SEW-Eurodrive MOVIFIT FC User manual

Drive Technology \ Drive Automation \ System Integration \ Services
Manual
MOVIFIT
®
FC
Functional Safety with S12 Safety Option
Edition 07/2013 20087756 / EN

SEW-EURODRIVE—Driving the world

Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option 3
Contents
Contents
1 General information ............................................................................................ 9
1.1 How to use this documentation................................................................... 9
1.2 Structure of the safety notes ....................................................................... 9
1.2.1 Meaning of signal words.............................................................. 9
1.2.2 Design of the section-related safety notes................................... 9
1.2.3 Design of the embedded safety notes ......................................... 9
1.3 Rights to claim under warranty ................................................................. 10
1.4 Content of the documentation................................................................... 10
1.5 Exclusion of liability................................................................................... 10
1.6 Other applicable documentation ............................................................... 10
1.7 Product names and trademarks................................................................ 10
1.8 Copyright................................................................................................... 10
2 Safety notes....................................................................................................... 11
2.1 General information .................................................................................. 11
2.2 Target group ............................................................................................. 11
2.3 Designated use ......................................................................................... 12
2.4 Transportation and storage....................................................................... 12
2.5 Installation................................................................................................. 13
2.6 Definitions ................................................................................................. 13
3 Safety concept................................................................................................... 14
3.1 Safety concept for MOVIFIT®FC frequency inverters ............................. 14
3.1.1 Description of the function ......................................................... 14
3.1.2 MOVIFIT®FC block diagram..................................................... 15
3.1.3 Restrictions ................................................................................ 15
3.2 Safety concept of S12 safety option ......................................................... 16
3.3 Drive safety functions................................................................................ 17
3.3.1 STO – Safe Torque Off.............................................................. 17
3.3.2 SS1(a) – Safe Stop 1................................................................. 18
3.3.3 SS1(c) – Safe Stop 1................................................................. 19
3.3.4 SLS – Safely Limited Speed...................................................... 20
3.3.5 SDI – Safe Direction .................................................................. 21
3.4 Safety concept of Assist S12 .................................................................... 22
3.4.1 Safety parameters ..................................................................... 22
3.4.2 Test concept and test procedure ............................................... 22
4 Safety conditions .............................................................................................. 24
4.1 Notes on stop categories .......................................................................... 24
4.2 Nameplates............................................................................................... 25
4.2.1 Nameplate position.................................................................... 25
4.2.2 Nameplate of complete unit....................................................... 25
4.2.3 Description of FS logo ............................................................... 26
4.3 Installation requirements........................................................................... 26
4.4 Sensor and actuator requirements............................................................ 27
4.5 Startup requirements ................................................................................ 27

4Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option
Contents
4.6 Operational requirements ......................................................................... 27
5 Hazard caused by a coasting drive ................................................................. 28
6 Electrical installation ........................................................................................ 29
6.1 Installation instructions.............................................................................. 29
6.1.1 UL-compliant installation............................................................ 29
6.2 Safe disconnection of MOVIFIT®.............................................................. 30
6.2.1 MOVIFIT®FC ............................................................................ 30
6.2.2 Connection example, power bus ............................................... 32
6.2.3 Safety-related stopping with S12 safety option.......................... 33
6.3 S12 safety option – electrical installation .................................................. 34
6.3.1 Terminal assignment ................................................................. 34
6.3.2 Safety-related inputs (F-DI.) ...................................................... 37
6.3.3 Safety-related outputs (F-DO. and F-DO_STO) ........................ 45
6.4 Incremental encoder EI7C FS................................................................... 51
6.4.1 Properties .................................................................................. 51
6.4.2 Installation.................................................................................. 51
7 Safety functions of the S12 safety option....................................................... 57
7.1 STO – Safe Torque Off ............................................................................. 57
7.1.1 Description of the function ......................................................... 57
7.1.2 Activation ................................................................................... 58
7.1.3 Status......................................................................................... 58
7.1.4 Parameter.................................................................................. 58
7.2 SS1(c) – Safe Stop 1 ................................................................................ 59
7.2.1 Description of the function ......................................................... 59
7.2.2 Activation ................................................................................... 59
7.2.3 Status......................................................................................... 59
7.2.4 Parameter.................................................................................. 59
7.3 SS1(a) – Safe Stop 1 ................................................................................ 60
7.3.1 Description of the function ......................................................... 60
7.3.2 Activation ................................................................................... 61
7.3.3 Status......................................................................................... 61
7.3.4 Parameter.................................................................................. 61
7.4 SLS – Safely Limited Speed ..................................................................... 62
7.4.1 Description of the function ......................................................... 62
7.4.2 Activation ................................................................................... 63
7.4.3 Status......................................................................................... 63
7.4.4 Error response ........................................................................... 63
7.4.5 Parameter.................................................................................. 64
7.4.6 Speed filter determination.......................................................... 64
7.5 SDI – Safe Direction ................................................................................. 66
7.5.1 Description of the function ......................................................... 66
7.5.2 Activation ................................................................................... 67
7.5.3 Status......................................................................................... 67
7.5.4 Error response ........................................................................... 67
7.5.5 Parameter.................................................................................. 67

Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option 5
Contents
7.6 Safety-related inputs ................................................................................. 68
7.6.1 Description of the function ......................................................... 68
7.6.2 Connection type......................................................................... 68
7.6.3 Parameter.................................................................................. 70
7.7 Safety-related outputs............................................................................... 71
7.7.1 Description of the function ......................................................... 71
7.7.2 Parameter.................................................................................. 71
7.8 Function assignment................................................................................. 72
7.8.1 Parameter.................................................................................. 72
7.9 Test mode ................................................................................................. 73
7.9.1 Description of the function ......................................................... 73
7.9.2 Activation ................................................................................... 73
7.9.3 Status......................................................................................... 73
7.10 Coasting time measurement ..................................................................... 74
7.10.1 Definition.................................................................................... 74
7.10.2 Description of the function ......................................................... 74
7.10.3 Activation ................................................................................... 75
7.10.4 Parameter.................................................................................. 75
8 Startup................................................................................................................ 76
8.1 General startup instructions ...................................................................... 76
8.2 Startup variants......................................................................................... 76
8.2.1 Startup with default parameter setting (without "Assist S12"
parameterization tool ................................................................. 76
8.2.2 Startup for independent operation ............................................. 77
8.2.3 Startup with PROFIsafe connection .......................................... 77
8.3 Setting the safety function parameters ..................................................... 78
8.3.1 Requirements ............................................................................ 78
8.3.2 Procedure .................................................................................. 78
8.4 Startup of the fieldbus and the higher-level F-PLC ................................... 80
8.4.1 Requirements ............................................................................ 80
8.4.2 Setting the PROFIsafe address................................................. 80
8.4.3 Configuring the S12 safety option in STEP 7 ............................ 82
8.5 Verification and validation ......................................................................... 86
8.5.1 Overview.................................................................................... 86
8.5.2 Verification................................................................................. 86
8.5.3 Validation................................................................................... 88
9 Assist S12 .......................................................................................................... 89
9.1 Structure of the user interface................................................................... 89
9.1.1 Menu bar.................................................................................... 90
9.1.2 Parameterization steps.............................................................. 90
9.1.3 Tool bar...................................................................................... 91
9.1.4 Parameterization window........................................................... 91
9.1.5 Plausibility error indication......................................................... 92
9.1.6 Status bar .................................................................................. 92
9.1.7 Change password...................................................................... 93

6Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option
Contents
9.2 Data management .................................................................................... 94
9.2.1 Project-relevant files .................................................................. 94
9.2.2 Data management with non-configured S12 safety option ....... 95
9.2.3 Data management with configured S12 safety option .............. 96
9.3 Parameterization....................................................................................... 97
9.3.1 Parameter setting ..................................................................... 97
9.3.2 Parameterization procedure ...................................................... 98
9.3.3 Changing the parameter settings............................................. 101
9.3.4 Parameter display.................................................................... 102
9.4 Device data ............................................................................................. 102
9.5 Status displays........................................................................................ 102
9.6 Safety functions ...................................................................................... 103
9.6.1 Overview.................................................................................. 103
9.6.2 Safety function status .............................................................. 104
9.6.3 F-DI inputs ............................................................................... 104
9.6.4 F-DO outputs ........................................................................... 106
9.6.5 Test mode................................................................................ 106
9.7 Process data ........................................................................................... 107
9.8 Encoder................................................................................................... 107
9.9 Error memory .......................................................................................... 108
10 Data exchange................................................................................................. 109
10.1 Introduction ............................................................................................. 109
10.2 F periphery access of the S12 safety option in STEP 7.......................... 110
10.2.1 F periphery DB of S12 safety option........................................ 110
10.2.2 F user data of S12 safety option.............................................. 112
10.2.3 Activation examples for the S12 safety option......................... 116
11 Response times............................................................................................... 120
12 Service ............................................................................................................. 121
12.1 Diagnostic LEDs ..................................................................................... 121
12.1.1 "FDI.." and "FDO.." LEDs ........................................................ 122
12.1.2 "F-FUNC" LED......................................................................... 122
12.1.3 "F-STATE" LED ....................................................................... 123
12.2 Error states of the S12 safety option....................................................... 123
12.2.1 Error in the safety module........................................................ 123
12.2.2 PROFIsafe timeout .................................................................. 123
12.2.3 Safety diagnostics using PROFIBUS DP................................. 124
12.2.4 Safety diagnostics via PROFINET IO...................................... 124
12.3 Diagnostics with Assist S12 .................................................................... 125
12.3.1 Status displays......................................................................... 125
12.3.2 Error memory........................................................................... 128
12.4 Unit replacement..................................................................................... 129
12.4.1 Replacing the EBOX................................................................ 130
12.4.2 Replacing the ABOX with/without EBOX ................................. 131
12.5 Error table of the S12 safety option ........................................................ 132

Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option 7
Contents
13 Parameter description .................................................................................... 137
13.1 General information ................................................................................ 137
13.1.1 10122.7 IO error effects........................................................... 137
13.1.2 10122.10 PROFIsafe fieldbus.................................................. 137
13.1.3 10122.2 Encoder type.............................................................. 137
13.1.4 10122.8 Maximum motor speed (n1)....................................... 137
13.1.5 10122.9 Minimum motor speed (n2)........................................ 138
13.2 F-DI ......................................................................................................... 138
13.2.1 Safety-related digital inputs ..................................................... 138
13.2.2 Diagnostics .............................................................................. 138
13.3 F-DO ....................................................................................................... 139
13.3.1 10124.6 F-DO-STO line diagnostics........................................ 139
13.3.2 10124.9 F-DO-STO test duration (t1) ...................................... 139
13.3.3 10124.12 F-DO-STO wire break monitoring............................ 139
13.3.4 10124.2, 10124.3 F-DO0/1 connection type............................ 140
13.3.5 10124.4, 10124.5 F-DO0/1 line diagnostics ............................ 140
13.3.6 10124.7, 10124.8 F-DO0/1 test duration (t2, t3)...................... 140
13.3.7 10124.10, 10124.11 F-DO0/1 wire break monitoring............... 140
13.4 STO / SBC .............................................................................................. 141
13.4.1 10125.3 STO delay (t1) ........................................................... 141
13.4.2 10125.2 STO status display delay (t2)..................................... 141
13.4.3 10125.4 Permitted coasting time (t3)....................................... 141
13.5 SS1 ......................................................................................................... 141
13.5.1 10126.2 Function..................................................................... 141
13.5.2 10126.3 SS1c delay (t1) .......................................................... 142
13.5.3 10126.6 SS1a ramp monitoring delay (t2)............................... 142
13.5.4 10126.5 SS1a ramp time (t3)................................................... 142
13.5.5 10126.7 SS1a distance to ramp (n1) ....................................... 142
13.5.6 10126.4 SS1a STO function selection delay (t4)..................... 142
13.6 SLS 0, 1, 2, 3 .......................................................................................... 143
13.6.1 10128.2 – 10131.2 Function.................................................... 143
13.6.2 10128.3 – 10131.3 Limit speed, positive (n1).......................... 143
13.6.3 10128.4 – 10131.4 Limit speed, negative (n1) ........................ 143
13.6.4 10128.5 – 10131.5 Distance to limit speed (n3) ...................... 143
13.6.5 10128.6 – 10131.6 SDI function .............................................. 143
13.7 SLS (general).......................................................................................... 144
13.7.1 10127.4 Ramp monitoring delay (t1) ....................................... 144
13.7.2 10127.2 Ramp time (t2)........................................................... 144
13.7.3 10127.3 Distance to ramp (n4) ................................................ 144
13.7.4 10127.5 Error response to overspeed ..................................... 144
13.7.5 10127.6 Speed filter................................................................. 144
13.7.6 10127.7 SDI tolerance............................................................. 145
13.8 Function assignment............................................................................... 145
13.8.1 Safety-related inputs................................................................ 145
13.8.2 Safety-related outputs.............................................................. 145

8Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option
Contents
14 Application examples ..................................................................................... 147
14.1 Example 1: Independent operation ......................................................... 147
14.2 Example 2: PROFIsafe connection ........................................................ 149
15 Technical data ................................................................................................. 151
15.1 Safety characteristics.............................................................................. 151
15.1.1 Overall assembly: S12 safety option ....................................... 151
15.1.2 Extended safety class for safety-related digital inputs
and outputs.............................................................................. 152
15.1.3 MOVIFIT®FC .......................................................................... 152
15.2 Technical data: S12 safety option........................................................... 153
15.2.1 Voltage supply ......................................................................... 153
15.2.2 Safety-related inputs................................................................ 153
15.2.3 Sensor supply of pulse outputs................................................ 153
15.2.4 Safety-related outputs.............................................................. 154
15.2.5 Encoder interface..................................................................... 155
15.2.6 Ambient conditions .................................................................. 155
15.3 Technical data of MOVIFIT®FC (safety technology).............................. 156
16 Address list...................................................................................................... 157
Index................................................................................................................. 169

Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option 9
1
How to use this documentation
General information
1 General information
1.1 How to use this documentation
The documentation is an integral part of the product and contains important information
on operation and service. The documentation is written for all employees who assemble,
install, start up, and service this product.
The documentation must be accessible and legible. Make sure that persons responsible
for the system and its operation, as well as persons who work independently on the unit,
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 graduation and meaning of the signal words for safety
notes, warnings regarding potential risks of damage to property, and other notes.
1.2.2 Design of the section-related safety notes
Section-related safety notes do not apply to a specific action, but to several actions per-
taining to one subject. The symbols used either indicate a general hazard or a specific
hazard.
This is the formal structure of a safety note for a specific section:
1.2.3 Design of the 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 disregarded.
– Measure(s) to prevent the hazard.
Signal word Meaning Consequences if disregarded
DANGER! Imminent hazard Severe or fatal injuries
WARNING! Possible dangerous situation Severe or fatal injuries
CAUTION! Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the drive system or its envi-
ronment
NOTE Useful information or tip: Simpli-
fies handling of the drive sys-
tem.
SIGNAL WORD!
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.

10 Manual – MOVIFIT®-FC – Functional Safety with S12 Safety Option
1Rights to claim under warranty
General information
1.3 Rights to claim under warranty
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 documentation. Therefore read the
documentation before you start working with the unit.
1.4 Content of the documentation
This document contains additional safety-related information and conditions for opera-
tion in safety-related applications.
1.5 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation and to achieve the specified product characteristics and performance fea-
tures. SEW-EURODRIVE assumes no liability for injury to persons or damage to equip-
ment or property resulting from non-observance of these operating instructions. In such
cases, any liability for defects is excluded.
1.6 Other applicable documentation
This manual supplements the existing documentation and limits the application notes
according to the information below. Use this manual only together with the following doc-
uments:
• "DR.71-225, 315 AC Motors" operating instructions
•"MOVIFIT
®FC" operating instructions
• Manuals for the corresponding function level and fieldbus:
–"MOVIFIT
®Function Level "Classic"" ...
–"MOVIFIT
®Function Level "Technology""...
• "Safety-Rated Encoders – Functional Safety for AC Motors" addendum
1.7 Product names and trademarks
All product names in this documentation are trademarks or registered trademarks of
their respective titleholders.
1.8 Copyright
© 2013 – SEW-EURODRIVE. All rights reserved.
Unauthorized reproduction, modification, distribution or any other use of the whole or
any part of this documentation is strictly prohibited.