TR-Electronic encoTRive MP Series User guide

TR-EMO-BA-GB-0023 v00 04/20/2022
Safety Manual
Illustrations similar
DIN EN 61508 / DIN EN 62061: SIL CL2
DIN EN ISO 13849: PL d
DIN EN 61800-5-2: Safe Torque Off (STO), Safe Stop 1 (SS1)
Original
Decentralized Positioning Drives
MP Series
Safety Manual
_Basic safety instructions
_Purpose
_General functional description
_General characteristics
_Installation instructions
_Error causes and solutions

Contents
TR-Electronic GmbH 2022, All Rights Reserved Printed in the Federal Republic of Germany
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TR-Electronic GmbH
D-78647 Trossingen
Eglishalde 6
Tel.: (0049) 07425/228-0
Fax: (0049) 07425/228-33
E-mail: [email protected]
https://www.tr-electronic.com/
Copyright protection
This Manual, including the illustrations contained therein, is subject to copyright protec-
tion. Use of this Manual by third parties in contravention of copyright regulations is not
permitted. Reproduction, translation as well as electronic and photographic archiving
and modification require the written consent of the manufacturer. Violations shall be
subject to claims for damages.
Subject to amendments
The right to make any changes in the interest of technical progress is reserved.
Document information
Release date / Rev. date: 04/20/2022
Document / Rev. no.: TR-EMO-BA-GB-0023 v00
File Name: TR-EMO-BA-GB-0023-00.docx
Author: MÜJ
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Contents
Contents.................................................................................................................. 3
Revision index........................................................................................................ 5
1 General information ............................................................................................ 6
1.1 Applicability............................................................................................................................. 6
1.2 Associated documentation...................................................................................................... 7
1.3 Abbreviations and terms used................................................................................................ 7
1.4 General functional description................................................................................................ 8
2 Basic safety information..................................................................................... 9
2.1 Definition of symbols and notes.............................................................................................. 9
2.2 General risks when using the product.................................................................................... 10
2.3 Residual risk ........................................................................................................................... 10
2.4 Intended use........................................................................................................................... 11
2.5 Improper use........................................................................................................................... 11
2.6 Conditions............................................................................................................................... 12
2.7 Integrated safety functions...................................................................................................... 12
2.7.1 Mode of operation................................................................................................... 12
2.7.2 STO (Safe Torque Off)............................................................................................ 13
2.7.3 SS1 (Safe Stop 1)................................................................................................... 14
2.8 Warranty and liability .............................................................................................................. 15
2.9 Organizational measures........................................................................................................ 15
2.10 Choice and qualifications of personnel; basic obligations.................................................... 16
2.11 Safety information................................................................................................................. 17
3 Transport / Storage ............................................................................................. 19
4 Installation instructions...................................................................................... 20
5 General technical data and installation instructions........................................ 21
5.1 Functional safety..................................................................................................................... 21
5.2 Safety functions ...................................................................................................................... 21
5.3 Supply..................................................................................................................................... 22
5.4 Safety-oriented function inputs............................................................................................... 23
5.5 Message outputs .................................................................................................................... 23
5.6 Mechanical.............................................................................................................................. 24
5.7 Connection instructions .......................................................................................................... 24
5.8 Equipotential bonding............................................................................................................. 25
6 Control of the safety-oriented function inputs.................................................. 26
7 Validation of the encoTRive safety functions ................................................... 27
7.1 STO function........................................................................................................................... 27
7.2 SS1 function............................................................................................................................ 28

Contents
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8 Safety-oriented error causes and solutions...................................................... 29
8.1 Optical LED display ................................................................................................................ 29
8.2 Error and warning messages via the fieldbus interface.......................................................... 30
9 Replacing the drive ............................................................................................. 31
10 Checklists........................................................................................................... 32
10.1 General................................................................................................................................. 32
10.2 Validation of the encoTRive safety functions STO, SS1...................................................... 33
11 Maintenance....................................................................................................... 34
12 Document download ......................................................................................... 35

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Revision index
Modification
Date
Index
First release
04/20/2022
00

General information
TR-Electronic GmbH 2022, All Rights Reserved Printed in the Federal Republic of Germany
Page 6 of 35 TR-EMO-BA-GB-0023 v00 04/20/2022
1 General information
This manual contains all safety-relevant information about the integrated safety functions of the enco-
TRive drive system and includes the following topics:
●General functional description
●Basic safety information with particulars of use
●General characteristics
●Installation instructions
●Error causes and solutions
As the documentation is arranged in a modular structure, this Manual is supplementary to other doc-
umentation, such as product data sheets, dimensional drawings, leaflets and interface-specific user
manuals etc..
1.1 Applicability
This Manual applies exclusively for the following decentralized encoTRive drive systems with
PROFINET-IO interface:
Type designation: MP-xxx-PN-xA-xxxx
Series
Performance
class
Interface
Approvals
Variant
xxx
country-
spec.
technical
MP
(positioning
drive)
060
100
140
180
200
PN
(PROFINET)
N
(without)
A
(with STO/SS1)
B
(Standard)
K
(customer-specific)
001
…
(serial no.)
The products are labeled with affixed nameplates and are components of a system.

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1.2 Associated documentation
●Operator’s operating instructions specific to the system
●This safety manual
●Plug assignment
●Interface-specific user manual
●The customer-specific user manual (optional)
●Product data sheet, including dimensional drawing (depending on the drive variant)
1.3 Abbreviations and terms used
DCavg
Average Diagnostic Coverage
EMC
Electro-Magnetic Compatibility
ESD
Electro Static Discharge
Functional safety
Part of the overall system safety, which depends on the correct function-
ing of safety-related systems for risk reduction. Functional safety is en-
sured when each safety function is executed as specified.
IEC
International Electrotechnical Commission
ISO
International Standard Organization
MTTFd
Mean Time To Failure, dangerous
Mean time until a dangerous error occurs
PFD
Probability of Failure on Demand
Probability of failure of a safety function
PFH
Probability of Failure per Hour
Operating mode with high requirement rate or continuous demand. Prob-
ability of dangerous failure per hour.
PL
Performance Level: Discrete level, which specifies the capability of safety-
related parts of a control to execute a safety function under foreseeable
conditions.
SIL
Safety Integrity Level: Four discrete levels (SIL1 to SIL4). The higher the
SIL of a safety-related system, the lower the probability that the system
cannot execute the required safety functions.
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik (Associa-
tion for Electrical, Electronic and Information Technologies)
Repeat test (proof test)
Repetitive test to detect hidden dangerous failures in a safety-related sys-
tem.

General information
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1.4 General functional description
The encoTRive drive systems MP-060…200-PN are optionally available with integrated safety tech-
nology, which safely switches off the motor torque after activation via a safe digital input and an op-
tional time duration.
●The two functions STO (Safe Torque Off) and SS1 (Safe Stop 1) comply with the standard
EN 61800-5-2 “Adjustable speed electrical power drive systems - Part 5-2: Safety requirements -
Functional Safety”
●The safety requirement level corresponds to SIL CL2 in accordance with EN 62061 “Safety of
machinery - Functional safety of safety-related electrical, electronic and programmable electronic
control systems” and PL d, Cat. 3 in accordance with EN ISO13849-1 “Safety of machinery - Safe-
ty-related parts of control systems - Part 1: General principles for design”.
The different configuration options are defined according to customer requirement and set in the facto-
ry.
The different selection options are:
●STO or SS1
●the desired SS1 time (e.g. 500 ms or 1000 ms)
●with or without short-circuit monitoring
The selection of the safety-oriented parameters occurs during the order process and is clearly as-
signed to a device variant. The selected parameters appear in the product data sheet, as well as in the
order papers for the respective variant and must be checked for correctness by the user when order-
ing.
As for drives without safety function, all drive functions are controlled via the standardized non-
safety-oriented PROFINET interface.

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2 Basic safety information
2.1 Definition of symbols and notes
means that death or serious injury will occur if the required precautions are
not met.
means that death or serious injury can occur if the required precautions
are not met.
means that minor injuries can occur if the required precautions are not
met.
means that damage to property can occur if the required precautions are
not met.
indicates important information or features and application tips for the
product used.
means that appropriate protective measures against ESD according to
DIN EN 61340 5-1 Supplement 1 must be applied.

Basic safety information
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2.2 General risks when using the product
The product, hereinafter referred to as encoTRive, is manufactured according to state-of-the-art tech-
nology and accepted safety rules.
Nevertheless, improper use can pose a danger to life and limb of the user or third parties, or
lead to impairment of the encoTRive or other property!
Only use the encoTRive in technically perfect condition, and only for its designated use taking safety
and hazard aspects into consideration, and with reference to Associated documentation! Faults
which could threaten safety should be eliminated without delay!
If the encoTRive does not function or only functions incorrectly, further procedure must be agreed with
TR-Electronic if necessary.
2.3 Residual risk
According to EN ISO 12100-1 “Safety of machinery – Basic concepts, general principles for design”
the residual risk is defined as the risk that remains after applying all protective measures.
The risk itself is defined as the “combination of the probability of occurrence of harm and the severity
of that harm”.
Throughout the safety lifecycle, TR-Electronic has applied risk elimination measures and
methods according to the state of the art in science and technology - however, residual risks
remain when using the encoTRive as intended!
The residual risks are not only specified in this chapter, but at all relevant points of the entire docu-
ment.
For the risk assessment of the overall system required by the EU Machinery Directive it is therefore
necessary to know the Associated documentation, including the documented boundary conditions,
safety instructions and residual risks and incorporate these into your own risk assessment.

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2.4 Intended use
The encoTRive drive system is generally intended as a decentralized positioning drive for setting up
and adjustment tasks, or for travel and rotational movements in the industrial area for fixed installation
in machines and systems, which are not subject to special electrical and mechanical safety require-
ments.
The encoTRive drive system with the integrated safety-oriented functions STO (Safe Torque Off) or
SS1 (Safe Stop 1) safely switches off the motor torque under defined conditions. With these safety-
oriented functions, the encoTRive can be used in machines and systems that require the protection
goal “Safe switch-off of motor torque”. The complete processing chain of the safety function must
then satisfy the requirements of the applied safety standard.
The system manufacturer must check that the characteristics of the encoTRive satisfy his application-
specific safety requirements. The responsibility or decision regarding the use of the encoTRive lies
with the system manufacturer.
Proper use also includes:
●observing all instructions in the further applicable documents,
●observing the nameplate and any prohibition or instruction signs on the encoTRive,
●observing attached documents,
●operating the encoTRive within the limit values specified in the technical data,
●observing the specified conditions for safe operation of the encoTRive,
●using the checklist in this document
2.5 Improper use
Danger of death, physical injuries and/or damage to property due to im-
proper use of the encoTRive!
The following areas of use are especially forbidden:
- Use of safety functions, which are not described in this document
and expressly approved
- In environments with an explosive atmosphere according to ATEX
Directive
- For medical purposes according to the Medical Devices Directive
- As a step or ladder
- As a support for tensioning chains and belts

Basic safety information
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2.6 Conditions
Optional attachments, such as e.g. mechanical brakes, are not designed in accordance with the re-
quirements on functional safety and are therefore not part of the safety functions
STO (Safe Torque Off) or SS1 (Safe Stop 1).
In the event of malfunction, overrunning of the drive can be significantly prolonged or the drive can
even accelerate. To ensure an active delay of the system, an additional braking system must be pro-
vided.
In safe condition, message output C1 = 24 VDC and drive torque-free, the end stage is blocked by the
internal connection. Operating voltage is still supplied to the drive. The power to the system must
therefore be switched off, when working on the electrical part of the drive.
The prerequisite for safe operation is correct fitting of the drive in the system/ machine. In all cases,
the system/machine manufacturer must perform a system/machine-specific risk assessment.
The system/machine manufacturer and the operator are responsible for ensuring that the system or
machine complies with the applicable safety requirements.
As proof, the system or machine must be validated by the manufacturer in respect of the safety func-
tions.
All requirements on installation, commissioning and operation must be fulfilled for correct fitting of the
drive in the system. These are specified in the respective documents/chapters.
2.7 Integrated safety functions
2.7.1 Mode of operation
A redundant shutdown path is opened with the help of the integrated safety functions Safe Torque Off
(STO) or Safe Stop (SS1) through opening of the control circuit I11/I12 or I11/I21. No further torque
can be generated and the motor shaft is switched torque-free.
The safety function SS1 also enables an automatic torque switch-off with a time delay.
The following states are signaled to the higher-level control system via message outputs C1 and C2:
C1 = 24 VDC: safe state, the drive is torque-free.
C2 = 24 VDC: Error in safety module
Via PROFINET the safe state is displayed by ERROR “400“ in PNU 947.
In addition, the drive and safety states are signaled by corresponding LEDs.
It is guaranteed that an individual error will not lead to loss of the safety function. Internal errors are
detected by means of cyclic self-monitoring, at the latest when the system is next switched off and on
again. Depending on the application, this must be performed periodically as part of a maintenance
plan.
The integrated safety function enables the user to safely prevent motor generation of torque. The fol-
lowing functions are implemented in this connection:

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2.7.2 STO (Safe Torque Off)
●Danger of death, serious injury and/or damage to property due to
uncontrolled motor shaft movements when the STO safety function is
activated.
The safety function does not prevent the motor shaft from creeping back
(no safe braking), but only active torque generation. The motor shaft can
be set in motion by external forces (tensioned spring, suspended load, ...).
The system risk analysis must take account of all active components,
which influence the passive behavior of the drive.
The correct function must first be ensured by a protected test run.
Safe torque switch-off occurs in accordance with EN 61800-5-2. The energy supply to the drive con-
troller is disconnected by a safe mechanism, which corresponds to an uncontrolled stop in accordance
with IEC 60204-1, Stop Category 0.

Basic safety information
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2.7.3 SS1 (Safe Stop 1)
●Danger of death, serious injury and/or damage to property due to
uncontrolled motor shaft movements when the SS1 safety function is
activated.
The behavior of the drive controller, in the time between triggering of the
SS1 function and activation of the time-delayed STO function, is not moni-
tored and does not represent a safe state. At the time of activation of the
STO function, the motor shaft can therefore still be in motion.
The system risk analysis must take into account that the drive is only in
the safe state after activation of the STO function. The behavior of the
drive before this point must be viewed as undefined in the worst case
scenario.
The correct function must first be ensured by a protected test run.
The safety function Safe Stop SS1 can be used, if the torque is not to be switched off immediately
after triggering of the safety function, but the drive controller is given a predefined time after which the
STO function will be triggered automatically.
During this delay time the drive can still be controlled as normal, in order to e.g. decelerate it in a de-
fined manner, before no further motion control is possible due to triggering of the STO function.
The SS1 function corresponds to the controlled stop in accordance with IEC 60204-1,
Stop Category 1.

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2.8 Warranty and liability
The General Terms and Conditions ("Allgemeine Geschäftsbedingungen") of TR-Electronic GmbH
always apply. These are available to the operator with the Order Confirmation or when the contract is
concluded at the latest. Warranty and liability claims in the case of personal injury or damage to prop-
erty are excluded if they result from one or more of the following causes:
●Improper use of the encoTRive.
●Improper assembly, installation, start-up and programming of the encoTRive.
●Inexpertly performed work on the encoTRive.
●Operation of the encoTRive with technical defects.
●Mechanical or electrical modifications to the encoTRive undertaken autonomously.
●Unauthorized repairs.
●Third party interference and acts of God.
2.9 Organizational measures
●The associated documentation must always be kept accessible at the place of operation of the
encoTRive.
●In addition to the associated documentation, the generally valid legal and other binding regulations
on accident prevention and environmental protection must be observed and communicated.
●The respective applicable national, local and system-specific provisions and requirements must be
observed and communicated.
●The operator is obliged to inform personnel about special operating features and requirements.
●Prior to commencing work, personnel working with the encoTRive must have read and understood
the Safety Manual, particularly chapter "Basic safety information".
●The nameplate and any prohibition or instruction symbols applied on the encoTRive must always
be maintained in a legible state.
●Do not carry out any mechanical or electrical changes to the encoTRive other than those express-
ly described in the associated documentation.
●Repairs may only be undertaken by the manufacturer or a center or person authorized by the
manufacturer.

Basic safety information
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2.10 Choice and qualifications of personnel; basic obligations
●All work on the encoTRive must be carried out by qualified personnel only.
Qualified personnel includes persons, who, due to their training, experience and instruction, as
well as their knowledge of the relevant standards, provisions, accident prevention regulations and
operating conditions, have been authorized to carry out the required work by the persons respon-
sible for the safety of the system. They are capable of identifying and avoiding potential hazards.
●The definition of “qualified personnel” also includes an understanding of the standards
VDE 0105-100 and IEC 364 (source: e.g. Beuth Verlag GmbH, VDE-Verlag GmbH).
●The responsibility for assembly, installation, commissioning and operation must be clearly defined.
The obligation exists to provide supervision for trainee personnel.

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2.11 Safety information
●Before starting any work on the encoTRive, the motor must be properly
isolated in accordance with the 5 safety rules according to DIN VDE 0105.
As well as the main circuits, attention must also be paid to any additional
or auxiliary circuits.
The measures prescribed in DIN VDE 0105 may only be withdrawn when
the assembly work on the motor is completely finished.
●As well as the general requirement of care, attention must be paid to the
risk of hair or items of clothing being caught in the equipment.
●Take care when touching the encoTRive. Temperatures of over 100°C can
occur on the surface of the encoTRive during operation. The temperature
must therefore be checked before work can be carried out again on the
encoTRive after operation.
●Risk of fire!
Before assembly, it must be ensured that an adequately large distance is
maintained from inflammable materials and cables laid in the immediate
vicinity. Furthermore, it must be ensured that heat losses can be ade-
quately dissipated.
●Protective devices must never be rendered inoperative, even during test-
ing.
●Check the direction of rotation of the encoTRive in the uncoupled state
before commissioning.
●Ensure that dangerous torques cannot occur on the encoTRive due to
commissioning or test adjustments in order to prevent damage to persons
or materials.
●Suitable measures must be taken to prevent limbs being trapped by mov-
ing actuators.
●All work on the encoTRive must be carried out in accordance with the
information and instructions given in this Safety Manual.
●Ensure that no dangerous torques are produced by switching off equip-
ment, machines and systems.
●When electrical components are used in complex systems, unpredictable
functions may occur during normal operation of the system if the electrical
parts of the system are not properly designed, or due to faulty compo-
nents. Proper design in accordance with the relevant technical regulations
is the responsibility of the system designer and the user.
●When operated in residential environments, the encoTRive can cause
high-frequency interference, which may make suppression measures nec-
essary.
●When the encoTRive is installed in a vertical position, it must be ensured
that no liquids can get into the bearing.
Continued on next page

Basic safety information
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Continued
●When installing, make sure that the permissible radial and axial forces on
the encoTRive drive shaft are not exceeded. It may be necessary to use
suitable output drive elements. Impacts and blows on the output drive
shaft must be avoided in order to prevent damage to the electromechani-
cal components.
●Guarantee of IP protection class
Unused cable openings and access points for adjusting devices must be
sealed with blanking plugs. Unused connection plugs must either be pro-
vided with a mating connector or a protective cap. The appropriate IP pro-
tection class must be selected to meet the relevant requirements.
●Higher IP protection class
If the encoTRive is operated in an environment that requires a higher pro-
tection class, sealing of the shaft and the housing transitions
(MP-060…180 with gear) must be provided by the user, e.g. through a ra-
dial shaft seal and housing coating or using covers, which keep dust and
moisture away from the shaft outlet and housing transitions (MP-060…180
with gear). Alternatively, the MP-200 version with gear can be used. The
information on the IP protection class in the respective product data sheet
must be observed.
●The cable outlets of the mating connectors must always be secured
against being pulled out with a cable strain relief.
●Potential hazards resulting from interactions with other systems and
equipment which are or will be installed in the vicinity must be checked.
The user is responsible for taking appropriate measures.
●Cables used must be suitable for the temperature range.
●Make sure that the installation environment is protected from aggressive
media (acids etc.)
●Opening the encoTRive is forbidden.
●The nameplate specifies the technical characteristics of the encoTRive. If
the nameplate is no longer legible or if the nameplate is completely miss-
ing, the encoTRive must not be operated.
●The encoTRive contains components and modules that are at risk from
electrostatic discharge, and can be destroyed if not handled properly.
Avoid touching the encoTRive connectors with the fingers. The appropriate
protective measures against ESD must be applied.
●Disposal
If disposal has to be undertaken after the lifespan of the encoTRive, the re-
spective applicable country-specific regulations are to be observed.

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3 Transport / Storage
●Shipping information
Use only the original packaging.
Inappropriate packaging material may cause damage to the unit in transit.
●Storage
Storage temperature: -20 to +50 °C
Store in a dry place

Installation instructions
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4 Installation instructions
Risk of fire due to high surface temperatures!
Depending on the power output of the drive, surface temperatures of over
100 °C can occur on the encoTRive during operation.
Before assembly, it must be ensured that an adequately large distance is
maintained from inflammable materials and cables laid in the immediate vi-
cinity. Furthermore, it must be ensured that heat losses can be adequately
dissipated.
●In general, the requirements and acceptance conditions for the complete system must be taken
into account for mounting, and the safety information on page 17 must also be observed.
●The encoTRive must be checked for externally visible damage before installation. If any damage
is found, the encoTRive must not be installed.
●It must be ensured that the IP protection class can be maintained at the place of installation.
●The unit can be mounted in any position, but the preferred orientation is horizontal.
●The drive must be fixed to a flat surface via the shaft-side flange. The respective mounting data
can be found in the associated dimensional drawing.
●All fastening screws must be secured against unintentional loosening.
●The maximum values for the permissible radial and axial forces of the motor shaft can be found in
the customer-specific product data sheet.
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