] Electrical isolation
[3] Voltage supply for controlling the power transistors
[4] Pulse width modulated signals for the output stage
27778037/EN – 01/2022

2Integrated safety technology
Safety subfunctions
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
10
2.5 Safety subfunctions
The following drive-related safety functions can be used:
•STO (Safe Torque Off according to EN61800-5-2) by disconnecting the STO in-
put.
If the STO function is activated, the frequency inverter no longer supplies power to
the motor for generating torque. This safety subfunction corresponds to a non-con-
trolled stop according to EN60204‑1, stop category0.
The STO input must be disconnected by a suitable external safety controller/safety
relay.
The following figure shows the STO function:
v
t
t1
2463228171
•SS1-t (Safe stop 1 with time control by means of suitable external control, e.g.
safety relay with delayed disconnection).
The following sequence is mandatory:
– Decelerate the drive using an appropriate brake ramp specified via the setpoint
input.
– Disconnect the STO input (= triggering the STO function) after a specified
safety-related time delay.
This safety subfunction corresponds to a controlled stop in accordance with
EN 60204‑1, stop category 1. The SS1-t function corresponds to the former
presentation of the SS1(c) function.
The following figure illustrates the SS1‑t function:
v
t
t1t t2
2463226251
v Velocity
t Time
t1Point of time when brake ramp is initiated
t2Point of time when STO is triggered
Δt Delay time until STO is triggered
Safe time delay range
Disconnection range
27778037/EN – 01/2022

2
Integrated safety technology
Restrictions
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 11
2.6 Restrictions
• Note that if the drive does not have a mechanical brake, or if the brake is defec-
tive, the drive may coast to a halt (depending on the 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. Addi-
tional safety measures might have to be implemented (e.g. safety brake system).
MOVIDRIVE®MDX60B/61B 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-t function as described in chapter "Safety subfunctions", the
brake ramp of the drive is not monitored with respect to safety. In the case of an
error, the drive might not be decelerated during the delay time, or it might even be
accelerated in the worst case. In this case, the safety-related disconnection via the
STO function is only activated after the set time delay has elapsed (see chapter
"Safety subfunctions"). The resulting hazard must be taken into account in the risk
assessment of the system/machine, and additional safety measures have to be im-
plemented.
WARNING
The safety concept is only suitable for performing mechanical work on driven sys-
tem/machine components.
If the STO signal is disconnected, the line voltage is still present at the DC link of
MOVIDRIVE®MDX60B/61B.
• Before working on the electric part of the drive system, disconnect it from the
supply voltage using an appropriate external disconnecting device, and secure it
against unintentional reconnection to the voltage supply.
INFORMATION
In case of safety-related disconnection of the DC24V supply voltage at X17 (STO
activated), the brake is always applied. The brake control in
MOVIDRIVE®MDX60B/61B is not safety-related.
27778037/EN – 01/2022

3Safety requirements
Requirements
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
12
3 Safety requirements
3.1 Requirements
The requirement for safe operation is that the safety functions of
MOVIDRIVE® MDX60B/61B are properly integrated into an application-specific,
higher-level safety function. In any case, a system/machine-specific risk assessment
must be carried out by the system/machine manufacturer and taken into consideration
for using the drive system with MOVIDRIVE®MDX60B/61B.
The system/machine manufacturer and the user are responsible for the compliance of
the system/machine with the applicable safety regulations.
The following requirements are mandatory when installing and operating
MOVIDRIVE®MDX60B/61B in safety-related applications.
The requirements are divided into:
• Approved devices
• Installation requirements
• Requirements for external safety controllers and safety relays
• Startup requirements
• Operational requirements
3.2 Approved devices
The following device variants of MOVIDRIVE®MDX60B/61B are permitted for safety-
related applications:
3.2.1 MOVIDRIVE® MDX60B/61B for a connection voltage of 3 × AC 380 – 500V
Power rating
kW
Size Type
0.55 0S MDX60B0005-5A3-4-XX
0.75 0S MDX60B0008-5A3-4-XX
1.1 0M MDX60B0011-5A3-4-XX
1.5 0M MDX60B0014-5A3-4-XX
0.55 0S MDX61B0005-5A3-4-XX
0.75 0S MDX61B0008-5A3-4-XX
1.1 0M MDX61B0011-5A3-4-XX
1.5 0M MDX61B0014-5A3-4-XX
1.5 1 MDX61B0015-5A3-4-XX
2.2 1 MDX61B0022-5A3-4-XX
3 1 MDX61B0030-5A3-4-XX
4 1 MDX61B0040-5A3-4-XX
5.5 2S MDX61B0055-5A3-4-XX
7.5 2S MDX61B0075-5A3-4-XX
27778037/EN – 01/2022

3
Safety requirements
Approved devices
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 13
Power rating
kW
Size Type
11 2 MDX61B0110-5A3-4-XX
15 3 MDX61B0150-503-4-XX
22 3 MDX61B0220-503-4-XX
30 3 MDX61B0300-503-4-XX
37 4 MDX61B0370-503-4-XX
45 4 MDX61B0450-503-4-XX
55 5 MDX61B0550-503-4-XX
75 5 MDX61B0750-503-4-XX
90 6 MDX61B0900-503-4-XX
110 6 MDX61B1100-503-4-XX
132 6 MDX61B1320-503-4-XX
160 7 MDX61B1600-503-4-XX
200 7 MDX61B2000-503-4-XX
250 7 MDX61B2500-503-4-XX
3.2.2 MOVIDRIVE® MDX61B for a connection voltage of AC 230V
Power rating
kW
Size Type
1.5 1 MDX61B0015-2A3-4-XX
2.2 1 MDX61B0022-2A3-4-XX
3.7 1 MDX61B0037-2A3-4-XX
5.5 2 MDX61B0055-2A3-4-XX
7.5 2 MDX61B0075-2A3-4-XX
11 3 MDX61B0110-203-4-XX
15 3 MDX61B0150-203-4-XX
22 4 MDX61B0220-203-4-XX
30 4 MDX61B0300-203-4-XX
27778037/EN – 01/2022

3Safety requirements
Requirements on the installation
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
14
3.3 Requirements on the installation
• The safety-related DC 24 V supply voltage must be routed according to EMC
guidelines as follows:
– Outside an electrical installation space, shielded cables must be routed perma-
nently (fixed) and protected against external damage, or other equivalent mea-
sures have to be taken.
– Single conductors can be routed inside an electrical installation space.
– Adhere to the regulations in force for the application.
• Power cables and safety-related control cables must be installed in separate
cables.
• Make sure that parasitic voltages cannot be generated in the safety-related control
lines.
• The wiring technology must comply with EN60204-1.
• Only grounded voltage sources with protective extra-low voltage (PELV) in accor-
dance with VDE0100 and EN60204-1 may be used. In case of a single fault, the
voltage between the outputs or between any output and grounded parts must not
exceed DC60V.
• For information concerning EMC-compliant cabling, refer to the
"MOVIDRIVE® MDX60B/61B" operating instructions. It is essential that you con-
nect the shield of the safety-related DC 24V supply cable to the housing at both
ends.
• The lines of the safety-related 24V supply voltage (terminal X17) must be clamped
under the signal electronics shield terminal.
• When planning the installation, observe the technical data of
MOVIDRIVE®MDX60B/61B.
• Observe without fail the values specified for safety components when designing
the safety circuits.
• The cable length of the safety-related DC 24 V supply voltage must not exceed
100m.
• The safety-related DC 24V supply voltage may not be used for feedback.
• All connections (e.g. lines or data communication using bus systems) must already
have been taken into account in the performance level of one of the subsystems
involved, or it must be possible that faults in the connections can be excluded or
neglected.
The fault assumption "Short circuit between any 2 conductors" can be excluded in
accordance with ENISO13849‑2 under the following conditions:
The conductors are
– Permanently (fixed) installed and protected against external damage (for ex-
ample, using a cable duct or armored conduit)
– Routed in different cables in an electrical installation space provided that both
the lines and the installation space fulfill the relevant requirements, see
EN60204-1
– Protected individually by a ground connection
The fault assumption "short circuit between any conductor and an exposed con-
ductive part or ground or a protective conductor" can be excluded under the follow-
ing condition:
27778037/EN – 01/2022

3
Safety requirements
Requirements on the installation
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 15
– Short circuits between a conductor and any exposed conductive part within an
installation space.
• For applications with safety-related drive disconnection, remove the jumpers on
X17:1 to X17:4 (see following figure).
SVI
SOV
24V
GND
X17
1797603595
Removing jumpers
27778037/EN – 01/2022

3Safety requirements
Requirements on the external safety controller
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
16
3.4 Requirements on the external safety controller
[4]
[3] [1]
[5]
[6]
[2] U
18014400103440907
[1] Safety relay with approval
[2] DC24V voltage supply
[3] Fuses in accordance with the manufacturer's specifications of the safety relay
[4] Safety-related DC24V voltage supply
[5] Reset button for manual reset
[6] Approved emergency stop actuating device
A safety relay can be used as an alternative to a safety controller. The following re-
quirements apply analogously.
• The safety controller and all other safety-related subsystems must be approved for
at least the safety class required in the overall system for the respective applica-
tion-related safety function.
The following table shows an example of the required safety class of the safety
controller:
Application Safety controller requirements
Performance Level d in accordance with
ENISO13849‑1
Performance Level d in accordance with
ENISO13849‑1
SIL2 in accordance with EN61508
• The wiring of the safety controller must be suitable for the required safety class
(see manufacturer documentation).
– If the DC24V supply voltage is safely disconnected at the positive pole only,
no test pulses must be applied to this pole in disconnected condition.
If the DC 24 V supply voltage is disconnected at both poles, the test pulses
must not be applied at the same time at the plus and minus outputs. In this
case, the test pulse must be applied with a time delay.
27778037/EN – 01/2022

3
Safety requirements
Requirements on startup
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 17
– SEW‑EURODRIVE recommends to switch off the 24 V voltage supply at two
poles.
• The values specified for the safety controller must be strictly adhered to when
designing the circuit.
• The switching capacity of the safety relays or the relay outputs of the safety con-
troller must correspond at least to the maximally permitted, limited output current
of the 24V supply voltage.
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ISO14118,
the safe control system must be designed and connected in such a way that reset-
ting the command device alone does not lead to a restart. This means that a re-
start may be carried out only after a manual reset of the safety circuit.
3.5 Requirements on startup
• To validate the implemented safety functions, they must be documented and
checked after successful startup (validation).
The limitations for the safety functions in chapter "Limitations" must be observed
for validating safety functions. Non-safety-related parts and components that affect
the result of the validation test (e.g. motor brake) must be deactivated, if neces-
sary.
• For using MOVIDRIVE®MDX60B/61B in safety-related applications, it is essential
that you perform and record startup checks for the disconnecting device and cor-
rect wiring.
3.6 Requirements on operation
• Operation is only allowed within the limits specified in the data sheets. This prin-
ciple applies to the external safety controller as well as to
MOVIDRIVE®MDX60B/61B and approved options.
• You must check the safety functions on a regular basis to ensure proper function-
ing. Test intervals must be specified in accordance with the risk assessment.
27778037/EN – 01/2022

4Connection variants
General information
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
18
4 Connection variants
4.1 General information
Generally, all the connection variants listed in this documentation are permitted for
safety-relevant applications as long as the basic safety concept is met. This means
that you must always make sure that the DC24V safety inputs are operated by an ex-
ternal safety relay or safety controller, thereby preventing an automatic restart.
All safety conditions mentioned in chapters 2, 3 and 4 of the present documentation
must be met for the basic selection, installation, and application of the safety compo-
nents, such as safety relay, EMERGENCY STOP switch, etc., and the approved con-
nection variants.
The wiring diagrams are block diagrams whose only purpose is to show the safety
function(s) with the relevant components. Circuit-related measures, which usually al-
ways have to be implemented additionally, are not shown in the diagrams to enhance
clarity. Such measures are taken, for example, to ensure protection against contact, to
handle overvoltage and undervoltage, to detect insulation faults, line-to-ground faults
and short circuits, which can occur on externally installed lines, or to ensure the nec-
essary immunity against electromagnetic interference.
4.1.1 Terminal X17 on the MOVIDRIVE® MDX60B/61B
The following figure shows the X17 terminal at the bottom of the control unit.
STOP RUN
DEL OK
123
456
789
0
+ /-
[1]
*
X17
[1]
XT
S11
S12
S13
S14
X12
X11
X13
X16
X10
3210370059
*View of the underside of the unit
[1] X17: Signal terminal block for STO safety contacts
27778037/EN – 01/2022

4
Connection variants
Requirements
Manual – MOVIDRIVE® MDX60B/61B Functional Safety 19
4.2 Requirements
4.2.1 Use of safety relays
The requirements of the manufacturers of safety relays (such as protecting the output
contacts against welding) or of other safety components must be strictly observed. For
cable routing, the basic requirements apply as described in this documentation.
For connecting MOVIDRIVE® to the safety relays, the installation requirements in ac-
cordance with chapter "Installation requirements"(→214) must be observed.
Other information from the manufacturer about the use of safety relays for specific ap-
plications must also be observed.
4.2.2 Using safety controllers
Observe the ZVEI specifications for safety sensors if you use a safety PLC.
The starting and stopping pulses of the safe digital outputs (F-DO) used must be
≤1ms. The ratio must not fall below 1:1000.
<1ms >1000ms
High
Low
t
9007202465784971
INFORMATION
If the DC 24 V supply at X17 is switched off safely (STO activated), you must observe
chapter "Requirements on the external safety controller" with regard to the test
pulses.
27778037/EN – 01/2022

4Connection variants
Disconnection of a single drive
Manual – MOVIDRIVE® MDX60B/61B Functional Safety
20
4.3 Disconnection of a single drive
4.3.1 STO according to PL d (EN ISO 13849-1)
The procedure is as follows:
• Recommendation: X13:1 and X13:4 are disconnected at the same time, e.g. in
the event of an emergency stop.
• The 24V safety input X17 is disconnected.
• The motor coasts to a halt, if no brake is installed.
STO – Safe Torque Off (EN61800-5-2)
t
n
X17
X13:4
X13:1
3211071243
INFORMATION
The shown STO disconnections can be used up to PL d in accordance with
ENISO13849-1, taking chapter "Requirements"(→219) into consideration.
Binary control with safety relay (dual-channel)
+24 V
Feedback
emergency stop
Reset
Higher-level
controller
PLC
IN OUT
Safety
relay
Emergency stop Start
Stop
GND
Mains
MDX60B/61B
2
X13
1
4
X17
4 5 6
1
2
3
4
'0'=Ctrl. inhibit
'1'=Ctrl. enable
'0'=Stop
'1'=START CW
'0'=Rapid stop
'1'=Enable
7 DCOM
DGND
VO24
SVI24
SOV24
X2
M
U V W
9007202463719051
27778037/EN – 01/2022