SEW-Eurodrive MOVIGEAR B User manual

*22746250_1216*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
Mechatronic Drive System
MOVIGEAR® B
Functional Safety
Edition 12/2016 22746250/EN

SEW-EURODRIVE—Driving the world

Contents
Manual – MOVIGEAR® B 3
Contents
1 General information.................................................................................................................. 4
1.1 About this documentation ...............................................................................................4
1.2 Underlying standards ......................................................................................................4
1.3 Structure of the safety notes ...........................................................................................4
1.4 Rights to claim under limited warranty ............................................................................5
1.5 Content of the documentation.........................................................................................6
1.6 Exclusion of liability.........................................................................................................6
1.7 Other applicable documentation .....................................................................................6
1.8 Product names and trademarks......................................................................................6
1.9 Copyright notice ..............................................................................................................6
2 Integrated safety technology................................................................................................... 7
2.1 Safe condition .................................................................................................................7
2.2 Safety concept ................................................................................................................7
2.3 Safety functions ..............................................................................................................9
2.4 Limitations.....................................................................................................................11
3 Safety conditions.................................................................................................................... 12
3.1 Approved units ..............................................................................................................13
3.2 Installation requirements...............................................................................................14
3.3 Requirements on external safety controllers and safety relays ....................................16
3.4 Startup requirements ....................................................................................................18
3.5 Operation requirements ................................................................................................18
4 Technical data......................................................................................................................... 19
5 Appendix ................................................................................................................................. 20
5.1 Unit variants with DynaStop® .......................................................................................20
5.2 Connection variants ......................................................................................................24
5.3 Connection of an external safety relay for STO ............................................................32
5.4 Connection of an external safety controller for STO .....................................................36
Index ........................................................................................................................................ 40
22746250/EN – 12/2016

1General information
About this documentation
Manual – MOVIGEAR® B
4
1 General information
1.1 About this documentation
This documentation is an integral part of the product. The documentation is written for
all employees who assemble, install, start up, and service this product.
Make sure this documentation is accessible and legible. Ensure that persons respons-
ible for the machinery and its 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 require further in-
formation, contact SEW‑EURODRIVE.
1.2 Underlying standards
The safety assessment of the unit is based on the following standards and safety
classes:
Underlying standards
Safety class/underlying standard • Performance level (PL) according to
ENISO13849‑1:2008
• Safety Integrity Level (SIL) according to
EN61800‑5‑2:2007
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 drive system or its
environment.
INFORMATION Useful information or tip: Simplifies
handling of the drive system.
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.
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1
General information
Rights to claim under limited warranty
Manual – MOVIGEAR® B 5
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
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
Warning of automatic restart
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 disreg-
arded. 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.
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1General information
Content of the documentation
Manual – MOVIGEAR® B
6
1.5 Content of the documentation
The current version of the documentation is the original.
This document contains additional safety-relevant information and conditions for use
in safety-related applications.
1.6 Exclusion of liability
Read the information in this documentation, otherwise safe operation is impossible.
You must comply with the information contained in this documentation to achieve the
specified product characteristics and performance features. SEW‑EURODRIVE as-
sumes no liability for injury to persons or damage to equipment or property resulting
from non-observance of these operating instructions. In such cases,
SEW‑EURODRIVE assumes no liability for defects.
1.7 Other applicable documentation
This document supplements the operating instructions and limits the application notes
according to the following information. Use this document only together with the oper-
ating instructions.
1.8 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.9 Copyright notice
©2016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.
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2
Integrated safety technology
Safe condition
Manual – MOVIGEAR® B 7
2 Integrated safety technology
The safety technology of MOVIGEAR® described below has been developed and
tested in accordance with the following safety requirements:
• SIL3 according to EN 61800-5-2:2007
• PL e according to EN ISO 13849-1:2008
This was certified by TÜV Nord. Copies of the TÜV certificate and the corresponding
report are available from SEW‑EURODRIVE on request.
2.1 Safe condition
For safety-related operation of MOVIGEAR®, safe torque off is defined as safe condi-
tion (see STO safety function). The safety concept is based on this definition.
2.2 Safety concept
• The MOVIGEAR® drive unit can be connected to an external safety controller or
safety relay. This disconnects the safety-related STO input via 2-pole 24 V switch-
ing signal (P-M switching) when a connected control device (e.g. emergency stop
button with latching function) is activated. This activates the STO function (safe
disconnection) of MOVIGEAR®.
• An internal, dual-channel structure with diagnostics prevents the generation of
pulse trains at the power output stage (IGBT). On the one hand, the internal supply
voltage for controlling the upper and lower IGBTs is disconnected, and on the
other hand the controlling pulse patterns are short-circuited. This means that the
output stage can no longer supply power to the motor for generating torque.
• Instead of galvanic separation of the drive from the supply system by means of
contactors or switches, the disconnection of the STO input described here safely
prevents the control of the power semiconductors in the output stage. The rotary-
field generation for the respective motor is deactivated even though the line
voltage is still present.
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2Integrated safety technology
Safety concept
Manual – MOVIGEAR® B
8
2.2.1 Schematic representation "Safety concept for MOVIGEAR®"
The following figure shows a schematic representation of the safety concept for
MOVIGEAR®:
24V
Safety M
UZ-
UZ+
[1]
[2]
[3]
[4]
[5]
µC
HV
SNT
SNT
2463070859
[1] Safety controller/safety relay external
[2] Connection "STO+"
[3] Connection "STO-"
[4] Motor phase
[5] Motor
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2
Integrated safety technology
Safety functions
Manual – MOVIGEAR® B 9
2.3 Safety functions
The following drive-related safety functions can be used:
2.3.1 STO
•STO (safe torque off according to EN61800-5-2) by disconnecting the STO input.
If the STO function is activated, the frequency inverter no longer supplies power to
the motor for generating torque. This safety function corresponds to a non-con-
trolled stop according to EN 60204-1, stop category 0.
The STO input must be disabled by a suitable external safety controller/safety re-
lay.
The following figure shows the STO function:
v
t
t1
2463228171
v Velocity
t Time
t1Time at which STO is triggered
Disconnection range
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2Integrated safety technology
Safety functions
Manual – MOVIGEAR® B
10
2.3.2 SS1(c)
•SS1(c) (safe stop 1, function variant c according to IEC61800-5-2) 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 setpoints.
– Disconnect the STO input (= triggering the STO function) after a specified
safety-related time delay.
This safety function corresponds to a controlled stop according to EN 60204-1,
stop category 1.
The following figure illustrates the SS1(c) function:
v
t
t1t t2
2463226251
v Velocity
t Time
t1Point of time when the brake ramp is initiated
t2Point of time when STO is triggered
Δt Time between initiating the brake ramp and STO
Safe time delay range
Disconnection range
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2
Integrated safety technology
Limitations
Manual – MOVIGEAR® B 11
2.4 Limitations
WARNING
The safety concept is only suitable for performing mechanical work on driven sys-
tem/machine components.
When the STO signal is disconnected, the line voltage is still present at the DC link
of the MOVIGEAR® drive unit.
• 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.
• MOVIGEAR® has no mechanical brake. This means coasting of the drive depends
on the application (subject to friction and mass moment of inertia of the system). In
case of regenerative loads, the drive can even accelerate. This must be taken into
account in a risk assessment of the system/machine. Additional safety measures
might have to be implemented (e.g. safety brake system).
→ MOVIGEAR® cannot be used without an additional brake system for applica-
tion-specific safety functions that require active deceleration (braking) of the dan-
gerous movement.
• When using the SS1(c) function as described in chapter "Safety functions", the
brake ramp of the drive is not monitored with respect to safety. In case of a fault,
the drive might not be decelerated after the delay time, or it might be accelerated
in the worst case. In this case, the STO function (see chapter "Safety functions") is
only activated after the set time delay has elapsed. The resulting danger must be
taken into account in the risk assessment of the system/machine. Additional safety
measures might have to be implemented.
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3Safety conditions
Manual – MOVIGEAR® B
12
3 Safety conditions
The requirement for safe operation is that the safety functions of MOVIGEAR® are
properly integrated into an application-specific higher-level safety function. A system/
machine-specific risk assessment must be carried out through the system/machine
manufacturer and taken into account for the use of the drive system with
MOVIGEAR®.
The system/machine manufacturer and the operator are responsible for compliance of
the system/machine with applicable safety regulations.
The following requirements are mandatory when installing and operating MOVIGEAR®
units in safety-related applications.
The requirements are divided into:
• Approved units
• Installation requirements
• Requirements on external safety controllers and safety relays
• Startup requirements
• Operational requirements
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3
Safety conditions
Approved units
Manual – MOVIGEAR® B 13
3.1 Approved units
Only the following unit variants of MOVIGEAR®B are permitted for safety-related ap-
plications.
Type code
example
MG F A S 2- DSM- SNI- B /XX
Description Product
family
Gear
unit
type
Shaft
type
Housing
mounting
Size Motor
type
Installation
technology
Ver-
sion
Op-
tions
Permitted
variants
MG F A
T
•
S
T
F
Z
2
4
DSM SNI
DSC
DAC
DBC
B /ECR
/ACR
/ET
/XT
/DSP
/IV
/EBW
/WA
/HA
/CA
/PE
/PG
Permitted application options:
• GIO12A
• GIO13A
• GIO12B
• GIO13B
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3Safety conditions
Installation requirements
Manual – MOVIGEAR® B
14
3.2 Installation requirements
• Power lines and STO control lines have to be routed in separate cables. This does
not apply to cables approved by SEW‑EURODRIVE specifically for this case of ap-
plication.
• The line length between the safety controller and MOVIGEAR® may not exceed
100m.
• The wiring technology used must comply with EN60204-1.
• The STO control lines must be routed according to EMC guidelines and as follows:
– Outside an electrical installation space: Shielded cables must be routed per-
manently (fixed) and protected against external damage, or equivalent meas-
ures have to be taken.
– Inside an electrical installation space: Individual conductors can be routed.
– Adhere to the relevant regulations in force for the application.
• Observe the values specified for safety components when designing the safety cir-
cuits.
• The STO signal may not be used for feedback.
• Observe the notes in the MOVIGEAR® operating instructions for EMC-compliant
installation.
It is important that the shielding of the STO control line is connected to the housing
at both ends.
• Only use grounded voltage sources with safe disconnection (PELV) according to
VDE 0100 for all signal interfaces (SBus, digital inputs, digital output, etc.) of
MOVIGEAR® and all SBus stations.
According to EN61131-2, the voltage between the outputs or between any output
and grounded parts may not exceed DC 60 V in case of a single fault in the
voltage supply.
• When planning the installation, observe the technical data of MOVIGEAR®.
• Do not use the DC 24 V output of MOVIGEAR® for safety-related applications with
MOVIGEAR®.
WARNING
No safety-related disconnection of the MOVIGEAR® drive unit.
Severe or fatal injuries.
• Do not use the 24 V output for safety-related applications with MOVIGEAR® drive
units.
• You may only jumper the STO input with 24 V when the MOVIGEAR® drive unit
is not used to fulfill any safety functions.
• For safety-related applications with MOVIGEAR® drive units, you have to remove
the jumpers labeled "Caution, remove jumper for safety operation", see following
figures (jumpers are not installed in unit variants with STO plug connectors X5502
and X5503):
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3
Safety conditions
Installation requirements
Manual – MOVIGEAR® B 15
MOVIGEAR® DBC-B and DAC-B
Remove the jumpers between STO input (terminals 1/2) and 24 V output (ter-
minals 6/7):
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
1.
2.
3.
CAUTION
remove jumper
for safety operation
9007202406743947
MOVIGEAR®DSC-B and SNI-B
Remove the jumpers between STO input (terminals 1/2) and 24 V output (ter-
minals 5/15):
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
CAUTION
remove jumper
for safety operation
1.
2.
3.
CAUTION
remove jumper
for safety operation
9007202406745867
22746250/EN – 12/2016

3Safety conditions
Requirements on external safety controllers and safety relays
Manual – MOVIGEAR® B
16
3.3 Requirements on external safety controllers and safety relays
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
and tested for at least that safety class which is required in the overall system for
the respective, application-related safety function.
The following table shows an example of the required safety class of the safety
controller:
Application Safety controller requirements
Performance level e according to
ENISO13849-1
Performance level e according to
ENISO13849-1
SIL3 according to EN61508
SIL3 according to EN62061 Performance level e according to
ENISO13849-1
SIL3 according to EN61508
• The wiring of the safety controller must be suitable for the required safety class,
(see manufacturer documentation). The STO input of the MOVIGEAR® drive unit
requires 2-pole disconnection (sourcing/sinking).
• MOVIGEAR® does not detect short circuits in the STO control cables. For this
reason, the safety control or the safety relay must detect crossfaults and interfer-
ence voltage of the STO control cable against any external potential, also cross-
faults and interference voltage against mass or PE.
• 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 voltage supply.
Observe the manufacturer's instructions concerning the permitted contact loads
and fusing that may be required for the safety contacts. If the manufacturer
provides no specific information, the contacts must be protected with 0.6 times the
nominal value of the maximum contact rating specified by the manufacturer.
• To ensure protection against unintended restart in accordance with EN 1037, the
safe control system must be designed and connected in such a way that resetting
the control device alone does not lead to a restart. A restart may only be carried
out after a manual reset of the safety circuit.
• Note the following for two-pole disconnection of MOVIGEAR® with tested, safe out-
puts:
– When disconnected, the switch-on test pulses may never occur at the plus and
minus output at the same time.
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3
Safety conditions
Requirements on external safety controllers and safety relays
Manual – MOVIGEAR® B 17
– When connected, the switch-off test pulses may not be longer than 1ms. The
next pulse blanking cannot reoccur earlier than after 20ms.
<1 ms >20 ms
t
High: no STO
Low: STO active
9007201720642187
3.3.1 Sample circuit "safety relay"
The following figure shows the basic connection of an external safety relay (according
to the requirements listed above) to MOVIGEAR®.
The information in the respective manufacturer's data sheets must be observed for
connection.
[4]
[3] [1]
[5]
[6]
[2] U
2466502411
[1] Safety relay with approval [4] STO signal
[2] DC 24 V voltage supply [5] Reset button for manual reset
[3] Fuses in accordance with the manu-
facturer's specifications of the safety
relay
[6] Permitted emergency stop actuating
device
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3Safety conditions
Startup requirements
Manual – MOVIGEAR® B
18
3.4 Startup requirements
• To validate the implemented safety functions, they must be documented and
checked after successful startup (validation).
Observe the limitations for safety functions in chapter "Limitations" for the valida-
tion of the safety functions. Non-safety-relevant parts and components that affect
the result of the validation test must be deactivated, if necessary.
• For using MOVIGEAR® in safety-relevant applications, it is essential that you per-
form and record startup checks for the disconnecting device and correct wiring.
3.5 Operation requirements
• Operation is only allowed within the limits specified in the data sheets. This prin-
ciple applies to the external safety controller as well as to MOVIGEAR® and ap-
proved options.
• The built-in diagnostic function is limited in case of a permanently enabled or per-
manently disabled STO input. Only when the STO signal is activated ("Low" to
"High"), extended diagnostic functions are performed. This means that the STO in-
put must be switched at least once in three months while the supply system is con-
nected to achieve a complete test coverage. Follow this test procedure:
max. 3 months >500 ms >500 ms
High: no STO
Low: STO active
internal
diagnostics
internal
diagnostics
t
2467673483
• To achieve complete test coverage after a unit reset (e.g. after connecting the sup-
ply system), the test transition (STO active → not active) can only be started min.
10 seconds later. The unit must (already) be signaling "ready for operation" or
"STO – safe torque off" and may not be in error state.
• A detected hardware fault in the internal switch-off channels for STO will lead to a
locking error state of MOVIGEAR®. When the error is reset (e.g. by switching the
power supply off and back on), a complete internal diagnostics test run must be
performed according to the above test procedure. If the error re-occurs, replace
the unit or contact SEW Service (for detailed information about possible error
states, refer to the respective MOVIGEAR® operating instructions).
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4
Technical data
Manual – MOVIGEAR® B 19
4 Technical data
The table below shows the technical data for MOVIGEAR® relating to the integrated
safety technology. The technical data and approvals in the respective MOVIGEAR®
operating instructions must be observed in addition.
Technical data of the STO input Min. Typical Max. Unit
Input voltage range -3 24 30 V DC
Input impedance 990 Ohm
Capacitance of the STO input (capa-
citance between STO+ and STO-)
≤ 10 nF
Switch-on/switch-off threshold 11 V
Input voltage for ON status (STO) 15 V
Input voltage for OFF status (STO) 5 V
Permitted leakage current of the ex-
ternal safety controller
0 2 mA
Required current for STO-IN supply 26 mA
Time from disconnecting the safety
voltage until the deactivation of the
rotating field
4 20 ms
Time from connecting the safety
voltage until the activation of the ro-
tating field
220 300 ms
Test interval for STO function: See
test procedure in chapter "Operation
requirements"
3 Months
Safety characteristics
Approved safety classes SIL3 according to EN61800-5-2
Performance level e according to EN ISO
13849-1
Probability of a dangerous failure per
hour (= PFH value)
1.9×10−9 1/h
Service life 20 years, after which the component must be
replaced with a new one.
Safe state Safe torque off (STO)
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5Appendix
Unit variants with DynaStop
Manual – MOVIGEAR® B
20
5 Appendix
5.1 Unit variants with DynaStop®
Unit
variants
with
DynaStop
WARNING
The electrodynamic deceleration function DynaStop® does not allow for a definite
stop at a position.
Severe or fatal injuries.
• Do not use the electrodynamic deceleration function for hoists.
• DynaStop® may only be used for inclining tracks after a risk assessment.
The optional DynaStop® function is not safety-related. It is not part of the safety func-
tions described in chapter "Integrated safety technology/safety functions".
5.1.1 Using the DynaStop® function in connection with the STO function
To use the DynaStop® function in connection with the STO function, we recommend
control in line with SS1(c).
In connection with electronic variants DAC, DSC, and SNI, the parameter "8584.0
– Brake function" must be set to "1" for this purpose.
The following table shows the behavior of the DynaStop® function depending on the
parameter setting:
Index Parameter/setting Meaning
DAC, DSC, SNI
electronics variant:
DBC electronics variant
8584.0 Brake function
0 = OFF
The drive decelerates along the
set ramp. When the drive reaches
speed "0", DynaStop® is not activ-
ated.
The drive decelerates along the
set ramp. When the speed is "0",
DynaStop® is activated.
Brake function
1 = ON
The drive decelerates along the set ramp. When a speed of "0" is
reached, there is no safety-related activation of DynaStop®.
9833.20 Activation of
DynaStop® for STO
0 = NO
The DynaStop® status remains unchanged when STO is triggered.
Activation of
DynaStop® for STO
1 = Yes
DynaStop® is activated (not safety-related) when STO is triggered.
Necessary setting in connection with electronic variants DAC, DSC, SNI
Recommended setting
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