TR-Electronic IH 8 Series User manual

TR - E
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E - BA -
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9
User Manual
_Basic safety instructions
_Intended use
_General functional description
_Characteristics
_Mounting
_Installation/Commissioning
_Causes of faults and remedies
IH-58
Position Sensor:
DIN EN 61508/62061: SIL CL2
DIN EN ISO 13849: PL d
Speed Sensor:
DIN EN 61508/62061: SIL CL3
DIN EN ISO 13849: PL e
Original manual
IS-58
Incremental Encoder I_-58
with Functional Safety (FS)
IV-58

Contents
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TR-Electronic GmbH
D-78647 Trossingen
Eglishalde 6
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
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 consent of the manufacturer. Violations
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. date: 10/23/2019
Document rev. no.: TR - ECE - BA - GB - 0120 - 13
File name: TR-ECE-BA-GB-0120-13.docx
Author: MÜJ, KUC
Font styles
Italic or bold font styles are used for the title of a document or are used for highlighting.
Courier
font displays text, which is visible on the screen and software menu
selections.
″< > ″indicates keys on your computer keyboard (such as <RETURN>).
Brand names
Specified products, names and logos serve exclusively for information purposes and
may be trademarks of their respective owners, without any special marking to indicate
this.

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Contents
Contents.................................................................................................................. 3
Revision index ........................................................................................................ 5
1 General information ............................................................................................ 6
1.1 Applicability............................................................................................................................. 6
1.2 Abbreviations and terms used ................................................................................................ 8
1.3 General functional description ................................................................................................ 9
1.3.1 Main features .......................................................................................................... 10
1.3.1.1 Variant 1 (IV58+FS01 SIN/COS, IH58+FS01 SIN/COS) .......................... 10
1.3.1.2 Variant 2 (IV58+FS01 TTL/HTL, IH58+FS01 TTL/HTL)............................ 10
1.3.2 Principle of the safety function................................................................................ 10
2 Basic safety information ..................................................................................... 11
2.1 Definition of symbols and notes.............................................................................................. 11
2.2 General risks when using the product .................................................................................... 11
2.3 Intended use ........................................................................................................................... 12
2.4 Non-intended use ................................................................................................................... 12
2.5 Safety functions of the fail-safe processing unit ..................................................................... 13
2.5.1 Mandatory safety checks / measures ..................................................................... 13
2.6 Warranty and liability .............................................................................................................. 14
2.7 Organizational measures........................................................................................................ 14
2.8 Personnel selection and qualification; basic obligations ........................................................ 15
2.9 Safety information................................................................................................................... 16
3 Transport / Storage ............................................................................................. 18
4 Technical data...................................................................................................... 19
4.1 Safety...................................................................................................................................... 19
4.2 Electrical characteristics ......................................................................................................... 20
4.2.1 General ................................................................................................................... 20
4.2.2 Device-specific........................................................................................................ 20
4.3 Ambient conditions ................................................................................................................. 21
4.4 Mechanical characteristics...................................................................................................... 22
4.4.1 Solid shaft ............................................................................................................... 22
4.4.2 Hollow shaft ............................................................................................................ 22
5 Mounting .............................................................................................................. 23
5.1 Solid shaft ............................................................................................................................... 23
5.1.1 Requirements.......................................................................................................... 23
5.2 Hollow shaft ............................................................................................................................ 25
5.2.1 Requirements.......................................................................................................... 25

Contents
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6 Installation / Preparation for Commissioning ................................................... 27
6.1 EMC requirements.................................................................................................................. 27
6.2 EMC conform wiring schemes................................................................................................ 28
6.2.1 Connection scheme 1 ............................................................................................. 28
6.2.2 Connection scheme 2 ............................................................................................. 28
6.2.3 Connection scheme 3 ............................................................................................. 29
6.3 Ground connection – measuring system ................................................................................ 30
6.4 Cable specification.................................................................................................................. 31
6.5 Permitted cable length............................................................................................................ 32
6.5.1 Analog incremental signals (SIN/COS)................................................................... 32
6.5.2 Square-wave incremental signals (TTL/HTL) ......................................................... 33
6.6 Connection - Notes ................................................................................................................. 34
6.6.1 Order number for the connectors............................................................................ 34
6.6.1.1 Suitably for the A coded male socket M12 - 8 pin..................................... 34
6.6.1.2 Suitably for the male socket M23 - 12 pin. ................................................ 34
7 Incremental interface........................................................................................... 35
7.1 Variant 1, analog incremental signals (SIN/COS) .................................................................. 36
7.2 Variant 2, square-wave incremental signals (TTL/HTL) ......................................................... 37
8 Replacing the Measuring System ...................................................................... 38
9 Checklist............................................................................................................... 39
10 Appendix ............................................................................................................ 40
10.1 TÜV certificate ...................................................................................................................... 40
10.2 Revision list........................................................................................................................... 40
10.3 EU Declaration of Conformity ............................................................................................... 40
10.4 Pin assignment ..................................................................................................................... 40
10.5 Drawings............................................................................................................................... 40

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Revision index
Modification Date Index
First release 07/15/16 00
Translation of the actual revision 01/16/17 08
- Chapter “Permitted cable length” added
- Supplementation for variant with square-wave
- Requirements of the fail-safe processing unit expanded
- Technical data updated
04/10/17 09
Concretion of requirements regarding the SCS in ch. 1.3 and 2.5 04/21/17 10
Correction of the revision of the revision list 09/27/18 11
Order number for the connectors on chapter 6.6.1 02/07/19 12
Warning: Surge voltages in relation to the signals
SIN+, SIN–, COS+, COS–, Ref+ or Ref– 10/23/19 13

General information
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1 General information
This Manual contains the following topics:
●General functional description
●Basic safety information with declaration of the intended use
●Characteristics
●Mounting
●Installation/Commissioning
●Error causes and remedies
As the documentation is arranged in a modular structure, this User Manual is
supplementary to other documentation, such as product data sheets, dimensional
drawings and brochures, etc.
1.1 Applicability
This User Manual applies exclusively for measuring system series in accordance with
the following keys for the article numbers and type code with incremental interface
and functional safety:
Article number
* 1 * 2 * 3 - *4 * 4 * 4 * 4 * 4
Position Designation Description
* 1
I
Incremental encoder
* 2
V
Solid shaft
H
Hollow shaft
S
Blind shaft
* 3
58
Outer diameter ∅58 mm
* 4
-
Consecutive number
Type
* 1 * 2 * 3 * 4 * 5 * 6
Position Designation Description
* 1
I
Incremental encoder, not programmable
* 2
V
Solid shaft
H
Hollow shaft
S
Blind shaft
* 3 58
Outer diameter
∅
58 mm
* 4
+FS
Safety-oriented product
* 5
01
Revision 01 (see revision list)
* 6
SIN/COS
SIN/COS interface, differential
TTL (RS422)
TTL square impulse interface, differential
HTL
HTL square impulse interface, differential
* = placeholder

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The measuring system stands out due to 2 variants which are distinguished in the
chapter “Main features” on page 10.
The variants are labeled with affixed nameplates and are components of a system.
The following documentation therefore also applies:
●operator’s operating instructions specific to the system
●and this User Manual

General information
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1.2 Abbreviations and terms used
I_58 Incremental encoder, all designs
DCavg
D
iagnostic
C
overage
Average diagnostic coverage
ESD Electro Static Discharge
EU
European Union
EMC
ElectroMagnetic Compatibility
Functional
safety
(FS)
Part of the overall system safety, which depends on the correct functioning of safety-
related systems for risk reduction. Functional safety is ensured
when each safety
function is executed as specified.
Fault
exclusion
Compromise between the technical safety requirements and the theoretical possibility
of an error occurring
HTL High-Threshold-Logic
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics Engineers
ISO
International Standard Organization
MTTFd
Mean Time ToFailure (dangerous)
Mean time until dangerous failure
PFDav
Average Probability of Failure on Demand
Average probability of failure of a safety function with low demand
PFH
Probability of Failure per Hour
Operating mode with high requirement rate or continuous demand. Probability of
dangerous failure per hour.
PFHDProbability of a dangerous Failure per Hour
Average probability of a dangerous failure per hour according to ISO 13849-1.
PL Performance Level, according to ISO 13849-
1: 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, according to IEC 62061: 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.
SIS
Safety Instrumented S
ystem: is used to protect a dangerous process and reduce the
risk of an accident. Pro
cess instruments are a constituent of a Safety Instrumented
System. This comprises the essential components of a complete safety-
relevant
process unit:
Sensor, fail-safe processing unit (control) and actuator
SCS
S
afety
C
omputer
S
ystem with control function
STP
S
hielded
T
wisted
P
air
TTL
T
ransistor-
T
ransistor-
L
ogic (RS422)
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik (Association for
Electrical, Electronic and Information Technologies)
Repeat test
(proof test) Repetitive test to detect hidden dangerous failures in a safety-related system.

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1.3 General functional description
The rotary measuring system is a safe and incremental position measuring system.
The measuring system has been designed so that it can be used in systems which
require the following safety functions according to EN 61800-5-2:
●Safe Direction (SDI)
●Safe Stop 1 (SS1)
●Safe Stop 2 (SS2)
●Safe Operating Stop (SOS)
●Safely Limited Speed (SLS)
●Safe Speed Range (SSR)
●Safe Speed Monitor (SSM)
●Safely-Limited Acceleration (SLA)
●Safe Acceleration Range (SAR)
●Safely-Limited Position (SLP)
●Safely-Limited Increment (SLI)
●Safe Cam (SCA)
The measuring system as a sensor is always part of a safety chain.
The following shaft designs can be used for the mechanical coupling:
●Solid shaft
●Blind shaft
●Hollow shaft
Depending on the safety functions safety-related differences arise:
●SIL3/PLe/Cat.3, in conjunction with velocity oriented safety functions
●SIL2/PLd/Cat.3, in conjunction with positioning oriented safety functions
see chapter “Safety” -> “Functional safety” on page 19.

General information
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1.3.1 Main features
The entire system electronics has a discrete design. Neither microcontrollers nor
programmable logic elements are contained in the system electronics. There is no
interpolation or signal multiplexing. All signal lines are led separately within the
electronics.
1.3.1.1 Variant 1 (IV58+FS01 SIN/COS, IH58+FS01 SIN/COS)
Incremental interface with analog output signals SIN±, COS± and Ref±; output level
1 Vss.
The safety-evaluated measuring system is designed for the implementation of safety-
related functions in relation to speed and direction of rotation. In the downstream fail-
safe processing unit an ideal error detection also occurs through evaluation of the
annulus relationship “SIN(x)2+ COS(x)2= 1”.
The Ref± reference signals are not evaluated from a safety viewpoint and may not be
used for safety-oriented purposes.
1.3.1.2 Variant 2 (IV58+FS01 TTL/HTL, IH58+FS01 TTL/HTL)
Incremental interface with digital square-wave output signals K1±, K2± and K0±;
output level in TTL or HTL logic.
The safety-evaluated measuring system is designed for the implementation of safety-
related functions in relation to speed and direction of rotation.
An internal signal monitor constantly checks the annulus relationship
"SIN(x)2+ COS(x)2= 1". Safety-relevant errors are indicated by switching of the signal
outputs to tri-state. The K0± reference signals are not evaluated from a safety
viewpoint and may not be used for safety-oriented purposes.
1.3.2 Principle of the safety function
System safety results when:
– the scanning channel is single fault safe thanks to its own diagnostic
measures and circuit measures
– the control checks that the received incremental data meet the expected
tolerance window according to the application.
– for variant 1, the control also checks the annulus relationship
SIN(x)2+ COS(x)2= 1; if the result is outside the tolerance range, the
incremental data must be evaluated as unsafe. In this way the control
achieves an ideal error detection.
– when errors are detected the control introduces appropriate safety
measures defined by the system manufacturer
– the system manufacturer ensures, through correct mounting of the
measuring system, that the measuring system is always driven by the axis
to be measured and is not overloaded. A fault exclusion is required for
mounting the measuring system to the drive function.
– the system manufacturer carries out a proven test during commissioning
– the downstream fail-safe processing unit evaluates the measuring system
differentially

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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.
2.2 General risks when using the product
The product, hereinafter referred to as the 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!
Only use the measuring system in perfect technical condition, paying attention to
safety and dangers, and in compliance with the User Manual! Faults which could
threaten safety should be eliminated without delay!

Basic safety information
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2.3 Intended use
The safety measuring system can be used for the detection of angular movement
and processing of measured data for a downstream safety computer system in
systems in which the protection goals of "Protection of speed" and "Protection
of direction of movement" must be safely achieved. The complete processing
chain of the safety function must then 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 check that the characteristics 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:
●observing all instructions in this User Manual,
●observing the nameplate and any prohibition or instruction symbols on the
measuring system,
●observing the enclosed documentation, e.g. product insert, pin assignment etc.
●observing the operating instructions from the machine/system manufacturer,
●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,
●observing and using the checklist in the appendix,
●safe mounting (form closure) of the measuring system to the driving axis, also see
chapter "Mounting" from page 23
2.4 Non-intended use
Danger of death, physical injury and damage to property in case of non-
intended use of the measuring system!

The following areas of use are especially forbidden:
- in environments where there is an explosive atmosphere,
- for medical purposes

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2.5 Safety functions of the fail-safe processing unit
The Safety Computer System (SCS), to which the measuring system is connected,
must perform the following safety checks.
With regard to "Single fault safety" and "Ideal error detection" please see IFA directive
"GS-IFA-M21". This can be downloaded under the following link:
www.tr-electronic.com/f/zip/TR-E-TI-DGB-0107
To enable the correct measures to be taken in the case of error, the following
applies:
●Safe state – passive, only for measuring system variant 1
In passive safe state the measuring system does not output any valid
SIN±/COS± – signals to the downstream fail-
safe processing unit. The processing
unit detects the error through evaluation of the annulus relationship SIN(x)2 +
COS(x)2 = 1. If the result is outside the tolerance range, the incremental data are
evaluated as unsafe. The downstream fail-safe processing unit has an ideal error
detection.
●Safe state – active, only for measuring system variant 2
In active safe state the signal outputs are switched to tri-state. The processing
unit detects the error via an implemented cable breakage detection.
2.5.1 Mandatory safety checks / measures
Measures for commissioning, changes SCS error reaction
Check that the desired automation task is executed as
required. STOP
Check by the SCS SCS error reaction
Check of incremental data according to the present
automation task and safety function. STOP
Two-channel monitoring of incremental outputs for cable
breakage. For tri-state state
-> STOP
Only for variant 1
Evaluation of the condition SIN(x)2 + COS(x)2 = 1. The number
of checks / revolution corresponds to the number of
periods/revolution: 1024, 2048 or 4096
For the safety functions SDI, SS1, SS2, SOS, SSR, SSM an
annulus monitoring with DC = 90 % is required.
For the SLS safety function a two-channel evaluation of the
frequency from (SIN/COS) with a DC of 90 % is required.
If outside tolerance
-> STOP
Only for variant 2
A cable break detection is required for the evaluation of the
square pulse signals.
In the safe state, the output drivers are in tri-state
(high-resistance state).
If a cable break is
detected
-> STOP
Only for variant 2
Evaluation of the incremental data in differential mode and
verification with respect to antivalence, quadrature and
against phase equivalence between channels A and B
If outside tolerance
-> STOP

Basic safety information
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2.6 Warranty and liability
In principle the "General Terms and Conditions" of TR-Electronic GmbH 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 property are excluded if they result from one or more of the following
causes:
●Non-intended use of the measuring system.
●Incorrect mounting, installation and commissioning of the measuring system.
●Work carried out incorrectly on the measuring system.
●Operation of the measuring system with technical defects.
●Unauthorized mechanical or electrical modifications to the measuring system.
●Unauthorized repairs.
●Third party interference and acts of God.
2.7 Organizational measures
●The User Manual must always be kept ready-to-hand at the place of use of the
measuring system.
●In addition to the User Manual, 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 measuring system must
have read and understood the chapter "Basic safety information".
●The type plate and any prohibition or instruction symbols applied on the
measuring system must always be maintained in a legible state.
●Do not undertake any mechanical or electrical modifications to the measuring
system, except for those expressly described in this User Manual.
●Repairs may only be undertaken by the manufacturer or a center or person
authorized by the manufacturer.

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2.8 Personnel selection and qualification; basic obligations
●All work on the measuring system must only be carried out by qualified personnel.
Qualified personnel includes 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.
●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.

Basic safety information
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2.9 Safety information
Destruction, damage and malfunction of the measuring system!
–
Only carry out wiring work or opening and closing of electrical
connections with the system de-energized.
–
Do not undertake any welding work if the measuring system is already
wired or switched on.
– Falling below or exceeding the permis
sible ambient temperature limit
values must be prevented through an appropriate heating/cooling
measure at the place of installation.
–
The measuring system must be installed so that no direct moisture
can affect the measuring system.
– Suitable aeration/venti
lation and heating/cooling measures must be
provided at the place of installation to prevent the temperature falling
below the dew point (condensation).
– If overvoltages of >7 V DC are inadvertently applied at the incremental
analog output signals SIN+, SIN–, COS+, COS–, Ref+ or Ref–, the
measuring system must be inspected at the factory, with specification
of the reasons or circumstances. The measuring system must be shut
down immediately.
–
Potential hazards resulting from interactions with other systems and
equipment which are or will be ins
talled in the vicinity must be
checked. The user is responsible for taking appropriate measures.
–
The power supply must be protected with a fuse suitable for the supply
lead cross-section.
– Cables used must be suitable for the temperature range.
– A defective measuring system must 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.
– Opening the measuring system is forbidden.
– When storing
and operating the measuring system unused connection
plugs must either be provided with a mating plug or a protective cap.
The appropriate IP protection class must be selected to meet the
relevant requirements.
– The type plate specifies the technical charac
teristics of the measuring
system. If the type plate is no longer legible or if the type plate is
completely missing, the measuring system must not be operated.

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The measuring system contains components and assemblies susceptible to
electrical discharge, which can be destroyed if incorrectly handled.
– Touching the measuring system connection contacts with the fingers must
be avoided, or the relevant ESD protective measures must be applied.
Disposal
– If disposal has to be undertaken after the lifespan of the device, the
applicable country-specific regulations must be observed.

Transport / Storage
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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.
– Use only the original packaging!
Inappropriate packaging material may cause damage to the device in
transit.
●Storage
– Storage temperature: -40 to +90 °C
– Store in a dry place

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4 Technical data
4.1 Safety
Functional safety
DIN EN 61508 Part 1-7 ...................................
Safety Integrity Level (SIL):
-
1
SDI, SS1, SS2, SOS, SLP, SLI, SCA.... - 2
-
1
SLS, SSR, SSM, SLA, SAR .................. - 3
EN ISO 13849-1..............................................
P
erformance
L
evel:
-
1
SDI, SS1, SS2, SOS, SLP, SLI, SCA.... - PLd / Cat. 3
-
1
SLS, SSR, SSM, SLA, SAR .................. - PLe / Cat. 3
Startup time..............................................................
Time between POWER-UP and safe
incremental output
Variant 1 ..........................................................
≤30 ms
Variant 2 ..........................................................
≤50 ms
PFH / PFH
D
, "High demand" operating mode
Variant 1 ..........................................................
5.34 * 10
-9
1/h
Variant 2 ..........................................................
6.57 * 10
-9
1/h
Notice ..............................................................
Measuring system is used only in
applications with high or continuous
demand rate
MTTFd........................................................................
high
Variant 1 ..........................................................
1558 a
Variant 2 ..........................................................
622 a
2
DC
avg
.......................................................................
medium (90 %)
Internal process safety time...................................
Time between occurrence of an F-error
and alarm indication
Overall system.................................................
≤1 ms
Process safety angle...............................................
Angle between error occurrence and
alarm indication
Through channel-internal self-diagnosis .........
± 0.3510°, at 1024 periods;
± 0.1760°, at 2048 periods;
± 0.0879°, at 4096 periods;
in relation to the measuring system shaft
T
1
, repeat test (proof test).......................................
20 years
1according to EN 61800-5-2
2The assessment occurred in accordance with Note 2 on Table 6 of EN ISO 13849-1

Technical data
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4.2 Electrical characteristics
4.2.1 General
Supply voltage .............................................
10…30 V DC according to IEC 60364-4-41, SELV/PELV
Reverse polarity protection ................
yes
Short-circuit protection .......................
yes, by internal 1 A safety fuse
Overvoltage protection .......................
yes, up to ≤60 V DC
Power consumption without load
..............
at 24 V DC
Analog output signals.........................
< 20 mA
Square-wave output signals...............
< 40 mA
4.2.2 Device-specific
Accuracy
Usable resolution................................
10 bit, 11 bit, 12 bit; depending on the device configuration
Safety-related .....................................
+ 2 bit interpolated
Functional...........................................
+ 8 bit interpolated
Variant 1
Incremental analog output signals
Periods / revolution.............................
1024, 2048, 4096 acc. to device variant
Incremental signals ............................ SIN+, SIN–, COS+, COS–
Track position, electrical.....................
90 °
Reference signals............................... Ref+, Ref–, once per revolution
Output level ........................................
1 Vss ± 0.2 V at 100 Ω, differential
Output current ....................................
20 mA
Output frequency................................
≤500 KHz
Short-circuit proof...............................
yes, incremental signals and reference signals among
each other, but not in relation to the supply voltage
Cable specification .............................
see page 31
Variant 2
Incremental square-wave output signals
Pulses / revolution..............................
1024, 2048, 4096 acc. to device variant
Incremental signals ............................
K1+, K1–, K2+, K2–
Track position, electrical.....................
90 °
Zero pulse ..........................................
K0+, K0–, once per revolution
Output level TTL.................................
EIA standard RS422 (2-wire)
Output level HTL ................................
Push-pull, supply voltage
Output current ....................................
50 mA, per channel
Output frequency................................
≤100 KHz
Short-circuit proof...............................
yes
Cable specification .............................
see page 31