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
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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
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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
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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
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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
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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.
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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
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