Manual. MOVIDRIVE MDX61B DCS31B Option. Edition 04/ / EN

Transcription

1 Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ s MOVIDRIVE MDX61B DCS31B Option Edition 04/ / EN Manual

2 SEW-EURODRIVE Driving the world

3 1 Structure of the Safety Notes Safety Notes General Target group Designated use Transportation, putting into storage Installation Electrical connection Operation Terminology Other applicable documents TÜV certificate Unit Design Unit designations and characteristics Nameplate DCS31B unit design Installation General installation information Installation of the DCS31B option card Connection and terminal description of the DCS31B option Measures to ensure electromagnetic compatibility (EMC) External DC 24 V voltage supply Connecting binary inputs DI1 to DI Connecting position and velocity sensors Wiring of binary outputs Startup General startup instructions Parameter descriptions Switch-on sequence Validation report Validation Procedure Maintenance Maintenance during operation Changing / handling changes on the unit Disposal Manual MOVIDRIVE MDX61B DCS31B Option 3

4 8 Local Diagnostics Meaning of the status LEDs Error and alarm classes Error messages Alarm messages Technical Data Plug connectors Response times of DCS31B option Appendix Description of the input elements List of encoders recommended by SEW-EURODRIVE Index Manual MOVIDRIVE MDX61B DCS31B Option

5 Structure of the Safety Notes 1 Operating Instructions 1 Structure of the Safety Notes The safety notes in this manual are designed as follows: Pictogram SIGNAL WORD! Type and source of danger. Possible consequence(s) if the safety notes are disregarded. Measure(s) to prevent the danger. Pictogram Signal word Meaning Consequences in case of disregard Example: DANGER! Imminent danger Severe or fatal injuries General danger WARNING! Possible dangerous situation Severe or fatal injuries CAUTION! Possible dangerous situation Minor injuries Specific danger, e.g. electric shock STOP! Possible damage to property Damage to the drive system or its environment NOTE Useful information or a tip Simplifies the handling of the drive system CAUTION! A requirement of fault-free operation and fulfillment of any rights to claim under limited warranty is that you adhere to the information in the manual. Therefore, read the manual before you start operating the unit! Make sure that the manual is available to persons responsible for the plant and its operation, as well as to person who work independently on the unit. You must also ensure that the documentation is legible. Exclusion of liability: You must comply with the information contained in this manual to ensure safe operation of the DCS31B option and to achieve the specified product characteristics and performance requirements. SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of this manual. In such cases, any liability for defects is excluded. Manual MOVIDRIVE MDX61B DCS31B Option 5

6 Safety Notes 2 General 2 Safety Notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The operator must make sure that the basic safety notes are read and observed. Make sure that persons responsible for the plant and its operation, as well as persons who work independently on the unit, have read through the operating instructions carefully and understood them. If you are unclear about any of the information in this documentation, or if you require further information, please contact SEW- EURODRIVE. 2.1 General Never install damaged products or take them into operation. Submit a complaint to the shipping company immediately in the event of damage. During operation, drive inverters can have live, bare and movable or rotating parts as well as hot surfaces, depending on their enclosure. Removing covers without authorization, improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to machinery. Consult the documentation for additional information. 2.2 Target group Only qualified personnel are authorized to install, startup or service the units or correct unit faults (observe IEC or CENELEC HD 384 or DIN VDE 0100 and IEC or DIN VDE 0110 as well as national accident prevention guidelines). Qualified personnel in the context of these basic safety notes are: All persons familiar with installation, assembly, startup, programming, parameter setting and operation of the product who possess the necessary qualifications. Furthermore, they must also be familiar with the applicable safety regulations and laws, particularly with the requirements of category 4 to EN and all other standards, guidelines and laws specified in this documentation. The staff responsible for this work must be given express permission from the company to startup, program, configure, label and ground units, systems and circuits in accordance with the standards of the safety technology. All persons involved in any other work, such as transportation, storage, operation and disposal, must have suitable training. 6 Manual MOVIDRIVE MDX61B DCS31B Option

7 Safety Notes Designated use Designated use The DCS31B option is designed for installation in the MOVIDRIVE MDX61B drive inverter, size 1 to 6. In case of installation in machines, startup of the DCS31B option (i.e. start of designated operation) is prohibited until it is determined that the machine meets the requirements stipulated in the EC Directive 98/37/EC (machine guideline); observe EN Startup (i.e. start of designated operation) is only permitted with adherence to the EMC guideline (89/336/EEC). The EMC test specifications EN , EN , EN , EN and EN must be taken into account during startup. Technical data and information on the connection requirements are provided on the nameplate and in the documentation; these must be observed under all circumstances. 2.4 Transportation, putting into storage Observe the notes on transportation, storage, and proper handling. Observe the climatic conditions in accordance with the section "Technical Data." 2.5 Installation The units must be installed and cooled in accordance with the guidelines listed in the corresponding documentation. Protect the DCS31B option from improper strain. Do not bend components or alter insulation spaces, particularly during transportation and handling. Avoid touching electronic components and contacts. The DCS31B option contains components that can easily be damaged by electrostatic energy and improper handling. Prevent mechanical damage or destruction of electric components (may pose health risk!). The following applications are prohibited unless measures have been expressly taken for them to be carried out: Use in potentially explosive atmospheres Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc. In non-stationary applications 2.6 Electrical connection Observe the applicable national accident prevention guidelines when working on live DCS31B options (e.g. BGV A3). Perform electrical installation according to the pertinent regulations (e.g. line cross sections, fusing, protective conductor connection). For any additional information, refer to the applicable documentation. You will find notes on EMC-compliant installation such as shielding, grounding, arrangement of filters and routing of lines in the documentation of the safety monitor. The system or machine manufacturer is responsible for maintaining the limits established by the EMC legislation. Preventive measures and protection devices must meet the regulations in force (e.g. EN 60204). Manual MOVIDRIVE MDX61B DCS31B Option 7

8 Safety Notes 2 Operation 2.7 Operation Systems with integrated MOVIDRIVE MDX61B with DCS31B option must be equipped with additional monitoring and protection devices, if necessary, according to the applicable safety guidelines, such as the law governing technical equipment, accident prevention regulations, etc. Keep all covers and doors closed during operation. The fact that the status LED and other display elements are no longer illuminated does not indicate that the unit has been disconnected from the power supply and no longer carries any voltage. Mechanical blocking or internal safety functions of the unit can cause a motor standstill. Eliminating the cause of the problem or performing a reset can result in the drive re-starting automatically. If, for safety reasons, this is not permitted for the driven machine, disconnect the unit from the mains before correcting the fault. 2.8 Terminology The designation MOVISAFE is the generic term for all design variants in the MOVISAFE 100B product series. If a particular design variant is referred to in the operating instructions, the complete designation is used. The term "safe" in this context refers to the classification as a safety function based on EN The configuration software "MOVISAFE CONFIG" is a programming and configuration tool for MOVISAFE. 2.9 Other applicable documents Description Configuration of MOVISAFE (without fieldbus) using the "MOVISAFE CONFIG" configuration software. Validation report of the implemented configuration Reference MOVISAFE CONFIG online help ( MOVISAFE software ROM, edition 02/2007, item number ) Technical safety check. This check can be generated using the MOVISAFE CONFIG configuration software and serves as an acceptance protocol. Approval TÜV certificate for DCS31B ( MOVISAFE software ROM, edition 02/2007, part no ) 8 Manual MOVIDRIVE MDX61B DCS31B Option

9 Safety Notes TÜV certificate TÜV certificate 60048AXX Manual MOVIDRIVE MDX61B DCS31B Option 9

10 Unit Design 3 Unit designations and characteristics 3 Unit Design 3.1 Unit designations and characteristics DCS31B Velocity monitoring: Speed monitoring Standstill monitoring Direction monitoring Emergency stop monitoring Position monitoring: Position range monitoring Travel range monitoring Target position monitoring 8 digital inputs 2 clock outputs 6 digital auxiliary outputs SSI / incremental / sin/cos encoder interface Diagnostics and configuration interface 10 Manual MOVIDRIVE MDX61B DCS31B Option

11 Unit Design Nameplate Nameplate DCS31B nameplate MOVIDRIVE MDX61B with built-in DCS31B option is supplied with two nameplates. The first nameplate ( following figure) is attached to the contact spring strip of the DCS31B option. It lists the part number and the serial number of the DCS31B option AXX MOVIDRIVE nameplate The second nameplate ( following figure) is attached to the MOVIDRIVE MDX61B. It contains the following information: Unit designation Part number Serial number Input data Version status Reference to the response times in the manual Permitted standards 59492AXX NOTE If the DCS31 option is supplied as a separate unit, attach the enclosed nameplate to the MOVIDRIVE MDX61B. Manual MOVIDRIVE MDX61B DCS31B Option 11

12 Unit Design 3 DCS31B unit design 3.3 DCS31B unit design [1] [2] [3] [4] [5] [6] [7] [8] 59385AXX [1] Status LED: Alarm / error Status LED: Watchdog Status LED: System B Status LED: System A [2] X80: Connection for voltage supply DC 24 V [3] X81: Connection binary inputs DI1... DI8 and clock signals P1, P2 [4] X82: Connection binary outputs DO0 / DO1 [5] X83: Connection binary output DO2 [6] X84: Connection incremental, sin/cos, absolute encoder (SSI) [7] X85: Connection incremental, sin/cos, absolute encoder (SSI) [8] X87: Connection service interface 12 Manual MOVIDRIVE MDX61B DCS31B Option

13 Installation General installation information 4 4 Installation 4.1 General installation information NOTES Route the signal cables for connection of the binary inputs separately from those for contact monitoring. It is essential that you route power cables separately from signal cables. The cables connected to outputs X82 and X83 may not exceed 30 m. 4.2 Installation of the DCS31B option card NOTES The DCS31B option card can only be installed in MOVIDRIVE MDX61B sizes 1 to 6, not in size 0. The DCS31B option card must be inserted in the expansion slot. Before you begin Read the following notes before installing or removing an option card: STOP! Electrostatic charge. Damage to electronic components. Disconnect the inverter from the power. Switch off the DC 24 V and the supply voltage. Take appropriate measures to protect the option card from electrostatic charge (use discharge strap, conductive shoes, etc.) before touching it. Before installing the option card, remove the keypad ( MOVIDRIVE MDX60B/61B operating instructions, Sec. "Removing/installing the keypad") and the front cover ( MOVIDRIVE MDX60B/61B operating instructions, Sec. "Removing/installing the front cover"). After having installed the option card, replace the front cover ( MOVIDRIVE MDX60B/61B operating instructions, Sec. "Removing/installing the front cover") and the keypad ( MOVIDRIVE MDX60B/61B operating instructions, Sec. "Removing/installing the keypad"). Keep the option card in its original packaging until immediately before you are ready to install it. Hold the option card by its edges only. Do not touch any of the components. Manual MOVIDRIVE MDX61B DCS31B Option 13

14 Installation 4 Installation of the DCS31B option card Basic procedure for installing/removing an option card (MDX61B, sizes 1-6) AXX 1. Remove the retaining screws holding the card retaining bracket. Pull the card retaining bracket out evenly from the slot (do not twist). 2. Remove the retaining screws of the black cover plate on the card retaining bracket. Remove the black cover plate. 3. Position the option card onto the retaining bracket so that the retaining screws fit into the corresponding bores on the card retaining bracket. 4. Insert the retaining bracket with installed option card into the slot, pressing slightly so it is seated properly. Secure the card retaining bracket with the retaining screws. 5. To remove the option card, follow the instructions in reverse order. 14 Manual MOVIDRIVE MDX61B DCS31B Option

15 Installation Connection and terminal description of the DCS31B option Connection and terminal description of the DCS31B option Part numbers DCS31B option: NOTES The DCS31B option can only be installed in connection with MOVIDRIVE MDX61B sizes 1 to 6. The DCS31B option must be inserted in the expansion slot. The DCS31B option must be supplied with 24V DC. The total current consumption is 2A DC. Front view of DCS31B DCS31B X84 X85 A/F WD B A X83 X82 X81 X Description LED Alarm / error LED Watchdog LED System B LED System B LED/ terminal LED A/F LED WD LED B LED A X80: Voltage supply connection X80:1 X80:2 X81: Connection binary inputs X81:1 P1 X81:2 DI1 X81:3 DI2 X81:4 DI3 X81:5 DI4 X81:6 P2 X81:7 DI5 X81:8 DI6 X81:9 DI7 X81:10 DI8 X82: Connection binary inputs DO0, DO1 X82:1 DO0_P X82:2 DO0_M X82:3 DO1_P X82:4 DO1_M X83: Connection binary output DO2 X83:1 DO2_P X83:2 DO2_M X84: Connection incremental, sin/cos, absolute encoder (encoder 1) X85: Connection incremental, sin/cos, absolute encoder (encoder 2) X84:1 X84:2 X84:3 X84:4 X84:5 X84:6 X84:7 X84:8 X84:9 X85:1 X85:2 X85:3 X85:4 X85:5 X85:6 X85:7 X85:8 X85:9 Function The LEDs show the status of the DCS31B option. ( Sec. "Local Diagnostics") DC 24 V Reference potential 0V24 Clock signal 1 for safe inputs; DC 24 V clocked Input 1 Input 2 Input 3 Input 4 Input 5 Clock signal 2 for safe inputs; DC 24 V clocked Input 6, fixed assignment 'Reset' Input 7 Input 8 HISIDE - output 0 LOSIDE - output 0 HISIDE - output 1 LOSIDE - output 1 HISIDE - output 2 LOSIDE - output 2 Assignment depends on connected encoder ( Sec. "Technical Data") Assignment depends on connected encoder ( Sec. "Technical Data") X87: Connection service interface X87 interface Baud rate: 38,4 kbaud For point-to-point connection only X AXX Manual MOVIDRIVE MDX61B DCS31B Option 15

16 Installation 4 Measures to ensure electromagnetic compatibility (EMC) 4.4 Measures to ensure electromagnetic compatibility (EMC) The DCS31 option is designed for industrial applications (based on the EMC test specifications EN ). Prerequisite for safe installation is that the electromagnetic compatibility of the entire system must be ensured by taking appropriate measures. The following measures ensure the designated operation of the DCS31B: Make sure that the voltage supply lines of the DCS31B option and the "switching cables" of the MOVIDRIVE MDX61B are routed separately. Route the inverter s signal cables and power cables in separate cable ducts. The cable ducts must be at least 10 mm apart. Only use shielded cables to connect the position and velocity sensors. The cable used to transfer signals must be suitable for the EIA485 standard (formerly RS485). Make sure the shield in the 9-pin sub-d connector for the position and velocity sensors is applied correctly. The shielding on the sensor side must also be applied correctly. Only use metal or metallized connectors. Make sure the installation of the inverter is EMC-compliant in the vicinity of the DCS31B. Check the routing and design of the shielding for the motor cable and braking resistor connection. All contactors in the vicinity of the DCS31B option have to be equipped with suitable suppressors. 16 Manual MOVIDRIVE MDX61B DCS31B Option

17 Installation External DC 24 V voltage supply External DC 24 V voltage supply The DCS31B option requires a DC 24 V voltage supply (SELV or PELV, EN 50178). During project planning and installation of the power supply unit, the following conditions must be taken into account: Make sure you adhere to the minimum and maximum tolerance of the supply voltage. Tolerance Minimum ( 15 %) Maximum (+15 %) Nominal voltage = DC 24 V DC 24 V 15 % = DC 20.4 V DC 24 V +15 % = DC 27.6 V To keep the residual ripple of the supply voltage as low as possible, we recommend using a 3-phase power supply unit or an electronically-controlled unit. The power supply unit must meet the requirements in EN (voltage dip). The external DC 24 V supply of the DCS31B option also powers the internal electronics and the external velocity and position sensors. These components are not protected separately against short circuits. The current consumption of the installed encoder should not exceed DC 300 ma. When using encoders with higher operating currents, the encoder voltage supply must be provided separately. You must ensure the external DC 24 V voltage supply is isolated from the voltage supply system (e.g. AC 230 V). To do so, choose power supply units that meet the guidelines stipulated in DIN VDE0551, EN and DIN VDE0160. When selecting a suitable unit, make sure there is equipotential bonding between PE and DC 0 V on the secondary side. Provide external protection for the DCS31B option by installing a 2 A fuse. Observe local guidelines when configuring the connection cables. The maximum external voltage that can be connected to the DCS31B option is DC 32 V. 4.6 Connecting binary inputs DI1 to DI8 The DCS31B option has 8 binary inputs (DI1... DI8). They are suitable for connecting single or dual-channel sensors with or without pulsing. NOTE To be able to acknowledge error messages, the binary input DI6 must be configured as reset input. The connected signals must have a "high" level of DC 24 V (DC +15 V... DC +30 V) and a "low" level of DC 0 V (DC 3 V... DC +5 V). The inputs are fitted with input filters. An internal diagnostic function checks cyclically whether the binary functions and the input filters are working properly. If an error is detected, the DCS31B option switches to alarm status and displays the error ( Sec. "Local diagnostics"). Manual MOVIDRIVE MDX61B DCS31B Option 17

18 Installation 4 Connecting binary inputs DI1 to DI8 Using clock outputs P1 and P2 In addition to the binary inputs DI1 to DI8, the DCS31B option has two clock outputs P1 and P2. Clock outputs P1 and P2 are switching DC 24 V outputs installed for monitoring binary inputs (DI1... DI8) only. Clock outputs may not be used for other functions of the application. The switching frequency is 240 Hz (stand-alone) for each clock output. For project planning, note that the maximum total current permitted for the outputs is 300 ma. NOTE Without changing the pulse, the binary inputs can be used with single-channel, selfmonitoring sensors in applications according to EN to category 2. With dualchannel sensors and a function test performed within 24 hours, two-channel sensors without pulsing can achieve category 4. If a function test is not performed within 24 hours, the sensors can achieve category 3. Note that external measures, particularly suitable cable routing, must be taken to prevent short circuits in the external wiring between different inputs and against the supply voltage of the DCS31B option. Each binary input of the DCS31B option can be configured separately for the following signal sources: Binary input is assigned to pulse P1 Binary input is assigned to pulse P2 Binary input is assigned to DC 24 V continuous voltage NOTE The following sample circuits assume that the switching elements are configured in accordance with the required EN category and that safety approval has been granted for the application in question. 18 Manual MOVIDRIVE MDX61B DCS31B Option

19 Installation Connecting binary inputs DI1 to DI8 4 Single-channel sensor, unchecked X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI DC 24 V DC 0 V Figure 1: Single-channel sensor, unchecked 59258AXX NOTE The single-channel sensor is connected to the DCS31B option without pulsing. The DCS31B option cannot detect cross faults or interruptions in the signal line. Note that this configuration is not permitted for safe applications without external measures. Manual MOVIDRIVE MDX61B DCS31B Option 19

20 Installation 4 Connecting binary inputs DI1 to DI8 Dual-channel sensor, unchecked Before using dual-channel sensors (homogeneous or diversified) check whether they have been approved for the intended purpose. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 DC 24 V DC 0 V Figure 2: Dual-channel sensor (homogeneous), unchecked 59259AXX Using dual-channel homogeneous sensors without a pulsing can lead to problems. Short circuits cannot be detected in the supply line of the dual-channel sensor, e.g. in the cable. Safe operation can only be achieved by routing the cables separately and making sure the terminals cannot short circuit. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 DC 24 V DC 0 V Figure 3: Dual-channel sensor (diversified), unchecked 59260AXX The DCS31B option can operate safely with dual-channel diversified sensors without pulsing. NOTE Category 3 in accordance with EN can be achieved with both circuits. 20 Manual MOVIDRIVE MDX61B DCS31B Option

21 Installation Connecting binary inputs DI1 to DI8 4 Single-channel sensor, checked Check whether the sensor is approved for use in fail-safe applications. X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI8 P1 P2 DC 24 V DC 0 V Figure 4: Single-channel sensor with pulsing 59261AXX When using a single-channel sensor with pulsing, the sensor must be connected to the clock output P1 or P2. The clock cycle must then be assigned on the DCS31B option. The following errors are detected if you use a single-channel sensor with pulsing: Short circuit in the DC 24 V supply voltage Short circuit on DC 0 V Cable interruption (power interruption is a safe state!) However, a short circuit in the cable between the two sensor connections is not detected. A short circuit between P1 and DI1 is also not detected. With a suitable switching element and careful cabling for the sensor, category 3 to EN can be achieved. NOTE Category 3 is achieved when there is no possibility of a short circuit between DI1 and P1 or between the sensor connections. Faults can be excluded in accordance with EN ISO , table D8. Manual MOVIDRIVE MDX61B DCS31B Option 21

22 Installation 4 Connecting binary inputs DI1 to DI8 Dual-channel sensor, checked All cross fault connections and connections to DC 24 V and DC 0 V can be detected when two independent clock signals are used on a homogeneous sensor. Only use NC contacts for safety applications. X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI P1 P2 DC 24 V DC 0 V Figure 5: Dual-channel homogeneous sensor with pulsing NOTE 59262AXX Note that when connecting a diversified sensor ( following figure), only the NO contact is tested regularly. As with the homogeneous sensor, all types of faults are detected in the supply line. P1 1 DI1 2 DI2 3 DI3 4 DI4 5 P2 6 DI5 7 DI6 8 DI7 9 DI8 10 X81 P1 P2 DC 24 V DC 0 V Figure 6: Dual-channel diversified sensor NOTE 59263AXX Category 4 to EN can be achieved in both cases when using permitted, positive opening switching elements. 22 Manual MOVIDRIVE MDX61B DCS31B Option

23 Installation Connecting position and velocity sensors Connecting position and velocity sensors Before you begin STOP! Do not plug in or remove encoder connections during operation. Doing so can cause irreparable damage to the electrical components on the encoder. Disconnect the connected encoders and the DCS31B option before plugging in or removing the encoder connections. The DCS31B option has two encoder interfaces for connecting standard incremental, sin/cos and absolute encoders. NOTE SEW-EURODRIVE recommends using the encoders listed in the appendix. Incremental, sin/cos or absolute encoders (binary or Gray Code) can be connected and operated via the same encoder interface. The internal encoder simulation can be used via backplane bus as well. The sin/cos encoders operate in the same way as incremental encoders. Please read the following notes carefully: The DCS31B option usually provides the connected sensors with the voltage supply. This voltage is monitored by a diagnostic process. If the sensors are powered by an external voltage supply. you must include the possibility of a voltage supply failure in the possible sources of error for the whole system. Particularly with shared external voltage supplies, you must document that this fault will be detected when the minimum operating voltage of the encoder system is not maintained. Check that EMC measures, such as shielding, etc., have been applied. The two encoders must not impact on each other. This refers to both the electrical and mechanical part. If both encoders are connected to the monitoring system with the same mechanical parts, the connection must be positive and may not include any parts that are subject to wear (chains, toothed belts, etc.). However, if parts subject to wear are used, you must install additional monitoring systems to check the mechanical connection of the sensors (e.g. monitoring function for a toothed belt). If position processing is activated, you must use at least one absolute encoder. If you only use one absolute encoder, connect it to X85 (encoder 2) on. Encoder 1 functions as a process sensor and encoder 2 as a reference sensor. If you are using encoders with different resolutions, configure the encoder with the higher resolution as "Encoder 1" (X84) and the encoder with the lower resolution as "Encoder 2" (X85). An internal number format is used in the input fields "Position", "Velocity" and "Acceleration" when the monitoring functions are configured. This can cause the values to be rounded up. Manual MOVIDRIVE MDX61B DCS31B Option 23

24 Installation 4 Connecting position and velocity sensors The following also applies to the use of absolute encoders: Absolute encoders can be read in in the data format SSI binary or SSI Gray Code. This setting is made in the encoder dialog box in the configuration software. The data length is 24 Bit. Combining different encoder types Encoder types can be combined depending on the specific application. Note the following limitations: If monitoring functions are used with position processing, at least one sensor must be assigned as an absolute encoder. When combining an absolute encoder with an incremental encoder, connect the incremental encoder to X84 and the absolute encoder to X85. If the internal encoder value of the inverter is to be used, the internal encoder has to be configured in the MOVISAFE CONFIG program as "encoder 1". If you change the encoder configuration at a later date, the existing parameters for the monitoring functions may no longer be compatible with the new encoder configuration. In this case, check the parameter settings and value ranges of all the monitoring functions in use. SEW-EURODRIVE recommends using the encoders listed in the appendix. Configuring the measuring types The most important input parameters for the monitoring functions of the DCS31B option are: Position Velocity Acceleration These input parameters are generated in a dual-channel from the connected encoder systems. Two independent encoder systems are required to achieve category 4 in accordance with EN One encoder system can be sufficient for certain applications to achieve category 3 in accordance with EN (e.g. only velocity monitoring). Travel types A and B must be configured accordingly for internal signal processing. This can be done using the encoder dialog box in the programming interface. Note the following parameters when configuring the travel type: Measuring type You can choose "linear" or "rotary" as the travel type. Units of the travel type For a linear measuring type, you can choose "mm/sec" or "m/sec" as the unit for velocity. For rotary travel, you can choose "mgrad/sec", "rps" or "rpm" as the unit for velocity. The selected resolution should correspond to the physics of the travel type to prevent rounding problems in the configuration. 24 Manual MOVIDRIVE MDX61B DCS31B Option

25 Installation Connecting position and velocity sensors 4 Positioning range The positioning range is used to determine the permitted range during positioning processes. If you do not define a positioning range, only monitoring functions with velocity processing properties will be activated during configuration. Monitoring functions with position processing properties will be deactivated in the dialog box. Once you have activated the positioning range window, i.e. allowed position processing, note that the current position of the drive must be within the measuring length window. The positioning range has a range of and is normalized with the unit specified for the travel type. Encoder type The following encoders can be used: Absolute encoder: SSI data interface with a constant data length of 24 Bit Binary or Gray Code data format Encoder with signal level to RS422 If the measuring channel is operated in slave mode, i.e. as a listener, the maximum external clock rate is 150 khz. The pulse break between the pulse clusters must be greater than 30 µs and less than 6 ms. Incremental encoder: Encoder with signal level to RS422 Measuring signal A/B track with 90 degree phase difference Maximum frequency of the input pulses 200 khz Sin/cos encoder: Encoder with AC 1 V ss Measuring signal A/B track with 90 degree phase difference Maximum frequency of the input pulses 200 khz Internal encoder simulation via backplane bus: The signals of the motor encoder can be used as encoder 1. The number of pulses of the encoder simulation via backplane bus is 4096 pulses per revolution after starting up the encoders in MOVIDRIVE. NOTE If the internal encoder simulation via backplane bus is used for reference travel of MOVIDRIVE B, the DCS31B option issues the error message "Plausibility position detection" (F109, subcode 036/037). Acknowledge the error message via the binary input DI6 with fixed "Reset"assignment ( Sec. 4.6). Safety-related switch-off thresholds The basic check is to perform a plausibility test between the two measuring channels A and B of the DCS31B option to compare the current position and velocity values with the configurable thresholds. The "incremental" switch-off threshold is the deviation in position permitted between the two recording channels A and B in the unit of velocity. The "velocity" switch-off threshold is the deviation in velocity permitted between the two recording channels A and B. Diagnostic functions are provided in the SCOPE dialog box of the configuration tool to determine the optimum parameter values. Manual MOVIDRIVE MDX61B DCS31B Option 25

26 Installation 4 Connecting position and velocity sensors Conversion example The ramp times of the MOVIDRIVE B inverter are based on a setpoint step change of Δn = /min. The acceleration value a is calculated using the following formula: a = v t a = Ramp time [ /min] [ min] 60 Example: In MOVITOOLS, P137 Emergency ramp is set to 2 seconds. [ ] [ ] /min 2 a = = [ 1/min ] 2 min 60 Conversion to 1/s 2 : 59723AEN 59725AXX [ 1/min ] 2 a = [ 1/min ] = = 25 [ 1/ s ] 60 [ s] 60 [ s] 59726AXX The values entered in the MOVISAFE CONFIG program are based on the travel type. This means that the motor revolutions still have to be converted to the travel type. Rotary system: Calculation of the velocity: v = i gear unit v i Motor add. gear 11464AXX 59728AEN v Motor i Gear unit i Additional gear = Motor velocity [1/min] = Gear unit ratio = Gear ratio of the additional gear 26 Manual MOVIDRIVE MDX61B DCS31B Option

27 Installation Connecting position and velocity sensors 4 Calculation of the acceleration: a = i gear unit a i Motor add. gear 59729AEN a Motor i Gear unit i Add. gear = Motor acceleration = Gear unit ratio = Gear ratio of the additional gear Linear system: Calculation of the velocity: 11465AXX v = i gear unit v i Motor add. gear D π drive wheel 59731AEN v v Motor i Gear unit i Add. gear D Drive wheel = Velocity [m/min] = Motor velocity [1/min] = Gear unit ratio = Gear ratio of the additional gear = Drive wheel diameter [m] Calculation of the acceleration a = i gear unit a x i Motor add. gear xd drive wheel x π 59729AEN a = Acceleration [m/min 2 ] a Motor = Motor acceleration [1/min 2 ] i Gear unit = Gear unit ratio i Add. gear = Gear ratio of the additional gear D Drive wheel = Drive wheel diameter [m] Manual MOVIDRIVE MDX61B DCS31B Option 27

28 Installation 4 Connecting position and velocity sensors In many cases, the data in millimeters or minutes can exceed the input s value range. In this case, you must scale the values from millimeters to meters (for linear systems) or from minutes to seconds (for rotary systems). Velocity: v [ mm/ s] v [ m/ s] = 1000 v [ U/min] v [ U/ s] = AXX Acceleration: 2 2 a[ mm/ s ] a[ m/ s ] = au [ /min ] au [ /min ] au [ / s] = = AXX Encoder wiring diagrams NOTES For connection of an encoder to both a MOVIDRIVE B and the DCS31B option, you can order a prefabricated cable from SEW-EURODRIVE under the part number The prefabricated cable allows you to split the encoder signals and to connect the encoder to the options DCS31B and DEH11B. The following encoder types can be connected: Incremental encoder Sin/cos encoder Hiperface encoder (only the sin/cos tracks are evaluated) Connecting an absolute encoder DCS31B X84/X85 max. 100 m CLK+ 3 CLK- 8 DATA+ 1 DATA- 6 DC 0 V DC 24 V AXX In this type of connection, the pulse signals run from the DCS31B option to the absolute encoder and the data runs from the encoder to the DCS31B option. 28 Manual MOVIDRIVE MDX61B DCS31B Option

29 Installation Connecting position and velocity sensors 4 Connecting an incremental encoder DCS31B X84/X85 max. 100 m B B A A DC 0 V DC 24 V 5 9 Figure 7: Connecting an incremental encoder 60552AXX Connecting a sin/cos encoder DCS31B X84/X85 max. 100 m COS+ 2 COS- 7 SIN+ 1 SIN- 6 DC 0 V DC 24 V 5 9 Figure 8: Connecting a sin/cos encoder 60553AXX Manual MOVIDRIVE MDX61B DCS31B Option 29

30 Installation 4 Connecting position and velocity sensors One-encoder concept For applications in category 3 it is possible to use only one encoder. In this case, the signal outputs of the encoder are split between X15 of the DEH11B option and X85 of the DCS31B option ( following figure). The internal encoder simulation via backplane bus can be used as encoder 1. Hiperface cos+ 3 RD cossin+ 4 BU YE sin- 6 GN DATA- 7 VT 4 5 DATA+ 8 BK TF/TH/KTY+ 9 BN TF/TH/KTY- 10 WH 11 GYPK U S 12 RDBU PK GY max. 100 m PE DEH11B, X15: PE PE NOTES 59388AXX Limitations apply to planned encoder systems for applications with one encoder system in sin/cos signal form in category 3. The errors listed below are detected in the external encoder system and in the wiring by using internal diagnostic measures. Mechanical faults such as shaft breakage and slip are not detected and have to be ruled out by appropriate measures in the system design. Faults within the encoder (electrical and mechanical) have to be considered individually depending on manufacturer and type and examined with respect to ruling out faults. The design of the mechanical system and of the encoder must be subjected to a failure mode and effect analysis based on the system. The operating system of the DCS31B option detects the following faults of the external encoder system. Short circuits between the safety-related signal lines Interruptions in the safety-related signal lines "Stuck at 0" or "1" on one or all safety-relevant signal lines Rectangular oscillation caused by in-phase signals PE DCS 31B X Manual MOVIDRIVE MDX61B DCS31B Option

31 Installation Wiring of binary outputs 4 If the used encoder is not listed, you have to take a closer look at possible faults of the used encoder and qualify them within the context of an FMEA. 4.8 Wiring of binary outputs The DCS31B option has a total of 6 binary outputs, which can be used individually or combined in groups. Binary output Category (EN 954-1) Comment DO0_P and DO0_M 4 Complete shutdown channel of category 4 DO0_P DO0_M Not safe Only functional DO1_P and DO1_M 4 Complete shutdown channel of category 4 DO1_P DO1_M Not safe Only functional DO2_P and DO2_M 4 Complete shutdown channel of category 4 The binary outputs are subjected to a plausibility test in all operating states. When switched on, the binary outputs are tested for correct functioning with a cyclical test pulse. The binary outputs are switched to their inverse value for the duration of the test (< 100 µs), i.e. a P binary output is switched briefly to DC 0V potential, and an M binary output is switched briefly to DC 24 V potential. The binary output test function is performed for group and individual control. Binary output Output voltage Output current DO0_P DO0_M 0.1 A DO1_P DO1_M DO2_P DO2_M DC 24 V 1.5 A NOTES The total current load of the DCS31B option may not exceed 2 A. The output power of the binary outputs DO0/DO1 depends on the output power of the binary output DO2 and the clock outputs P1 and P2. Cross and short circuits in the external wiring of the binary outputs are not detected. For safe outputs, the faults cross circuit and short circuit have to be prevented according to EN ISO table D.4 Manual MOVIDRIVE MDX61B DCS31B Option 31

32 Installation 4 Wiring of binary outputs Using the binary outputs DO2_P and DO2_M The binary outputs DO2_P and DO2_M can be used for control of the safe stop function (X17) of MOVIDRIVE B. X83 1 DO2_P 2 DO2_M MOVIDRIVE MDX61B X SVI24 SOV24 VO24 DGND 59293AXX Single-pole switching P binary output without check You can use external contactors to connect multi-phase applications or in applications with an increased current consumption. Note that with single-pole connection without an external check, welding of one or more external contacts will not be detected by the DCS31B option. The following sample circuit is not suitable for safety applications. X82 DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 X83 DO2_P DO2_M 1 2 DC 24 V DC 0 V Figure 9: Single-pole switching P binary output Not suitable for safety applications! 59268AXX 32 Manual MOVIDRIVE MDX61B DCS31B Option

33 Installation Wiring of binary outputs 4 Single-pole switching M binary output without check Similar to the previous wiring example, the following sample circuit shows a single-pole M binary output without check. The following sample circuit is not suitable for safety applications. X82 DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 X83 DO2_P DO2_M 1 2 DC 24 V DC 0 V Figure 10: Single-pole switching M binary output Not suitable for safety applications! 59267AXX NOTE Single-pole connections with monitoring of the external safety contact are permitted for use in safety applications up to category 2. Up to category 2, the status of the signal contact can be displayed and evaluated via binary outputs DO1 / DO2 or via the fieldbus interface. Manual MOVIDRIVE MDX61B DCS31B Option 33

34 Installation 4 Wiring of binary outputs Dual-channel switching binary output DO0 with external monitoring The dual-channel wiring can also be implemented with a check. The prerequisite for this solution is a switching element with checked forced contacts and test contact (NC contact). The monitoring contact is fed via clock output P1 and read via any input. The EMU1 (Emergency Monitoring Unit 1) must be configured correctly for this solution to function properly. X82 DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 X83 DO2_P DO2_M 1 2 X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI Figure 11: Dual-channel switching binary output with external contact monitoring 59280AXX NOTE Dual-channel connections of a relay with monitoring of the external safety contact are permitted for use in safety applications up to category 2! Up to category 2, the status of the signal contact can be displayed and evaluated via an additional auxiliary output, e.g. DO0_M. 34 Manual MOVIDRIVE MDX61B DCS31B Option

35 Installation Wiring of binary outputs 4 Dual-channel switching binary output DO0 with external monitoring For safety applications in category 3 and 4, two complementary binary outputs are connected as a group to control two external power contactors. DO0_P 1 X82 DO0_M X83 DO2_P DO2_M 1 2 X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI Figure 12: Dual-channel switching binary output DO0 with external monitoring 59278AXX NOTE Take into account the maximum output current of the binary outputs and the maximum current consumption of the contactors. Manual MOVIDRIVE MDX61B DCS31B Option 35

36 I Startup 5 General startup instructions 0 5 Startup 5.1 General startup instructions Prerequisites The following prerequisites must be fulfilled to ensure successful startup The system must be configured correctly The installation of the MOVISAFE CONFIG configuration software. The software is available on the MOVISAFE software ROM, edition 02/2007, item number MOVITOOLS version 4.50 or higher Firmware status or higher of the MOVIDRIVE MDX61B For detailed project planning information and a description of the parameters, refer to the online helps in the MOVISAFE CONFIG and in the MOVITOOLS operating software. Prerequisites for operating the MOVISAFE CONFIG configuration software: MOVISAFE CONFIG must be activated with a USB dongle (part number ) Operating system: Microsoft Windows 2000 or XP Hard disk storage: Approximately 100 MB RAM: min. 256 MB, recommended 512 MB or more Required hardware components: Interface adapter type UWS21A (RS232 RS485) or interface adapter USB11A (USB RS485). For more information on the hardware components, refer to the MOVIDRIVE MDX60B/61B catalog. Startup steps Make sure that the installation of the DCS31B option the cabling the terminal assignment and the safety cut-outs have been configured correctly and are suited to the application. Prevent unintentional start up of the motor by implementing the following measures: Implement additional safety features for certain applications to prevent possible injuries to people and damage to machinery. Switch on the mains voltage and, if necessary, the DC 24 V supply voltage. Startup the drive with MOVIDRIVE MDX61B as described in the "MOVIDRIVE MDX60B/61B" operating instructions. Configure and program the DCS31B option according to your application. There is no need to activate the factory settings. If you have activated the factory settings, the terminal assignment and the parameter of the MOVIDRIVE MDX61B are reset to the basic setting. Use the parameters P555/P556 to set the error and alarm response of the DCS31B option to "NO RESPONSE" or to "DISPLAY FAULT" ( Sec. 5.2 "Parameter descriptions"). The fault response will also be triggered in the CONTROLLER INHIBIT inverter status. Perform a validation ( Sec. 6 "Validation"). Create a validation report ( Sec. 5.4 "Validation report"). 36 Manual MOVIDRIVE MDX61B DCS31B Option

37 Startup Parameter descriptions I Parameter descriptions The parameter group P55x DCS safety monitor includes display and setting values that are specific to the DCS31B option. The factory setting is indicated by underline. P550 status DCS safety monitor Display value that cannot be changed. The parameter P550 displays the current status of the DCS31B option. RUN: Normal operation. STOP: The operation of the DCS31B option was stopped via the programming interface. ALARM: The DCS31B option has issued an alarm. ERROR: The DCS31B option has issued an error. You have the following options to read the corresponding error or alarm message from the fault memory of the DCS31B option: via the X87 service interface with the DBG60B keypad with the MOVISAFE CONFIG configuration software, if P555/P556 is set to "NO RESPONSE". P551 binary inputs DCS DI1... DI8 Display value that cannot be changed. The parameter P551 displays the current status of the binary inputs of the DCS31B option in the order DI1... DI8. P552 binary outputs DCS DO0_P... DO2_M Display value that cannot be changed. The parameter P552 displays the current status of the binary outputs of the DCS31B option in the following order: DO0_P DO0_M DO1_P DO1_M DO2_P DO2_M P553 DCS series number Display value that cannot be changed. The parameter P553 displays the series number of the DCS31B option. The series number displayed must be identical with the series number on the nameplate of DCS31B, which is attached to the MOVIDRIVE MDX61B. You have to enter the series number in the validation report ( Sec. "Validation"). Manual MOVIDRIVE MDX61B DCS31B Option 37

38 I Startup 5 Parameter descriptions 0 P554 CRC DCS Display value that cannot be changed. The parameter CRC DCS displays the CRC (cyclic redundancy check) of the program stored on the DCS31B option. You have to enter the CRC in the validation report ( Sec. "Validation"). P555 DCS error response / P556 DCS alarm response Factory setting: IMM. STOP /FAULT If the DCS31B option issues a fault (P555) or an alarm (P556), the inverter performs the set response. The following responses can be programmed: Response NO RESPONSE DISPLAY FAULT Description No fault is displayed and no fault response is triggered. The fault which is signaled is completely ignored. The fault is displayed (in 7-segment display and SHELL), the fault output is set (if programmed). The unit has no other fault responses. The fault can be reset (terminal, RS485, fieldbus, auto-reset). P557 DCS actual position source Setting range: Motor encoder (X15) / ext. encoder (X14) / absolute encoder If the option "Encoder inverter" is set as encoder 1 in the MOVISAFE CONFIG configuration software, the setting in P557 determines which encoder signal is evaluated by the DCS31B option. 38 Manual MOVIDRIVE MDX61B DCS31B Option

39 Startup Switch-on sequence I Switch-on sequence After each restart of the DCS31B option, the following operating states are performed and displayed at the front status LEDs in case of fault-free operation. DCS31B A/F WD B A Status LED LED A/F: Alarm / fault LED WD: Watchdog LED B: System B LED A: System A 60577AXX Operating state LED display Mode Description 1 LEDs "A" and "B" flash in sync (changes every 1.2 s) LED "WD" off LED "A/F" off 3 LEDs "A" and "B" flash in sync (changing every 0.8 s) LED "WD" off LED "A/F" off STARTUP The processor systems are synchronized and the configuration/firmware data is checked. 2 SENDCONFIG Configuration/firmware data is distributed and checked again. An internal check is performed for the configuration data. 4 LEDs "A" and "B" flash in sync (changing every 0.4 s) LED "WD" on LED "A/F" off STARTUP BUS RUN If applicable. Watchdog is active, which means that all outputs can be switched. NOTE In operating states 1, 2 and 3, the outputs are switched off automatically by the firmware. In the "RUN" mode (operating state "4"), the outputs are controlled by the implemented PLC program. Manual MOVIDRIVE MDX61B DCS31B Option 39

40 I Startup 5 Validation report Validation report To make sure that the implemented safety functions function correctly, the user must check and document the parameters and connections after startup and configuration. This is supported by the MOVISAFE CONFIG configuration software. You can call up the validation report directly from the programming interface under the menu item [File] / [Configuration report]. You can use the first page of the validation report to enter generation information on the system (type system, customer, supplier, setup operator, etc.). You can use the second page to enter more detailed information on the system / machine. This data is for information only, but the content and scope must be checked with the approval authorities / inspector. The last page of the report contains an itemization on the safety check. You must make the following entries here: Serial number (identical to the serial number on the nameplate) Correspondence between the serial number read off and the serial number on the nameplate of the DCS31B option Identity of the subassembly Here, the inspector of the safety subassembly confirms that the CRC displayed in the programming interface is identical to the one in the DCS31B option. This CRC signature comprises a five-digit number that is displayed in the connection dialog box of the configuration tool in the diagnostic system information section. In this case, the DCS31B option must have an active connection. Once all header data has been entered, you can generate the validation report by pressing the "Save" button. The configuration tool creates a text file (.TXT) with the file name of the parameter/parameter dataset. The text file includes the following information: The 3 pages of the header data listed above Encoder configuration Parameters of the monitoring functions Monitoring functions not required are also listed. These functions must also be checked! NOTES The correct program data and parameter data must be loaded to create the validation report. All listed parameters and program instructions must be validated at the system / machine and confirmed by a signature in the validation report. The inspector must validate all the configured data again in a printout of the validation report. All limit values set for the monitoring functions must be tested. The printed out AWL code must be validated. 40 Manual MOVIDRIVE MDX61B DCS31B Option