SICK MOC3ZA User manual

OPERATING INSTRUCTIONS
MOC3ZA
Standstill Monitor

Described product
MOC3ZA
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Purpose of this document........................................................................ 5
1.2 Scope......................................................................................................... 5
1.3 Target groups of these operating instructions........................................ 5
1.4 Additional information.............................................................................. 5
1.5 Symbols and document conventions...................................................... 6
2 Safety information............................................................................ 7
2.1 General safety notes................................................................................ 7
2.2 Intended use............................................................................................. 7
2.3 Requirements for the qualification of personnel.................................... 8
3 Product description........................................................................... 9
3.1 General description.................................................................................. 9
3.2 Control elements and status indicators.................................................. 10
3.3 Function of the Standstill Monitor .......................................................... 11
3.4 External device monitoring (EDM)........................................................... 12
4 Project planning................................................................................ 13
4.1 Manufacturer of the machine.................................................................. 13
4.2 Operating entity of the machine.............................................................. 13
4.3 Integrating the equipment into the electrical control............................. 13
4.3.1 External device monitoring (EDM).......................................... 13
4.3.2 Operation with DC motors....................................................... 13
4.3.3 Operation with electronic motor controllers........................... 14
4.3.4 Motors with switched windings............................................... 14
4.3.5 Connection diagrams.............................................................. 15
4.4 Testing plan............................................................................................... 17
4.4.1 Planning the thorough check during commissioning and in
certain situations..................................................................... 17
4.4.2 Planning the regular thorough check..................................... 18
5 Mounting............................................................................................. 19
5.1 Mounting the Standstill Monitor.............................................................. 19
5.2 Removing the Standstill Monitor............................................................. 19
5.3 Plug-in terminal blocks............................................................................. 19
5.4 Removing the pluggable terminal blocks................................................ 20
6 Electrical installation........................................................................ 21
6.1 Device connection.................................................................................... 21
6.1.1 Internal circuitry....................................................................... 23
7 Commissioning.................................................................................. 24
7.1 General acceptance ................................................................................ 24
7.2 Commissioning......................................................................................... 24
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7.3 Check during commissioning and modifications.................................... 25
8 Troubleshooting................................................................................. 26
8.1 In the event of faults or errors................................................................. 26
8.2 Error monitoring........................................................................................ 26
8.2.1 Internal errors.......................................................................... 26
8.2.2 Wire break/offset.................................................................... 27
8.2.3 EDM error................................................................................. 27
8.2.4 Simultaneity of the measured signals.................................... 27
8.2.5 Error storage and deletion....................................................... 28
8.3 Fault indicators......................................................................................... 28
9 Decommissioning............................................................................. 32
9.1 Disposal..................................................................................................... 32
10 Technical data.................................................................................... 33
10.1 Data sheet................................................................................................. 33
10.2 Dimensional drawings.............................................................................. 37
11 Ordering information........................................................................ 38
11.1 Ordering information MOC3ZA................................................................. 38
12 Glossary.............................................................................................. 39
13 Annex.................................................................................................. 41
13.1 Checklist for initial commissioning and commissioning........................ 41
13.2 Conformities and certificates................................................................... 41
13.2.1 EU declaration of conformity................................................... 41
13.2.2 UK declaration of conformity.................................................. 42
14 List of figures..................................................................................... 43
15 List of tables....................................................................................... 44
CONTENTS
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1 About this document
1.1 Purpose of this document
These operating instructions are designed to address the technical personnel of the
machine manufacturer or the machine owner in regards to safe mounting, installation,
configuration, electrical installation, commissioning, operation and maintenance of the
Standstill Monitor.
These operating instructions do not provide instructions for operating machines on
which the MOC3ZA is, or will be, integrated. Information on this is to be found in the
operating instructions for the machine.
1.2 Scope
Product
This document applies to the following products:
•Product code: MOC3ZA
•“Operating instructions” type label entry: 8014608
Document identification
Document part number:
•This document: 8027992
•Available language versions of this document: 8014608
You can find the current version of all documents at www.sick.com.
1.3 Target groups of these operating instructions
Some chapters of these operating instructions are intended for certain target groups.
However, the entire operating instructions are relevant for intended use of the product.
Table 1: Target groups and selected chapters of these operating instructions
Target group Chapters of these operating instructions
Project developers (planners, developers,
designers)
"Project planning", page 13
"Technical data", page 33
Installers "Mounting", page 19
Electricians "Electrical installation", page 21
Safety experts (such as CE authorized repre‐
sentatives, compliance officers, people who
test and approve the application)
"Project planning", page 13
"Commissioning", page 24
"Technical data", page 33
"Checklist for initial commissioning and com‐
missioning", page 41
Operators "Troubleshooting", page 26
Maintenance personnel "Troubleshooting", page 26
1.4 Additional information
www.sick.com
The following information is available on the Internet:
•Data sheets and application examples
•CAD data and dimensional drawings
•Certificates (e.g. EU declaration of conformity)
•Guide for Safe Machinery Six steps to a safe machine
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1.5 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
bThe arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓The check mark denotes the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
oThe LED is off.
ÖThe LED is flashing.
OThe LED is illuminated continuously.
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 General safety notes
Product integration
DANGER
The product can not offer the expected protection if it is integrated incorrectly.
bPlan the integration of the product in accordance with the machine requirements
(project planning).
bImplement the integration of the product in accordance with the project planning.
Mounting and electrical installation
DANGER
Death or severe injury due to electrical voltage and/or an unexpected startup of the
machine
bMake sure that the machine is (and remains) disconnected from the voltage
supply during mounting and electrical installation.
bMake sure that the dangerous state of the machine is and remains switched off.
Repairs and modifications
DANGER
Improper work on the product
A modified product may not offer the expected protection if it is integrated incorrectly.
bApart from the procedures described in this document, do not repair, open, manip‐
ulate or otherwise modify the product.
2.2 Intended use
The Standstill Monitor is used for the sensor-less monitoring of electric motors for
standstill. It makes possible the safe detection of the standstill of electric motors, e.g.
to enable the unlocking of guards on machine tools or to activate retaining brakes. The
Standstill Monitor can be used as per the following standards:
•IEC 61508 and IEC 61511 up to SIL3
•IEC 62061 up to SIL3
•ISO 138491 up to category 4
•ISO 138491 up to Performance Level e
The degree of safety actually attained depends on the external circuit and the design of
the wiring.
NOTICE
The Standstill Monitor complies with the requirements as defined for class B as per EN
55011:2009 + A1:2010.
Class B devices are devices that are suitable for operation in the residential sector as
well as in those sectors that are connected directly to a low voltage supply network that
(also) supplies residential buildings.
The Standstill Monitor must be used only by qualified personnel and only on the
machine where it has been installed and initialized by qualified safety personnel in
accordance with these operating instructions.
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The product may be used in safety functions.
Incorrect use, improper modification or manipulation of the product will invalidate any
warranty from SICK; in addition, any responsibility and liability of SICK for damage and
secondary damage caused by this is excluded.
2.3 Requirements for the qualification of personnel
The product must be configured, installed, connected, commissioned, and serviced by
qualified safety personnel only.
Project planning
You need safety expertise to implement safety functions and select suitable products
for that purpose. You need expert knowledge of the applicable standards and regula‐
tions.
Mounting, electrical installation and commissioning
You need suitable expertise and experience. You must be able to assess if the machine
is operating safely.
Operation and maintenance
You need suitable expertise and experience. You must be instructed in machine oper‐
ation by the machine operator. For maintenance, you must be able to assess if the
machine is operating safely.
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3 Product description
3.1 General description
Overview
The Standstill Monitor permits the sensor-less monitoring of electric motors for safe
standstill. It detects the standstill of three-phase motors, single-phase motors and
DC motors that generate a voltage due to their remanence as they coast down. By
adjusting the voltage threshold for the standstill detection (Uan) and the standstill time
(ts: time delay between the voltage dropping below the voltage threshold and switching
on the safety-related output relay) the function can be adapted to a large number of
different motors and applications.
Properties:
•safe standstill monitoring of three-phase and single-phase AC motors
•safe standstill monitoring of DC motors
•suitable for use with frequency inverters
•no external sensors necessary
•direction of rotation-independent standstill detection
•wire break detection in the measurement circuit
•adjustable voltage threshold for standstill detection
•adjustable standstill time
•LED indicators for motor standstill, wire break and supply voltage
•3 enable current paths as safe outputs for up to 250 V AC (normally open contact)
•1 positively guided N/C contact for up to 250 V AC
•1 non-safety output as application diagnostic output for 250 V AC (normally open
contact)
•2 non-safety outputs as semiconductor application diagnostic outputs for 24 V DC
Important information
WARNING
You are responsible for the correct setting of the MOC3ZA in relation to the voltage
threshold Uan and standstill time ts. The correct setting must be determined by corre‐
sponding tests under worst-case conditions.
bAlways ensure the MOC3ZA setting is safe in the context of your application.
WARNING
Test the suitability of the motor!
If the motor current is gradually reduced to zero by a frequency inverter or soft starting
device, the motor may be demagnetized.
bIn this case check whether the remaining remanence voltage is sufficient to
ensure correct standstill detection.
MOC3ZA
The MOC3ZA measures the voltage induced at the terminals of the winding by the
residual magnetization of a motor coming to a standstill. Two redundant measurement
channels (L2 against L1, and L3 against L1) are used for this purpose. If the induction
voltage on both channels drops below the configured voltage threshold (Uan) at the
same time, this means the motor of the device is coming to a standstill and the output
relay is activated, i.e. the outputs are enabled.
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To be able to adjust the device to a large number of different motors and applications,
the voltage threshold Uan is adjustable. Also adjustable is the length of time for which
the voltage must drop below Uan so that standstill is finally detected and the output
circuit is enabled (standstill time ts).
The device detects wire breaks on the measurement channels (L1/L2/L3). If a wire
break is detected, the output relay switches to the safe position (as when the motor is
running). This state is saved and can be deleted by bridging the terminals S2/X1.
The input voltages on the measurement channels (L1/L2/L3) are continuously com‐
pared. If the input voltages are different for longer than approx. 2.5s, a simultaneity
error is triggered. This error is reset when all measurement channels simultaneously
have input voltages that are above the voltage threshold Uan set.
The terminals S1/X1 are the feedback loop for monitoring externally connected contac‐
tors (EDM or contactor monitoring, N/C contact). If no external device monitoring is
required, the terminals S1/X1 must be bridged, otherwise an error message is issued.
3.2 Control elements and status indicators
Figure 1: Control elements and status indicators of the Standstill Monitor MOC3ZA
3 PRODUCT DESCRIPTION
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