SEW-Eurodrive MOVISAFE CS A Series User manual

*28482271_0319*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIDRIVE® modular/system/technology
MOVISAFE® CS..A Safety Card (Version 2)
Edition 03/2019 28482271/EN

SEW-EURODRIVE—Driving the world

Table of contents
Manual – MOVISAFE® CS..A Safety Card (Version 2) 3
Table of contents
1 General information.................................................................................................................. 8
1.1 About this documentation ...............................................................................................8
1.2 Structure of the safety notes ...........................................................................................8
1.2.1 Meaning of signal words ................................................................................ 8
1.2.2 Structure of section-related safety notes........................................................ 8
1.2.3 Structure of embedded safety notes .............................................................. 9
1.3 Rights to claim under limited warranty ............................................................................9
1.4 Content of the documentation.........................................................................................9
1.5 Other applicable documentation .....................................................................................9
1.6 Decimal separator in numerical values .........................................................................10
1.7 Copyright notice ............................................................................................................10
1.8 Product names and trademarks....................................................................................10
1.8.1 Trademarks of Beckhoff Automation GmbH ................................................ 10
2 Safety notes ............................................................................................................................ 11
2.1 Preliminary information .................................................................................................11
2.2 Duties of the user..........................................................................................................11
2.3 Target group .................................................................................................................11
2.4 Designated use .............................................................................................................12
2.5 Transport.......................................................................................................................12
2.6 Installation/assembly.....................................................................................................13
2.6.1 Restrictions of use........................................................................................ 13
2.7 Electrical installation .....................................................................................................13
2.8 Definitions .....................................................................................................................14
2.9 Startup/operation ..........................................................................................................14
3 Safety concept ........................................................................................................................ 15
3.1 General .........................................................................................................................15
3.2 Notes on stop categories ..............................................................................................15
3.3 Pluggable safety key.....................................................................................................16
3.4 Identification and authentication ...................................................................................16
3.5 Report and safety check ...............................................................................................16
3.6 MOVISAFE® CS..A safety concept ..............................................................................16
3.7 Drive safety functions according to EN 61800-5-2........................................................17
3.7.1 STO – Safe Torque Off ................................................................................ 18
3.7.2 SS1(c) – Safe Stop 1 with time control ........................................................ 19
3.7.3 SS1(b) – Safe Stop 1 with monitoring of the deceleration ramp .................. 20
3.7.4 SS1(a) – Safe Stop 1 with control and monitoring of the deceleration ramp .....
21
3.7.5 SS2(c) – Safe Stop 2 with time control ........................................................ 22
3.7.6 SS2(b) – Safe Stop 2 with monitoring of the deceleration ramp .................. 23
3.7.7 SS2(a) – Safe Stop 2 with control and monitoring of the deceleration ramp .....
24
3.7.8 SOS – Safe Operating Stop ......................................................................... 25
3.7.9 SLA – Safely Limited Acceleration ............................................................... 25
3.7.10 SLS – Safely Limited Speed ........................................................................ 26
28482271/EN – 03/2019

Table of contents
Manual – MOVISAFE® CS..A Safety Card (Version 2)
4
3.7.11 SSR – Safe Speed Range ........................................................................... 26
3.7.12 SSM – Safe Speed Monitoring..................................................................... 27
3.7.13 SDI – Safe Direction..................................................................................... 27
3.7.14 SLI – Safely Limited Increment .................................................................... 28
3.7.15 SBC – Safe Brake Control ........................................................................... 28
3.8 Safety concept of Assist CS..........................................................................................29
3.8.1 Safety parameters........................................................................................ 29
3.8.2 Test concept and test procedure.................................................................. 29
4 Safety requirements ............................................................................................................... 30
4.1 Installation requirements...............................................................................................30
4.2 Encoder cable requirements .........................................................................................30
4.2.1 SINE/COSINE encoder cable ...................................................................... 30
4.2.2 HTL encoder cable....................................................................................... 31
4.3 Sensor and actuator requirements................................................................................31
4.4 Startup requirements ....................................................................................................31
4.5 Requirements for stopping in an emergency according to EN60204-1 (emergency stop)
32
4.6 Encoder requirements...................................................................................................32
4.6.1 Permitted safety encoders ........................................................................... 32
4.6.2 Quantization error ........................................................................................ 33
4.6.3 Counting direction ........................................................................................ 34
4.6.4 Preventing the mechanical limit speed from being exceeded ...................... 34
4.7 Requirements for operation ..........................................................................................35
4.8 Acceptance ...................................................................................................................35
5 Device structure ..................................................................................................................... 36
5.1 Firmware version ..........................................................................................................36
5.2 Type designation...........................................................................................................36
5.3 Nameplate.....................................................................................................................37
5.4 Scope of delivery ..........................................................................................................37
5.5 Compatibility .................................................................................................................38
5.5.1 CS..A safety card firmware version and MOVIDRIVE® device status .......... 38
5.5.2 CS..A safety card firmware version and MOVISUITE® version.................... 40
5.6 MOVISAFE® CSS21A/CSB21A ...................................................................................41
5.7 MOVISAFE® CSB31A/CSS31A ...................................................................................42
6 Mechanical installation .......................................................................................................... 43
6.1 Before you start.............................................................................................................43
6.2 Installation of the MOVISAFE®CS..A safety card........................................................43
6.3 Installation of the MOVISAFE®CS..A – MOVIDRIVE® modular safety card................43
6.4 Installation of the MOVISAFE®CS..A safety card MOVIDRIVE® system/technology ..46
7 Electrical installation.............................................................................................................. 49
7.1 Important note...............................................................................................................49
7.2 Installation instructions..................................................................................................49
7.3 Terminal assignment.....................................................................................................50
7.4 Safe disconnection........................................................................................................50
7.5 Safe digital inputs (F-DI.) ..............................................................................................50
28482271/EN – 03/2019

Table of contents
Manual – MOVISAFE® CS..A Safety Card (Version 2) 5
7.5.1 Discrepancy monitoring................................................................................ 52
7.5.2 Interlocking................................................................................................... 52
7.5.3 Signal monitoring ......................................................................................... 53
7.5.4 Pulsed voltage supply and crossfault monitoring ......................................... 53
7.5.5 Contact-equipped sensors (single-channel)................................................. 54
7.5.6 Sensors with contact (dual-channel) ............................................................ 55
7.5.7 Active sensors (dual-channel)...................................................................... 57
7.5.8 Sensors with semiconductor outputs (OSSD, dual-channel) ....................... 59
7.6 Safe digital outputs (F-DO.) ..........................................................................................60
7.6.1 General ........................................................................................................ 60
7.6.2 Capacitive loads........................................................................................... 61
7.6.3 Inductive loads ............................................................................................. 61
7.6.4 Ohmic loads ................................................................................................. 61
7.6.5 Information about line diagnostics and test pulses ...................................... 62
7.6.6 F-DO_STO output ........................................................................................ 63
7.6.7 Actuator (dual-channel, sourcing/sinking output) ......................................... 64
7.6.8 Actuator (dual-channel, sourcing output) ..................................................... 65
7.6.9 Actuator (single-channel, sourcing output)................................................... 66
7.7 Built-in encoder EI7C FS ..............................................................................................67
7.7.1 Features ....................................................................................................... 67
7.7.2 Installation .................................................................................................... 67
8 Startup ..................................................................................................................................... 68
8.1 Important note...............................................................................................................68
8.2 General startup instructions ..........................................................................................68
8.3 Startup options..............................................................................................................68
8.3.1 Design 1: Independent operation (without connection to safe communication).
68
8.3.2 Design 2: With PROFIsafe connection......................................................... 69
8.4 Adjusting the maximum test duration for load with unknown capacitance....................69
8.5 Parameterization of the drive safety functions ..............................................................70
8.5.1 Requirements............................................................................................... 70
8.5.2 Parameterization procedure......................................................................... 70
8.5.3 STO drive safety function with MOVISAFE® CS..A...................................... 71
8.5.4 SS1(c) drive safety function with MOVISAFE® CS..A .................................. 72
8.5.5 SS1(a/b) drive safety function with MOVISAFE® CS..A ............................... 73
8.5.6 SS2(c) drive safety function with MOVISAFE® CS..A .................................. 74
8.5.7 SS2(a/b) drive safety function with MOVISAFE® CS..A ............................... 75
8.5.8 SOS drive safety function with MOVISAFE® CS..A...................................... 76
8.5.9 SLA drive safety function with MOVISAFE® CS..A....................................... 77
8.5.10 SLS drive safety function with MOVISAFE® CS..A....................................... 78
8.5.11 SSR drive safety function with MOVISAFE® CS..A...................................... 78
8.5.12 SSM drive safety function with MOVISAFE® CS..A...................................... 79
8.5.13 SDI drive safety function with MOVISAFE® CS..A ....................................... 80
8.5.14 SLI drive safety function with MOVISAFE® CS..A........................................ 81
8.5.15 Encoder fault muting .................................................................................... 82
8.5.16 Muting safe process output data (muting F-PO) .......................................... 83
28482271/EN – 03/2019

Table of contents
Manual – MOVISAFE® CS..A Safety Card (Version 2)
6
8.5.17 Test mode .................................................................................................... 83
8.6 Startup of the safety card at the F-protocol...................................................................84
8.6.1 Requirements for F-communication ............................................................. 84
8.6.2 PROFIsafe protocol...................................................................................... 84
8.6.3 FSoE protocol .............................................................................................. 85
8.6.4 ISOFAST® protocol....................................................................................... 86
8.7 Operating states............................................................................................................87
8.7.1 Operating state "Operation" ......................................................................... 87
8.7.2 Operating state "Parameterization".............................................................. 87
8.7.3 Operating state "Safe state" after critical fault.............................................. 87
8.8 Safety-relevant acceptance ..........................................................................................87
8.8.1 Sequence ..................................................................................................... 88
8.8.2 Creating an acceptance report..................................................................... 88
8.8.3 Structure of the acceptance report............................................................... 88
8.8.4 Confirming acceptance ................................................................................ 89
8.9 Restoring the delivery state ..........................................................................................89
8.9.1 Requirements............................................................................................... 89
8.9.2 Procedure..................................................................................................... 89
8.10 Reset the password ......................................................................................................90
8.10.1 Procedure..................................................................................................... 90
9 Operation................................................................................................................................. 91
9.1 Hazard caused by coasting of the drive........................................................................91
10 Data exchange with higher-level controller ......................................................................... 92
10.1 Introduction ...................................................................................................................92
10.1.1 Number of safety cards on the MOVI-C® CONTROLLER............................ 92
10.2 F-periphery access of the safety card in the TIA portal ................................................92
10.2.1 F-periphery-data component of the safety card ........................................... 93
10.3 F process data profile ...................................................................................................95
10.3.1 CSS21A/CSS31A profile design "Technology Standard" ............................ 95
10.3.2 CSB31A profile design "Technology Bus F-DO"........................................ 100
10.3.3 CSB21A profile design "Technology Bus STO" ......................................... 102
10.3.4 Process input data (F-PI) substitute values ............................................... 104
10.3.5 Process output data (F-PO) substitute values ........................................... 105
10.4 Acknowledgment of safety card ..................................................................................106
10.4.1 Acknowledgment of PROFIsafe data exchange ........................................ 106
10.4.2 Acknowledgment of safety card ................................................................. 106
11 Response times .................................................................................................................... 107
11.1 Calculation of response times.....................................................................................107
11.1.1 Encoder...................................................................................................... 108
11.1.2 Safe digital input F-DI................................................................................. 108
11.1.3 Safe communication................................................................................... 109
11.1.4 Selection of a drive safety function via a safe digital input in independent
operation .................................................................................................... 109
11.1.5 Selection of a drive safety function via safe communication...................... 109
11.1.6 Response time in case of limit value violation in independent operation ... 112
28482271/EN – 03/2019

Table of contents
Manual – MOVISAFE® CS..A Safety Card (Version 2) 7
11.1.7 Response time in case of limit value violation with safe communication ... 113
11.1.8 Deselection of a drive safety function via a safe digital input..................... 114
11.1.9 Deselection of a drive safety function via safe communication.................. 114
12 Service................................................................................................................................... 115
12.1 Modification/changes to the device.............................................................................115
12.2 Waste disposal............................................................................................................115
12.3 Status LEDs ................................................................................................................116
12.3.1 "F-RUN" LED.............................................................................................. 116
12.3.2 "F-ERR" LED.............................................................................................. 117
12.4 Error states of the MOVISAFE®CS..A safety card ....................................................118
12.4.1 Fault classes .............................................................................................. 118
12.4.2 Starting behavior of the safety card ........................................................... 120
12.5 "Emergency mode" function........................................................................................120
12.5.1 Safety notes ............................................................................................... 121
12.5.2 Approved devices....................................................................................... 121
12.5.3 Requirements............................................................................................. 121
12.5.4 Starting emergency mode .......................................................................... 121
12.5.5 Ending emergency mode ........................................................................... 121
12.6 Fault diagnostics .........................................................................................................122
12.6.1 Fault messages.......................................................................................... 122
12.6.2 Diagnostics with MOVISUITE®Assist CS.. ................................................ 123
12.6.3 Diagnostics with PROFIsafe connection .................................................... 123
12.6.4 Fault memory ............................................................................................. 124
12.7 Device replacement ....................................................................................................124
12.7.1 Device replacement with MOVI-C®CONTROLLER ................................... 125
12.7.2 Device replacement with MOVISUITE®...................................................... 125
13 Technical data....................................................................................................................... 126
13.1 General technical data ................................................................................................126
13.2 General electrical data ................................................................................................126
13.2.1 Current and power consumption of the safety cards.................................. 126
13.3 Encoder interface........................................................................................................127
13.4 Safe digital inputs........................................................................................................127
13.5 Sensor supply .............................................................................................................128
13.6 Safe digital outputs .....................................................................................................128
13.7 Characteristic safety values ........................................................................................129
13.7.1 Drive safety functions without encoder evaluation ..................................... 129
13.7.2 Drive safety functions with encoder evaluation .......................................... 129
Index ...................................................................................................................................... 130
28482271/EN – 03/2019

1General information
About this documentation
Manual – MOVISAFE® CS..A Safety Card (Version 2)
8
1 General information
1.1 About this documentation
The current version of the documentation 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 Structure of the safety notes
1.2.1 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.
1.2.2 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.
28482271/EN – 03/2019

1
General information
Rights to claim under limited warranty
Manual – MOVISAFE® CS..A Safety Card (Version 2) 9
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
Warning of automatic restart
1.2.3 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 disregar-
ded. Measure(s) to prevent the hazard.
1.3 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.
1.4 Content of the documentation
This documentation contains additional safety-related information and conditions for
operation in safety-related applications.
1.5 Other applicable documentation
This document supplements the operating instructions and limits the application notes
according to the following information. Use this document only in connection with the
operating instructions.
• "MOVIDRIVE® modular", "MOVIDRIVE® system" and MOVIDRIVE® technology"
operating instructions
• Addendum to "Safety Encoders and Safety Brakes DR.., DRN.., DR2.., EDR..,
EDRN.. AC Motors" operating instructions functional safety
• Addendum to the operating instructions "AK0H/AK1H Safety Encoders – CMP40 –
150, CMPZ71 – 100 Synchronous Servomotors Functional Safety".
28482271/EN – 03/2019

1General information
Decimal separator in numerical values
Manual – MOVISAFE® CS..A Safety Card (Version 2)
10
1.6 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.7 Copyright notice
©2019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.
1.8 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.8.1 Trademarks of Beckhoff Automation GmbH
EtherCAT® and Safety over EtherCAT® are registered trademarks and patented tech-
nologies, licensed by Beckhoff Automation GmbH, Germany.
25798632331
28482271/EN – 03/2019

2
Safety notes
Preliminary information
Manual – MOVISAFE® CS..A Safety Card (Version 2) 11
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 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following is carried out
only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
and wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and conditions
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and le-
gislation governing technical work equipment and accident prevention regulations.
2.3 Target group
Specialist for me-
chanical work
Any mechanical work may only be performed by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons familiar with the design, me-
chanical installation, troubleshooting, and maintenance of the product who possess
the following qualifications:
• Qualification in the mechanical area in accordance with the national regulations
• Familiarity with this documentation
28482271/EN – 03/2019

2Safety notes
Designated use
Manual – MOVISAFE® CS..A Safety Card (Version 2)
12
Specialist for elec-
trotechnical work
Any electrotechnical work may only be performed by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons familiar with electrical installation, startup, troubleshooting, and maintenance
of the product who possess the following qualifications:
• Qualification in the electrotechnical area in accordance with the national regula-
tions
• Familiarity with this documentation
Additional qualifi-
cation
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation. The persons must have the express authorization of the com-
pany to operate, program, parameterize, label, and ground units, systems, and circuits
in accordance with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the instruction is
that the persons are capable of performing the required tasks and work steps in a safe
and correct manner.
2.4 Designated use
The product is intended for installation in inverters.
The product is a configurable safety control for realizing safety cutoffs and functions.
The product is intended for use:
• In emergency stop devices
• As a safety-related component pursuant to Machinery Directive 2006/42/EC
• As a PES for risk reduction pursuant to EN61508
• In safety circuits according to EN60204-1
• As a PES for functional safety pursuant to EN62061
• As a SRP/CS pursuant to ENISO13849
• As a device for implementing the safety functions pursuant to EN61800-5-2
In the case of installation in electrical systems or machines, it is prohibited to start the
proper operation of the product until it is determined that the machine meets the re-
quirements stipulated in the local laws and directives.
The standards given in the declaration of conformity apply to the product.
Unintended or improper use of the product may result in severe injury to persons and
damage to property.
Technical data and information on the connection conditions are provided on the
nameplate and in the chapter "Technical data" in the documentation. Always comply
with the data and conditions.
2.5 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
Observe the following notes when transporting the device:
• Ensure that the product is not subject to mechanical impact.
28482271/EN – 03/2019

2
Safety notes
Installation/assembly
Manual – MOVISAFE® CS..A Safety Card (Version 2) 13
If necessary, use suitable, sufficiently dimensioned handling equipment.
Observe the information on climatic conditions in the chapter "Technical data" of the
documentation.
2.6 Installation/assembly
Ensure that the product is installed and cooled according to the regulations in the doc-
umentation.
Protect the product from strong mechanical strain. The product and its mounting parts
must never protrude into the path of persons or vehicles. Ensure that components are
not deformed and insulation spaces are not changed, particularly during transportation
and handling. Electric components must not be mechanically damaged or destroyed.
Observe the notes in chapter "Mechanical installation" (→ 2 43) in the documenta-
tion.
2.6.1 Restrictions of use
The following applications are prohibited unless the device is explicitly designed for
such use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation
• Operation in applications with impermissibly high mechanical vibration and shock
loads in excess of the regulations stipulated in EN61800-5-1
• Use at an elevation of more than 3800m above sea level
2.7 Electrical installation
Ensure that all of the required covers are correctly attached after carrying out the elec-
trical installation.
Make sure that preventive measures and protection devices comply with the applic-
able regulations (e.g. EN60204-1 or EN61800-5-1).
28482271/EN – 03/2019

2Safety notes
Definitions
Manual – MOVISAFE® CS..A Safety Card (Version 2)
14
2.8 Definitions
• The designation "F-DI." stands for a safe input.
• The designation "F-DO." stands for a safe output.
• The designation "CS..A" is used as a generic term for all derivatives of the
MOVISAFE® CS product series. If a particular derivative is referred to in the
manual, then the complete designation is used.
• The term "safe" used in this manual refers to the classification as a safe function
according to ENISO13849-1.
• The "Assist CS.." parameter tool is the parameterization interface in MOVISUITE®
for the MOVISAFE® CS..A safety card.
2.9 Startup/operation
Observe the safety notes in the chapters "Startup" (→ 2 68) and "Opera-
tion"(→291) in the documentation.
Depending on the degree of protection, products may have live, uninsulated, and
sometimes moving or rotating parts, as well as hot surfaces during operation.
Mechanical blocking or internal protective functions of the product can cause a motor
standstill. Eliminating the cause of the problem or performing a reset may result in the
drive restarting automatically. If, for safety reasons, this is not permitted for the drive-
controlled machine, first disconnect the product from the supply system and then start
troubleshooting.
The fact that the operation LED and other display elements are no longer illuminated
does not indicate that the product has been disconnected from the supply system and
no longer carries any voltage.
In the event of deviations from normal operation, switch the product off. Possible devi-
ations are increased temperatures, noise, or vibration, for example. Determine the
cause. Contact SEW‑EURODRIVE if necessary.
Do not deactivate monitoring and protection devices of the machine or system even
for a test run.
Additional preventive measures may be required for applications with increased haz-
ard potential. Be sure to check the effectiveness of the protection devices after every
modification.
28482271/EN – 03/2019

3
Safety concept
General
Manual – MOVISAFE® CS..A Safety Card (Version 2) 15
3 Safety concept
3.1 General
The MOVISAFE® CS..A safety card is a safe assembly with safe digital inputs and out-
puts and, depending on the parameterization, safe communication.
MOVISAFE® CS..A is fully integrated in the MOVIDRIVE® modular/system/technology
inverters. This means that MOVISAFE® CS..A inside the devices activates the STO
drive safety function of the inverter. Instead of galvanic isolation of the drive from the
supply system by means of contactors or switches, the disconnection via STO within
the device 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.
The safety concept is based on a safe state existing for all safe process values. A safe
state of the MOVISAFE®CS..A safety card is defined as follows:
• The internal output F-DO_STO is disabled. This activates the STO drive safety
function.
• All other existing safe digital outputs are disabled.
• With parameterized safe communication, either substitute values are sent for the
data (i.e. all data is "0"), or the communication is interrupted.
3.2 Notes on stop categories
• The STO drive safety function corresponds to stop category 0.
• The SS1(c), SS1(b) and SS1(a) drive safety functions correspond to stop category
1.
• The SS2(c), SS3(b) and SS2(a) drive safety functions correspond to stop category
2.
28482271/EN – 03/2019

3Safety concept
Pluggable safety key
Manual – MOVISAFE® CS..A Safety Card (Version 2)
16
3.3 Pluggable safety key
The safety key must be inserted upon activation of the MOVISAFE®CS..A safety card
and may not be removed when the safety card is activated.
The parameterization data of the MOVISAFE® CS..A safety card is divided into appli-
cation-related data and the key data set. The key data set ensures the data integrity.
The application-related data is stored in the device. The application-related data is re-
leased with the aid of the key data set on the pluggable safety key. The safety card
becomes operational only if the key data set on the pluggable safety key matches the
parameterization.
The pluggable safety key is also used to establish a location reference in the system.
Since the application-related data set is released only with the matching key data set
on the pluggable safety key, the location reference can be established in this way. It is
the user’s responsibility to secure the location reference of the pluggable safety key in
the system. The data for safe communication is also stored on the pluggable safety
key, because this data has the same location reference. This ensures that, in the
event of a device replacement, the application-related data and the communication
data are available again immediately.
3.4 Identification and authentication
In the "Assist CS.." parameterization tool, unique identification of the device and an
authentication of the user is necessary for the steps "Parameterize", "Create report"
and "Confirm validation". To identify the device, enter the ID of the pluggable safety
key in the login dialog of the parameterization tool. The safety key ID is printed on the
safety key. As an alternative, the safety key ID can be read by the "Assist CS.." para-
meterization tool. To do this, the user must perform an identity verification using the
LED display of the device. This mechanism with the safety key ID ensures that the pa-
rameterization tool Assist CS.. is connected to the correct device. The user is authen-
ticated via the entry of a password.
3.5 Report and safety check
The acceptance report can be created once the parameters are downloaded. The ac-
ceptance of the safety card within the system can be carried out (see chapter "Re-
quirements for startup") with this acceptance report. Following acceptance, this must
be confirmed in the safety card. The confirmation is not a replacement for the test that
must be carried out. The "Checksum of the report" of the safety card is announced as
confirmation of the acceptance in the "Assist CS.." parameterization tool.
3.6 MOVISAFE® CS..A safety concept
MOVISAFE
®CS..A
safety
concept
• The MOVISAFE®CS..A safety card is an integrated, safe electronic assembly that
can be operated with or without a safe communication. PROFIsafe, FSoE, and
ISOFAST® are available for safe communication. MOVISAFE® CS..A is equipped
with safe inputs and outputs (F-DI, F-DO) and is available in the following designs.
MOVISAFE® CSB21A safety card:
– 4 safe inputs
MOVISAFE® CSS21A safety card:
28482271/EN – 03/2019

3
Safety concept
Drive safety functions according to EN 61800-5-2
Manual – MOVISAFE® CS..A Safety Card (Version 2) 17
– 4 safe inputs
– 2 safe dual-channel outputs
MOVISAFE® CSB31A safety card:
– 4 safe inputs
– 2 safe dual-channel outputs
– Second encoder slot (not used for functional safety)
MOVISAFE® CSS31A safety card:
– 4 safe inputs
– 2 safe dual-channel outputs
– Second encoder slot (not used for functional safety)
• The MOVISAFE® CS..A safety card can release or safely deactivate the output
stage of the inverter. The switching state of the internal output F-DO_STO, and
thus the STO drive safety function, must stable on "1" or stable on "0" once within
60seconds for at least 2seconds (2.5seconds with extended diagnostics).
• The safety concept of the MOVISAFE®CS..A safety card is based on a safe state
existing for all safe process values. For the MOVISAFE®CS..A, this value is "0" for
all F-DI inputs and F-DO outputs.
• The MOVISAFE® CS..A safety card was designed pursuant to IEC61508 for SIL3
and ENISO13849-1 for Performance Level e.
• The MOVISAFE® CSS21A and CSS31A safety cards can reliably monitor motion
functions in conjunction with encoders.
3.7 Drive safety functions according to EN 61800-5-2
This chapter describes the drive safety functions pursuant to EN61800-5-2. The fol-
lowing table shows the availability of the drive safety functions described below, de-
pending on the respective MOVISAFE®CS..A safety card used.
MOVISAFE®
safety card
Drive safety functions
Standstill Motion
STO SBC SS1(c) SS1(a)
SS1(b)
SS2(c) SS2(a)
SS2(b)
SOS SLS SSM SSR SDI SLI SLA
Only with FS encoder
CSB21A x x
CSS21A x x x x x x x x x x x x x
CSB31A1) x x x
CSS31A1) x x x x x x x x x x x x x
1) has a second encoder connection (not used for functional safety)
28482271/EN – 03/2019

3Safety concept
Drive safety functions according to EN 61800-5-2
Manual – MOVISAFE® CS..A Safety Card (Version 2)
18
3.7.1 STO – Safe Torque Off
If the STO function is activated, the drive inverter no longer supplies power to the mo-
tor. As a result, the drive cannot generate torque. This drive safety function corres-
ponds to a non-controlled stop according to EN60204-1, stop category 0.
t
V
t1
9007201225613323
=Drive safety function active
v = Speed
t = Time
t1=Point of time when STO is triggered.
INFORMATION
The motor coasts to a halt or is stopped mechanically.
Controlled standstill is preferred, if possible.
28482271/EN – 03/2019

3
Safety concept
Drive safety functions according to EN 61800-5-2
Manual – MOVISAFE® CS..A Safety Card (Version 2) 19
3.7.2 SS1(c) – Safe Stop 1 with time control
When the SS1(c) function is active, the inverter brings the motor to a standstill electri-
cally. The drive safety function STO is triggered after a specified, safety-related time.
This drive safety function corresponds to a controlled stop of the drive according to
EN60204-1, stop category 1.
t2 t1
t
V
∆t
9007201225618443
=Drive safety function monitoring
=STO drive safety function active
v = Speed
t = Time
t1=Point of time when SS1(c) is activated and motor deceleration is triggered.
t2=Point of time when STO is triggered.
Δt = Safety-relevant period of time
INFORMATION
• The SS1(c) function does not monitor the stopping of the drive.
• The safety-related period of time Δt allows the drive to come to a stop. In the
event of a fault, the drive does not come to a stop and becomes de-energized at
the time t2 (STO).
28482271/EN – 03/2019

3Safety concept
Drive safety functions according to EN 61800-5-2
Manual – MOVISAFE® CS..A Safety Card (Version 2)
20
3.7.3 SS1(b) – Safe Stop 1 with monitoring of the deceleration ramp
When the SS1(b) function is active, the drive inverter brings the motor to a standstill e-
lectrically. The deceleration is monitored. The STO drive safety function is triggered
when the monitored deceleration is exceeded or when standstill is reached.
This drive safety function corresponds to a controlled stop of the drive according to
EN60204-1, stop category 1.
t
V
t1t2
9007201225616011
=Drive safety function monitoring
=Drive safety function trips
v = Speed
t = Time
t1=Point in time when SS1(b) is activated and motor deceleration is triggered.
t2=Point of time when STO is triggered.
28482271/EN – 03/2019