TR-Electronic CD_-582 Series User guide

TR - ECE - BA - GB - 0142 - 01 06/12/2019
Safety Manual
_Basic safety instructions
_Intended use
_General functional description
_General characteristics
_Assembly
Pictures show similar items
DIN EN 61508: SIL CL2 / SIL CL3
DIN EN ISO 13849:
PL d / PL e
Translation of the original manual
Absolute Encoder CD_
-582
Safety Manual

Contents
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TR-Electronic GmbH
D-78647 Trossingen
Eglishalde 6
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
http://www.tr-electronic.de
Copyright protection
This Manual, including the illustrations contained therein, is subject to copyright
protection. 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 content of the manufacturer. Violati
ons
shall be subject to claims for damages.
Subject to modifications
The right to make any changes in the interest of technical progress is reserved.
Document information
Release date /Rev.-Datum: 06/12/2019
Document no./Rev no.: TR - ECE - BA - GB - 0142 - 01
File name: TR-ECE-BA-GB-0142-01.docx
Author: MÜJ
Font styles
Italic or bold font styles are used for the title of a document or are used for highlighting.
Courier
font displays text that is visible on the screen and software/software menu
selections.
″< > ″indicates keys on your computer keyboard (such as <RETURN>).
Brand names
Products, names and logos in this
Manual are only mentioned for information
purposes and may be brands of their owners without this fact being expressly
declared.

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Contents
Contents.................................................................................................................. 3
Revision index ........................................................................................................ 5
1 General information ............................................................................................ 6
1.1 Applicability............................................................................................................................. 6
1.2 Other Applicable Documents.................................................................................................. 8
1.3 Abbreviations and terms used ................................................................................................ 8
1.4 General functional description ................................................................................................ 9
2 Basic safety instructions .................................................................................... 10
2.1 Definition of symbols and notes.............................................................................................. 10
2.2 General risks when using the product .................................................................................... 11
2.3 Residual risk ........................................................................................................................... 11
2.4 UL / CSA approval .................................................................................................................. 11
2.5 Intended use ........................................................................................................................... 12
2.6 Non-intended use ................................................................................................................... 12
2.7 Usage in explosive atmospheres............................................................................................ 13
2.8 Combination measuring system and draw-wire box (CDW582)............................................. 13
2.9 Safety functions of the fail-safe processing unit ..................................................................... 15
2.10 Warranty and liability ............................................................................................................ 15
2.11 Organizational measures...................................................................................................... 16
2.12 Personnel selection and qualification; basic duties .............................................................. 16
2.13 Safety-related instructions .................................................................................................... 17
3 Transport / Storage ............................................................................................. 19
4 Technical Data – general..................................................................................... 19
4.1 Functional safety..................................................................................................................... 19
4.2 Safety functions ...................................................................................................................... 19
4.3 Supply..................................................................................................................................... 19
5 Assembly.............................................................................................................. 20
5.1 Solid shaft ............................................................................................................................... 20
5.1.1 Requirements.......................................................................................................... 20
5.2 Blind-hole shaft / hollow shaft................................................................................................. 22
5.2.1 Requirements.......................................................................................................... 22
5.3 Potential equalization – connection ........................................................................................ 23
6 Replacing the measuring system....................................................................... 24
7 Checklist, Part 1 of 2 ........................................................................................... 25
8 Maintenance......................................................................................................... 27

Contents
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9 Accessories ......................................................................................................... 28
10 Document Download......................................................................................... 29

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Revision index
Modification Date Index
First release 05/28/19 00
Draw-wire box added 06/12/19 01

General information
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1 General information
This Manual addresses the following topics:
●General functional description
●Basic safety information with declaration of the intended use
●General specifications
●Assembly
Since it has a modular structure, this Manual is supplementary to other documentations, such as
product data sheets, dimensional drawings, brochures, interface-specific user manuals, etc.
1.1 Applicability
This Manual applies exclusively to measuring system series according to the following keys for article
numbers and types:
Article number
* 1 * 2 * 3 * 4 * 5 - * 6 * 6 * 6 * 6 * 6
Position Designation Description
* 1 A
Explosion protection enclosure (ATEX);
C
Absolute encoder, programmable
* 2
D
Redundant dual scanning unit
* 3
V
Solid shaft
H
Hollow shaft
S
Blind shaft
W
Rope length transmitter (wire)
* 4
582
Outer diameter
∅
58 mm, Generation 2
* 5
M
Multi-turn
S
Singleturn
* 6
-
Consecutive number
* = placeholder
Type key
See Revision Lists:
CD_582M +FS02: www.tr-electronic.de/f/TR-ECE-TI-D-0343
CD_582M +FS03: www.tr-electronic.de/f/TR-ECE-TI-D-0349

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The products are labeled with affixed nameplates and are components of a system.
1: Date of manufacture in the format YYYY: Year, MM: Month, DD: Tag
2: Maximum achievable Safety Integrity Level or Performance Level,
see Chapter 4.1 on Page 19
3: Number or identifier of the enclosed pin assignment,
see Chapter 10 -> Pin assignments on Page 29
4:
- Supply voltage range, max. power consumption,
see Chapter 10 -> Product data sheets on Page 29
- Class 2 power supply unit with UL/CSA approval, see Chapter 2.4 on Page 11.
5: Measuring system – interface / security log,
see Chapter 10 -> -> Interface-specific User Manual on Page 29
6: IP rating (IP-Code), to DIN EN 60529
7: Resolution in steps per revolution
8: Article Number or Order Number
9: Number of revolutions
10: Optional customer note
11: Devices – Serial no.
12: Optional additional note
13: Data Matrix Code
14: UL/CSA approval, see Chapter 2.4 on Page 11
15: MAC address, for IP-based measuring system interface

General information
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1.2 Other Applicable Documents
●The responsible organization’s system-specific operating instructions
●This Safety Manual
●Pin assignment
●interface-specific User Manual
●Product data sheet
●optional: User Manual
1.3 Abbreviations and terms used
B10dNumber of operations that a device will operate prior to 10 % of a sample
of those devices would fail to danger
CDx Absolute encoder with redundant dual scanning unit, all designs
EMC ElectroMagnetic Compatibility
ESD Electro Static Discharge
Fault exclusion
Compromise between technical safety requirements and the theoretical
possibility that an error occurs
Functional safety
Part of the overall system
safety, which depends on the correct
functioning of safety instrumented systems for risk reduction. Functional
safety is ensured when each safety function is executed as specified.
IEC International Electrotechnical Commission
ISO
I
nternational
S
tandard
O
rganisation
MTTF
d
M
ean
T
ime
T
o
F
ailure,
d
angerous
nop Number of operations/cycles in one year
PL
P
erformance
L
evel according to EN ISO 13849-1
SIL
Safety Integrity L
evel: Four discrete levels (SIL1 to SIL4). The higher the
SIL of a safety instrumented system, the lower the probability that the
system cannot execute the required safety functions.
Standard measuring-
system
Definition:
Safety instrumented measuring system, without explosion protection
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik
(Association for Electrical, Electronic and Information Technologies e.V.)

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1.4 General functional description
The rotary measuring system is a safe and absolute multi-turn position measuring system with a
safety protocol and a standardized interface that is, however, NOT safety instrumented.
The safety measuring system consists of a redundant, dual-channel system in which
●variant 1: optical and magnetic scanning units, or
●variant 2: two magnetic scanning units
are arranged on a drive shaft that is designed either as a hollow shaft, a blind-hole shaft, or as a solid
shaft.
The measuring system has primarily been designed for use in systems that require safe position
detection.
The additional safe velocity measurements allow the following safety functions to be implemented
according to DIN EN 61800-5-2:
●Safe Direction (SDI)
●Safe Stop 1 (SS1)
●Safe Stop 2 (SS2)
●Safe Operating Stop (SOS)
●Safely Limited Velocity (SLS)
●Safe Velocity Range (SSR)
●Safe Velocity Monitor (SSM)
●Safely-Limited Position (SLP)
●Safe Cam (SCA)
As a sensor, the measuring system is always part of a safety chain.

Basic safety instructions
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2 Basic safety instructions
2.1 Definition of symbols and notes
means that death or serious injury will occur if the user fails to take the
respective precautionary measures.
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 ESD protective measures according to
DIN EN 61340-5-1 supplementary sheet 1 must be taken.

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2.2 General risks when using the product
The product, hereinafter referred to as measuring system, is manufactured according to state-of-the-
art technology and accepted safety rules.
Nevertheless, non-intended use can pose a danger to life and limb of the user or third parties,
or lead to impairment of the measuring system, or other property values!
The measuring system may only be used in technically perfect condition in accordance with its
intended use and the instructions set out in the Other Applicable Documents and only by safety-
conscious persons who are fully aware of the risks involved in operating the measuring system. Faults
which could threaten safety should be eliminated without delay!
2.3 Residual risk
According to EN ISO 12100-1 “Safety of machinery – Basic concepts, general principles for design”,
residual risk is defined as the risk remaining after application of all protective measures.
Risk itself is defined as the “combination of the likelihood of a hazard and the severity of the potential
damage”.
During the entire safety lifecycle, TR-Electronic has applied risk minimizing measures and
methods according to the state of the art and technology – however, residual risks still remain
even when properly using the measuring system!
Residual risks are not only indicated in this chapter, but also in all relevant parts of the entire
document, in some cases also by referencing the corresponding interface-specific user manual.
The risk assessment of the entire system required by the EU Machinery Directive requires knowledge
of all Other Applicable Documents, including any documented general conditions, safety instructions
and residual risks, and to incorporate such into the company’s own risk assessment.
2.4 UL / CSA approval
The nameplate of measuring systems with this approval carry the UL symbol:
File No.: E300802
Measuring system running UL applications may therefore only be operated on NEC Class 2 approved
power supply units. For further information, please refer to this document: TR-ECE-TI-DGB-0152

Basic safety instructions
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2.5 Intended use
The safety measuring system can be used for the detection of angular movement and processing of
measured data for a downstream safety host in systems in which the safety-related requirements of
“Safeguarding travel”, “Safeguarding velocity” or “Safeguarding direction of travel” must be
reliably achieved. In this case, the complete processing chain of the safety function must satisfy the
requirements of the applied safety standard.
The safety measuring system may only be used in safety applications in conjunction with a control
certified according to the applied safety standard.
The system manufacturer must verify that the properties of the measuring system satisfy his
application-specific safety requirements. The responsibility or decision regarding the use of the
measuring system lies with the system manufacturer.
Intended use also includes:
●following all instructions provided in the other applicable documents,
●observing the nameplate and any prohibition or instruction symbols on the measuring system;
●observing enclosed documents,
●operating the measuring system within the limit values specified in the technical data;
●ensuring that the fail-safe processing unit fulfills all required safety functions;
●ensuring that the checklist – part 1 in the present document and part 2 in the interface-specific
User Manual – is used and went through completely;
●safely attaching (form-locking) the measuring system to the driving axis.
2.6 Non-intended use
Any non-intended use of the measuring system results in the risk of
death, physical injury and damage to property.

The following areas of use are especially forbidden:
- standard measuring-system:
in environments with an explosive atmosphere according to the
ATEX Directive
- for medical purposes in accordance with the Medical Devices
Directive
- as a step or climbing aid
- for wiring as antitwist protection (torque arm)
- as an abutment for tension chains and belts

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2.7 Usage in explosive atmospheres
The standard measuring system must be installed in an appropriate explosion protection enclosure as
required when used in explosive atmospheres.
The products are labeled with an additional marking on the nameplate.
The “intended use” as well as any information on the safe usage of the ATEX-compliant measuring
system in explosive atmospheres are contained in the User Manual.
Standard measuring systems that are installed in the explosion protection enclosure and are intended
for use with safety instrumented applications can therefore be used in explosive atmospheres.
When the measuring system is installed in the explosion protection enclosure, which means that it
meets explosion protection requirements, the properties of the measuring system will no longer be as
they were originally.
Following the specifications in the User Manual, please check whether the properties defined in
that manual meet the application-specific requirements.
Fail-safe usage requires additional measures and requirements. Such measures and requirements
must be determined prior to initial commissioning and must be taken and met accordingly.
2.8 Combination measuring system and draw-wire box (CDW582)
➊: Measuring system
Device type 1 with SIL value or PL value
➋: Draw-wire box
Device type 3 with B10d value
Figure 1: Combination measuring system and draw-wire box
From a safety viewpoint the combination of measuring system and draw-wire box is a series
connection with a device type 1 (measuring system) and a device type 3 with a category 1 structure in
accordance with EN ISO 13849-1 (draw-wire box).
Device type 1 is characterized by the fact that the device can already be used as the safety-relevant
part of a control system.

Basic safety instructions
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Device type 3 refers to devices with a failure behavior which is dependent on the switching frequency
(cycle) and in terms of the draw-wire corresponds to complete extension and retraction of the wire.
This fact is expressed by the B10d-value and represents the average number of cycles by which
10 % of the components have failed dangerously. The draw-wire box has not been developed in
accordance with any specific safety standard, but this does not in principle exclude its use in
accordance with DIN EN 61508, EN ISO 13849-1 or IEC 62061.
Generally, however, the use of such devices, if they are used as a safety-relevant part of a control
system, must be independently assessed by the user in relation to safety.
As the combination of measuring system and draw-wire box is a series connection, this "unified
structure" must be reassessed in relation to safety. The component with the lowest reliability in the
series connection is determining for the highest possible level of safety that can be achieved. For
mechanical reasons draw-wires only have a limited number of cycles, which in turn is strongly
dependent on the type used.
In practice this means that the draw-wire is the limiting component in the series connection
and the safety requirement level of the measuring system can never be achieved for the unified
structure. For this reason there is also no TÜV certification for the combination of measuring
system and draw-wire box!
This fact means that the unified structure may only be used as the subsystem of a safety
function if the safety requirement level of the unified structure corresponds to the required
safety requirement level for the subsystem.
To enable the user to assess the safety function, TR-Electronic provides the relevant safety indicators
in the product data sheets valid for the respective measuring system,
see www.tr-electronic.com/s/S020955.
TR-Electronic can provide the relevant B10d value for the draw-wire box on request.
1) The MTTFdvalue for the draw-wire box can be calculated as follows:
MTTFd=
B10d
0.1 * nop
The total MTTFdvalue for the draw-wire box + measuring system can be calculated from this:
MTTFd(total)=
( MTTFd (draw-wire box) * MTTFd (measuring system) )
= value in years [a]
( MTTFd (draw-wire box) + MTTFd (Mess-System) )
1) Abbreviations, also see page 8

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2.9 Safety functions of the fail-safe processing unit
It is mandatory that the safety control, which the measuring system is connected to, executes the
safety checks required by the interface-specific User Manual.
2.10 Warranty and liability
The “General Terms and Conditions” of TR-Electronic GmbH are generally applicable. They will be
submitted to the responsible organization along with the order confirmation or on conclusion of the
contract at the latest. Warranty and liability claims are excluded in the event of personal injury or
damage to property if they result from one or more of the following causes:
●Non-intended use of the measuring system.
●Improper assembly, installation, commissioning and programming of the measuring system.
●Work on the measuring system that is carried out improperly.
●Operation of the measuring system with technical defects.
●Unauthorized mechanical or electrical modifications to the measuring systems.
●Unauthorized repairs.
●Catastrophic events beyond human control and acts of God.

Basic safety instructions
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2.11 Organizational measures
●The other applicable documents must always be within reach where the measuring system is
used.
●In addition to the other applicable documents, 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 responsible organization is obliged to inform personnel on special operating features and
requirements.
●Personnel handling the measuring system must have read and understood the Safety Manual, in
particular Chapter “Basic safety instructions” prior to commencing work.
●It must be ensured that the nameplate and any prohibition or instruction symbols provided on the
measuring system are always legible.
●Do not modify the measuring system in any mechanical or electrical way; the only modifications
allowed are those expressly described in the other applicable documents.
●Repairs may only be made by the manufacturer or a center or person authorized by the
manufacturer.
2.12 Personnel selection and qualification; basic duties
●Only qualified personnel may work with the measuring system.
Qualified personnel are persons, who, through their training, experience and instruction, as well as
their knowledge of the relevant standards, provisions, accident prevention regulations and
operating conditions, have been authorized by the persons responsible for the system to carry out
the required work and are able to recognize and avoid potential hazards. Such personnel is
capable of identifying and avoiding potential hazards.
●The additional definitions of “qualified personnel” given in the VDE 0105-100 and IEC 364
standards must also be understood (source: e.g. Beuth Verlag GmbH, VDE-Verlag GmbH).
●The responsibilities for assembly, installation, commissioning and operation must be clearly
defined. Personnel to be trained or educated must be supervised.

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2.13 Safety-related instructions
●The instructions listed below must be followed to prevent
destruction, damage and malfunction of the measuring system and
downstream electronic devices.
–
Wiring work may only be carried out and electrical connections only be
opened and closed while the system is de-energized.
– Voltages equal to the supply voltage at the additional incremental
interface output. Ensure the ground reference point is present at all
times, respectively the organization responsible for the system must
provide appropriate protective measures for downstream electronic
devices.
– Cable outlets of mating connectors must always be secured with a
cable grip against pulling out.
– Do not carry out any welding work after the measuring system has
already been wired or switched on.
– Ambient temperature values may never fall below or exceed the
permissible limit values; this must be ensured by taking the
appropriate heating/cooling measures at the place of installation.
– The measuring system must be installed such that it is not exposed to
any direct moisture.
– Suitable aeration/ventilation and heating/cooling measures must be
taken at the place of installation to prevent the temperature falling
below the dew point (condensation).
– Potential hazards resulting from interactions with other systems and
equipment which are or will be installed in the vicinity must be
determined. The user is responsible for taking appropriate measures.
– Voltage supply must be protected with a fuse suitable for the supply
lead cross-section.
– Cables used must be suitable for the temperature range.
– If defective, the measuring system may not be operated.
– Make sure that the installation environment is protected from
aggressive media (acids, etc.).
– Avoid shocks (e.g., hammer blows) to the shaft during installation.
– It is prohibited to open the measuring system.
– After having set the address switches and LEDs, ensure that they are
no longer accessible by firmly closing the access with the screw plug.
– Connector plugs of the measuring system that are unused during
storage and/or operation of the system have to be provided either with
a mating connector or a protective cap. The IP degree of protection is
to be selected according to requirements.
– The nameplate specifies the technical properties of the measuring
system. If the nameplate is no longer legible or is completely missing,
the measuring system may no longer be put into operation.
– The measuring system cannot detect a break in the coupling or the
torque arm. The operator must include this circumstance in the safety
concept of the system.

Basic safety instructions
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●The measuring system contains components and assemblies susceptible
to electrical discharge, which can be destroyed if incorrectly handled.
– Do not touch the connection contacts of the measuring system with your
fingers or apply the relevant ESD protective measures.
●Disposal
– Electronic waste is hazardous waste.
The disposal must observe the local regulations.

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3 Transport / Storage
●Shipping information
– Do not drop the device or subject it to heavy impacts!
The device contains an optical system.
– Only use the original packaging.
Inappropriate packaging material may cause damage to the unit in transit.
●Storage
– Storage temperature: see product data sheet
– Store at a dry place
4 Technical Data – general
4.1 Functional safety
The achievable Safety Integrity Level or Performance Level depends on the device and is noted on
the nameplate.
DIN EN 61508 Part 1-7, Safety Integrity Level (SIL)
........
CL2 or CL3
EN ISO 13849-1, Performance Level
...............................
PLd / Cat. 3 or PLe / Cat. 4
4.2 Safety functions
DIN EN 61800-5-2, Electric power drive systems
............
SDI, SS1, SS2, SOS, SLS, SSR, SSM,
SLP, SCA
Operating mode or requirement rate, DIN EN 61508
.......
high or continuous
The measuring system, functioning as a sensor, is always part of a safety chain.
4.3 Supply
The measuring system may only be operated on SELV/PELV (IEC 60364-4-41:2005) compliant power
supply units.
Measuring system running UL applications may only be operated on NEC Class 2 approved power
supply units.
Nominal voltage................................
................................
24 V DC
Power consumption ................................
..........................
≤ 6 Watt

Assembly
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5 Assembly
●If the safety functions are deactivated because of an unstable shaft
drive, there will be the danger of death, serious physical injury and/or
damage to property!

The system manufacturer must take suitable design measures to ensure
that the measuring system is reliably driven by the shaft and firmly
attached at any time (fault exclusion). The specifications of DIN EN
61800-5-2:2017 “Electrical power drive systems with speed control,
Safety requirements – Functional, Table D.8 – Motion and position
feedback sensors“ must be observed.
The requirements and acceptance conditions for the overall system
must always be taken into account when assembling the measuring
system.

All fastening screws must be secured such that they cannot be loosened
accidentally.
In case of applications with low ambient temperatures, the start-up
torque will be increased. This fact must be taken into account during
assembly and when providing the shaft drive.
5.1 Solid shaft
5.1.1 Requirements
The following instructions are not exhaustive as the assembly situation may be different for
each application.
The coupling used must be suitable for the application and allow form-locking connection.
The coupling manufacturer's information and installation requirements must be observed.
In particular, you must ensure that
– the coupling is suitable for the specified speed and the potential axial offset,
– installation is on a grease-free shaft,
– there is no axial load on the coupling and the measuring system,
– the clamping screws are tightened with the torque defined by the coupling manufacturer,
– the coupling screws are secured such that they cannot be loosened accidentally.
Axial slipping of the measuring system on the drive shaft must be prevented by fixing the
coupling in position, see Figure 1, (1).
Radial slipping of the measuring system on the drive shaft must be prevented by a form-
locking connection, using a parallel key / groove combination (Figure 1, (2)); a coupling with
groove must be used for this purpose.