SEW-Eurodrive CMP40 User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Operating Instructions
Safety-Rated Encoders
Functional Safety for CMP Synchronous Servomotors
CMP40 – CMP100
CMPZ71 – CMPZ100
Edition 01/2010 16907612 / EN

SEW-EURODRIVE—Driving the world

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 3
1 General Information ............................................................................................... 4
1.1 How to use the operating instructions............................................................ 4
1.2 Underlying standards ..................................................................................... 4
1.3 Structure of the safety notes .......................................................................... 5
1.4 Rights to claim under limited warranty ........................................................... 5
1.5 Exclusion of liability........................................................................................ 6
1.6 Motor type notation ........................................................................................ 6
1.7 Copyright........................................................................................................ 6
2 Safety Notes ........................................................................................................... 7
2.1 Preliminary information .................................................................................. 7
2.2 General information ....................................................................................... 7
2.3 Target group .................................................................................................. 8
2.4 Designated use .............................................................................................. 9
2.5 Functional safety (FS).................................................................................... 9
2.6 Transportation/storage................................................................................. 10
2.7 Mounting/installation .................................................................................... 10
2.8 Electrical connection .................................................................................... 11
2.9 Startup/operation ......................................................................................... 11
2.10 Inspection/maintenance ............................................................................... 11
2.11 Disposal ....................................................................................................... 11
3 Scope of Delivery and Unit Design..................................................................... 12
3.1 Functional safety technology (FS)................................................................ 12
3.2 Nameplate.................................................................................................... 13
4 Mechanical Installation........................................................................................ 14
4.1 Retrofitting a safe encoder........................................................................... 14
5 Electrical Installation ........................................................................................... 15
6 Startup................................................................................................................... 16
6.1 Prerequisites for startup............................................................................... 16
7 Malfunctions ......................................................................................................... 17
7.1 Servomotor malfunctions ............................................................................. 17
7.2 Brake malfunctions ...................................................................................... 18
8 Inspection/Maintenance....................................................................................... 19
8.1 Functional safety.......................................................................................... 20
9 Technical Data of the Safety-Rated Encoder Systems..................................... 22
9.1 Characteristic safety values ......................................................................... 22

4Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
1How to use the operating instructions
General Information
Operating Instr uctions
1 General Information
1.1 How to use the operating instructions
This addendum to the operating instructions "Functional Safety for Synchronous Servo-
motors" contains special information about the safety-rated encoder of the CMP motor.
The operating instructions "CMP Synchronous Servomotors" contain information about
CMP motors without safety-rated mount-on components.
The documentation for a motor with safety-rated mount-on components comprises
• the "CMP Synchronous Servomotors" operating instructions
• and the addendum to the "Functional Safety for Synchronous Servomotors" operat-
ing instructions.
The operating instructions and the addendum to the operating instructions are an inte-
gral part of the product and contain important information for operation and service.
They are intended for staff responsible for the assembly, installation, startup and main-
tenance of the product.
The operating instructions and the addendum to the operating instructions must be leg-
ible and accessible at all times. Make sure that staff responsible for the plant and its op-
eration, as well as persons who work independently on the unit, have read the operating
instructions and the addendum to the operating instructions carefully and understood
them. If you are unclear about any of the information in this documentation, or if you re-
quire further information, contact SEW-EURODRIVE.
1.2 Underlying standards
The safety assessment of the encoder is based on the following standards and safety
classes:
Underlying standards for safety-rated encoder
Safety class/underlying standard • Safety Integrity Level (SIL) according to IEC 61508
• Performance Level (PL) according to EN ISO 13849-1

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 5
1
Structure of the safety notes
General Information
1.3 Structure of the safety notes
1.3.1 Meaning of the signal words
The following table shows the grading and meaning of the signal words for safety notes,
notes on potential risks of damage to property, and other notes.
1.3.2 Structure of the section safety notes
The section safety notes do not apply to a specific action, but to several actions pertain-
ing to one subject. The used symbols indicate either a general or a specific hazard.
This is the formal structure of a section safety note:
1.3.3 Structure of the embedded safety notes
The embedded safety notes are directly integrated in the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
•SIGNAL WORD Nature and source of hazard.
Possible consequence(s) if disregarded.
– Measure(s) to prevent the danger.
1.4 Rights to claim under limited warranty
Compliance with the provisions in the addendum to the operating instructions "Function-
al Safety for Synchronous Servomotors" is a prerequisite for maintaining the guaranteed
functional safety properties for this drive.
Performing any actions that go beyond those described in the addendum to the operat-
ing instructions, or failure to comply with the requirements, will shift the responsibility for
the traceability of the safety components and the liability for functional safety to the op-
erator.
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the operating instructions and the ad-
dendum to the operating instructions. Consequently, read the operating instructions and
the addendum to the operating instructions before you start working with the unit.
Signal word Meaning Consequences if
disregarded
DANGER Imminent danger Severe or fatal
injuries
WARNING Possible dangerous situation Severe or fatal
injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the drive system or its
environment
INFORMATION Useful information or tip: Simplifies the
handling of the drive system.
SIGNAL WORD
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.

6Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
1Exclusion of liability
General Information
1.5 Exclusion of liability
You must comply with the information contained in these operating instructions to en-
sure safe operation of the electric motors and to achieve the specified product charac-
teristics and performance features. SEW-EURODRIVE assumes no liability for injury to
persons or damage to equipment or property resulting from non-observance of the op-
erating instructions. In such cases, any liability for defects is excluded.
1.6 Motor type notation
These operating instructions cover the motor types CMP and CMPZ.
If information refers to both CMP and CMPZ motors, the notation CMP. motors is used.
If information refers to either CMP or CMPZ motors, the motor type is stated explicitly.
1.7 Copyright
© 2010 - SEW-EURODRIVE. All rights reserved.
Copyright law prohibits the unauthorized duplication, modification, distribution, and use
of this document, in whole or in part.

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 7
2
Preliminary information
Safety Notes
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons and
damage to property. The operator must ensure that the basic safety notes are read and
observed. Make sure that persons responsible for the plant and its operation, as well as
persons who work independently on the unit, have read through the operating instruc-
tions and the addendum to the operating instructions carefully and understood them. If
you are unclear about any of the information in this documentation, or if you require fur-
ther information, please contact SEW-EURODRIVE.
2.1 Preliminary information
The following safety notes are concerned with the use of motors. If using gearmotors,
please also refer to the safety notes for gear units in the corresponding operating in-
structions.
2.2 General information
Removing the required protection cover or the housing without authorization, improper
use as well as incorrect installation or operation may result in severe injuries to persons
or damage to property.
Refer to the detailed operating instructions for additional information.
DANGER
Servomotors, gearmotors and gear units may have live, uninsulated (in case of open
connector/terminal boxes), and sometimes moving or rotating parts as well as hot sur-
faces during operation.
Severe or fatal injuries.
• All work related to transportation, storage, setup/mounting, connection, startup,
maintenance and repair may only be carried out by qualified personnel, in strict ob-
servation of:
– The relevant detailed operating instructions
– The warning and safety signs on the motor/gearmotor
– All other project planning documents, operating instructions and wiring diagrams
related to the drive
– The specific regulations and requirements for the system
– National/regional regulations governing safety and the prevention of accidents
• Never install damaged products
• Immediately report any damages to the shipping company

8Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
2Target group
Safety Notes
2.3 Target group
Any mechanical work may only be performed by adequately qualified personnel. Quali-
fied personnel in this context are persons who are familiar with the setup, mechanical
installation, trouble shooting and maintenance for this product. Further, they are quali-
fied as follows:
• Completed apprenticeship in the field of mechanical engineering (e.g. mechanic or
mechatronic technician).
• Knowledge of the content of the detailed operating instructions.
Any electric work may only be performed by adequately qualified personnel. Qualified
electricians in this context are persons who are familiar with the electronic installation,
startup, trouble shooting and maintenance for this product. Further, they are qualified as
follows:
• Completed apprenticeship in the field of electrical engineering (e.g. electric or
mechatronic technician).
• Knowledge of the content of the detailed operating instructions.
Any activities regarding transportation, storage, operation, and disposal must be carried
out by persons who have been instructed appropriately.
2.3.1 Functional safety
If you perform any work on safety-rated encoders (identified by the FS logo on the name-
plate) yourself, note that disassembly and assembly work on the safety-rated encoder
may only be performed by qualified personnel, and that the responsibility for the trace-
ability of the safety-rated encoder and the liability for functional safety shifts to the oper-
ator.
In addition to the qualifications listed above, these persons must be familiar with:
• Functional safety
• The relevant safety regulations and laws, especially with the requirements of EN ISO
13849-1 and all other standards, directives and laws specified in this documentation.
• The content of the publication "Addendum to the Operating Instructions: Functional
Safety for CMP Synchronous Servomotors".
• The content of the detailed operating instructions.
04

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 9
2
Designated use
Safety Notes
2.4 Designated use
The designated use refers to the procedure specified in the operating instructions and
the addendum to the operating instructions.
CMP and CMPZ synchronous servomotors are drive motors designed for use in indus-
trial and commercial systems. Motor utilization other than that specified and areas of ap-
plication other than industrial and commercial systems can only be used after consulta-
tion with SEW-EURODRIVE.
The CMP and CMPZ synchronous servomotors meet the requirements of the low volt-
age directive 2006/95/EC. Do not take the unit into operation until you have established
that the end product complies with the EC Machinery Directive 2006/42/EC.
You must observe the technical data and information on the connection requirements
as provided on the nameplate and in the documentation.
2.5 Functional safety (FS)
Observe the notes and measures described below.
2.5.1 Labeling
If functional safety is integrated in the motor, this is indicated with a FS symbol on the
nameplate.
2.5.2 Encoder
The described, safety-rated encoders can only be used with this motor. It is not possible
to adapt them to other motors.
The safety-related use of encoder systems is necessary for implementing safety-related
functions regarding speed, direction of rotation and standstill from the encoder that is
coupled directly with the motor shaft. A higher-level, safe evaluation unit is required in
addition, as the encoder with its encoder-internal diagnostic function is not able to trigger
responses such as initiating a safe status on its own initiative.
Increased demands are placed on the electrical and mechanical coupling, e.g. the
shielded connection lead stranded in pairs, and the strict observation of the assembly
instructions.
AK0H The RS485 interface (Hiperface®) cannot be used in connection with safety technology
for transferring absolute position data and other data (nameplate, diagnostics) due to
the relatively long transmission time. This information can be used for general diagnostic
purposes.
04
Type Part number Safety class Safety function
AK0H 1335 6615
SIL2 according to IEC 61508
Up to PL d according to EN ISO
13849-1
SLS, SDI, SLA, SS1, SS2, SOS, SLI

10 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
2Transportation/storage
Safety Notes
2.6 Transportation/storage
Follow the instructions on transportation, storage and proper handling.
Inspect the shipment for any damage that may have occurred in transit as soon
as you receive the delivery. Inform the shipping company immediately. If you no-
tice any transport damage, do not startup the motor, consult the SEW-
EURODRIVE Service.
Remove securing devices used for transportation prior to startup.
Tighten installed transportation eyebolts. They are designed to only carry the weight of
the motor/gearmotor; do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. The loads and regulations
specified in this standard must always be observed. If the gearmotor has 2 sus-
pension eye lugs or lifting eyebolts, then you should also use both suspension
eye lugs for attaching transport ropes. In this case, the tension force vector of the
slings must not exceed a 45° angle according to DIN 580.
Store the servomotor in a dry, dust-free environment if it is not to be installed straight
away. The servomotor can be stored for one year without requiring any special mea-
sures before startup.
2.7 Mounting/installation
Observe the instructions in chapter "Mechanical Installation" and chapter "Electrical In-
stallation" of the detailed operating instructions.
The units must be installed and cooled according to the regulations and specifications
in the corresponding documentation.
Protect the synchronous servomotors from excessive strain. Ensure that components
are not deformed, particularly during transportation and handling.
INFORMATION
• Screw in the lifting eyes all the way.
• Make sure that the lifting eyes carry only a reduced load, as the angle of the load
exceeds 45°.
• Due to the angle of the load, the lifting eyes are oversized. Note that the lifting eyes
are not designed to hold the entire load of the gear unit.

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 11
2
Electrical connection
Safety Notes
2.8 Electrical connection
Perform electrical installation according to the pertinent regulations (e.g. cable cross
sections, fusing, protective conductor connection). For any additional information, refer
to the applicable documentation.
Observe the wiring information and differing data on the nameplate.
Observe the instructions in chapter "Electrical Installation" of the detailed operating in-
structions.
2.9 Startup/operation
Whenever changes to normal operation occur, such as increased temperatures, noise,
vibrations, determine the cause and consult the manufacturer.
See the notes in chapter "Startup" of the detailed operating instructions.
2.10 Inspection/maintenance
Comply with the instructions in section 8, "Inspection/Maintenance.
2.11 Disposal
This product consists of:
•Iron
•Aluminum
• Copper
• Plastic
• Electronic components
Dispose of all components in accordance with applicable regulations.

12 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
3Functional safety technology (FS)
Scope of Delivery and Unit Design
3 Scope of Delivery and Unit Design
3.1 Functional safety technology (FS)
Drives of SEW-EURODRIVE can be supplied with safety-relevant components.
MOVIMOT®, encoders or brakes, or other accessories, can be integrated in the AC mo-
tor as safety-relevant components either individually or in combination.
SEW-EURODRIVE indicates such an integration by the FS mark and a number on the
nameplate.
The number is a code that indicates which components in the drive are safety-related.
See the following code table for all products:
If the FS logo on the nameplate contains the code "FS 04", for example, the motor is
equipped with a safe encoder.
You find the characteristic safety values of the following components in the technical
data section on page 22 so you can determine the security level for systems and ma-
chines yourself.
The characteristic safety values of SEW components are also available on the SEW
homepage on the Internet and in the SEW library for the Sistema software of the Institute
for Occupational Safety and Health of the German Social Accident Insurance (IFA, for-
merly BGIA).
04
Functional
safety
Inverter
(e.g.
MOVIMOT®)
Brake
Manual
brake
release
monitoring
Brake
monitoring
Motor
protection Encoder
01 x
02 x
03 x
04 x
05 xx
06 xx
07 x x
08 xx
09 xx
10 xx
11 xx
12 xx
13 xx x
14 xxx
15 xx x
16 xxx
17 xxx
18 xxx x
19 xxx x
20 xx xx
21 xxxx
22 xx xx
23 xxx xx
24 xx xxx
25 xxxxxx

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 13
3
Nameplate
Scope of Delivery and Unit Design
3.2 Nameplate
3.2.1 FS logo on the nameplate on the servomotor
The labels on the upper edge of the nameplate are only present if the motor has been
designed accordingly or if it includes at least one safety-rated component.
The FS logo on the nameplate is based on the combination of safety-related compo-
nents that is installed, see code table above.
Inverter duty motor
1342 168 9
Ins.Cl.
A
A
V
i
kg
Nm
U Sys
Imax
rpm
I
Nm
n
M
76646 Bruchsal/Germany
N
00
E189357
Brake
IM
Nm
3 Phase
°C
Motor
IP
Gear
Made in Germany
rpm
Ma pk
Vbr
/ne pk
na pk
ML
TENV
Inverter VPWM
0-
VT
04
FS

14 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
4Retrofitting a safe encoder
Mechanical Installation
4 Mechanical Installation
This chapter contains no special information about safety-rated components.
4.1 Retrofitting a safe encoder
To retrofit a safe encoder to an existing encoder mounting adapter from SEW-
EURODRIVE, proceed as described in chapter "Inspection/Maintenance".

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 15
5
Retrofitting a safe encoder
Electrical Installation
5 Electrical Installation
The wiring diagram for motor and brake is supplied in a bag attached to the motor.
Note the information and explanations about correct wiring in the corresponding operat-
ing instructions.
DANGER
Danger of electric shock.
Severe or fatal injuries!
•It is essential to comply with the safety notes in Sec. 2 during installation!
• Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for
switching the motor and the brake.
• Use switch contacts in utilization category DC-3 according to EN 60947-4-1 for
switching the brake with DC 24 V.
• When motors are powered by inverters, you must adhere to the wiring instructions
issued by the inverter manufacturer.
• Observe the operating instructions of the servo inverter.
INFORMATION
A bag containing the following information is attached to the motor:
• Safety notes
• Wiring diagram
You must comply with these notes.

16 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
6Prerequisites for startup
Startup
6Startup
6.1 Prerequisites for startup
DANGER
Danger of electric shock.
Severe or fatal injuries!
•It is essential to comply with the safety notes in chapter 2 during installation.
• Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for
switching the motor and the brake.
• When motors are powered by inverters, you must adhere to the wiring instructions
issued by the inverter manufacturer.
• Observe the operating instructions of the servo inverter.
INFORMATION
The rated speed of the motor in a gearmotor can be higher than the permitted, input
speed of the gear unit.
Limit the maximum speed at the servo inverter. For information on the procedure, refer
to the documentation of the servo inverter.
00
I

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 17
7
Servomotor malfunctions
Malfunctions
7 Malfunctions
For any work performed on the motor during which the sealed screw fittings of the
safety-rated encoder are loosened, you must observe the notes on page 20.
7.1 Servomotor malfunctions
Fault Possible cause Remedy
Motor does not start up
Supply cable interrupted Check connections, correct if necessary
Fuse has blown Replace fuse
Motor protection has triggered Check motor protection for correct setting, correct fault if
necessary
Inverter faulty, overloaded, incorrectly
wired or incorrectly set Check inverter, check wiring
Incorrect direction of rotation Incorrect setpoint polarity Check inverter, check setpoints
Motor hums and has high
current consumption
Drive is blocked Check drive
Brake does not release Possible cause: No brake voltage
Encoder cable malfunction Check encoder cable
Wrong inverter setting Check the inverter
Motor heats up excessively
(measure temperature, sig-
nificantly higher than 100 °C)
Overload Measure power, use larger motor or reduce load if neces-
sary, check travel profile
Ambient temperature is too high Comply with permitted temperature range
Insufficient cooling Correct cooling air supply or clear cooling air passages,
retrofit forced cooling fan if necessary
Forced cooling fan does not run Check connection, correct if necessary
Rated operating mode (S1 to S10, EN
60034) exceeded, e.g. caused by exces-
sive effective torque
Adjust the rated operating mode of the motor to the
required operating conditions; consult a professional to
determine the correct drive if necessary
Inverter not optimized Check the inverter
Running noise on motor
Bearing damage • Contact SEW-EURODRIVE customer service
• Replace the motor
Vibration of rotating parts Rectify cause, possible imbalance
Forced cooling fan: Foreign bodies in cool-
ing air passages Clean the cooling air passages
00
I

18 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
7Brake malfunctions
Malfunctions
7.2 Brake malfunctions
For any work performed on the motor during which the sealed screw fittings of the
safety-rated encoder are loosened, you must observe the notes on page 20.
7.2.1 Brake BP
7.2.2 BY brake
Fault Possible cause Remedy
Brake does not
release
Brake connected incorrectly Check brake connection
Max. permitted working air gap exceeded because
brake lining worn down
• Consult SEW-EURODRIVE
• Replace the motor
Incorrect voltage at brake control unit, e.g. voltage
drop in the supply cable > 10%
Check voltage at motor connection:
Ensure correct connection voltage; check cable cross
section
Brake coil has interturn short circuit or a short circuit
to frame Consult SEW-EURODRIVE
Motor does not brake
Brake lining worn • Consult SEW-EURODRIVE
• Replace the motor
Incorrect braking torque. • Consult SEW-EURODRIVE
• Replace the motor
Noises/squeaking in
vicinity of brake Brake parameters set incorrectly in the inverter Check brake release and application times
Fault Possible cause Remedy
Brake does not
release
Brake control unit failed
Install a new brake control system, check internal
resistance and insulation of brake coil, check switch-
gear
Brake connected incorrectly Check brake connection
Max. permitted working air gap exceeded because
brake lining worn down
• Consult SEW-EURODRIVE
• Brake disk replacement by SEW-trained staff
Brake coil has interturn short circuit or a short circuit
to frame
• Check switchgear
• Replace the entire brake and brake control system
(consult SEW-EURODRIVE)
Motor does not brake
Brake lining worn • Consult SEW-EURODRIVE
• Brake disk replacement by SEW-trained staff
Incorrect braking torque. • Consult SEW-EURODRIVE
• Brake disk replacement by SEW-trained staff
Manual brake release device not set correctly Set the setting nuts correctly
Brake is applied with
time lag Brake is switched on AC voltage side Switch both, the DC and AC voltage sides; observe wiring diagram
Noises/squeaking in
vicinity of brake Brake parameters set incorrectly in the inverter Check brake release and application times
00
I

Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors 19
8
Brake malfunctions
Inspection/Maintenance
8 Inspection/Maintenance
CAUTION
Only use original spare parts, otherwise the motor can be damaged.
Possible damage to property.
• Use only genuine spare parts in accordance with the valid parts list.
CAUTION
The motor must be disassembled when replacing the brake which cannot be adjusted.
Possible damage to motor and brake
• Only SEW-EURODRIVE may perform maintenance on the brake because the en-
coder or resolver has to be reset each time the system is disassembled.
DANGER
The servomotor has live parts during and after operation.
Severe or fatal injuries from electric shock.
• De-energize all power, brake and signal cables before unplugging the power or sig-
nal plug connector.
• Secure the motors against unintended power-up.
• The motor can generate power when the shaft is rotated. Do not touch the connec-
tor pins.
WARNING
The servomotor can have a surface temperature of more than 100 °C during operation.
Risk of burns and fire.
• Never touch the CMP synchronous servomotor during operation or in the cool down
phase once it has been switched off.

20 Addendum to the Operating Instructions – Functional Safety for CMP Synchronous Servomotors
8Functional safety
Inspection/Maintenance
8.1 Functional safety
Certain demands on the mechanical coupling of the encoder system to the motor must
be met so that the encoder can be used for safety-related tasks.
SEW-EURODRIVE assumes responsibility for the delivered motor with safety-rated en-
coder in terms of compliance with the functional safety regulations. Safety-relevant con-
nection elements are coated with a sealing wax to be able to proof the delivery condition,
see the following figures.
There are two options for performing work on the encoder or motor during which these
sealed screw connections must be opened:
• Commission the SEW-EURODRIVE Service to perform this work.
• If you perform any work on safety-rated encoders yourself, note that disassembly
and assembly work on the safety-rated encoder may only be performed by qualified
personnel, and that the responsibility for the traceability of the safety-rated encoder
and the liability for functional safety shifts to the operator.
CMP40 CMP50/63
CMP71 - 100 CMP71/80/100 /BP
CMPZ71/80/100
[1] Sealed screw connections of the encoder
[1]
[1]
[1]
[1]