Addendum to the Operating Instructions

Drive Technology \ Drive Automation \ System Integration \ Services Addendum to the Operating Instructions Safety-Rated Encoders Functional Safety for CMP Synchronous Servomotors CMP40 CMP100 CMPZ71 CMPZ100 Edition 10/2011 19380828 / EN

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Contents Contents 1 General Information... 4 1.1 How to use the operating instructions... 4 1.2 Underlying standards... 4 1.3 Structure of the safety notes... 5 1.4 Rights to claim under limited warranty... 6 1.5 Exclusion of liability... 6 1.6 Motor type notation... 6 1.7 Copyright... 6 1.8 Product name and trademarks... 6 2 Safety Notes... 7 2.1 Preliminary information... 7 2.2 General notes... 7 2.3 Target group... 8 2.4 Designated use... 9 2.5 Functional safety (FS)... 9 2.6 Transportation/storage... 10 2.7 Installation/assembly... 11 2.8 Electrical connection... 11 2.9 Startup/operation... 11 2.10 Inspection/maintenance... 11 2.11 Disposal... 11 3 Scope of Delivery and Unit Structure... 13 3.1 Functional safety technology (FS)... 13 3.2 Nameplate... 15 4 Mechanical Installation... 16 4.1 Retrofitting a safe encoder... 16 5 Electrical Installation... 17 6 Startup... 18 6.1 Prerequisites for startup... 18 7 Malfunctions... 19 7.1 Servomotor malfunctions... 19 7.2 Encoder malfunctions... 20 7.3 Brake malfunctions... 20 8 Inspection/Maintenance... 22 8.1 Functional safety... 24 9 Technical Data of the Safety-Rated Encoder Systems... 26 9.1 Encoder... 26 9.2 Safety characteristics... 26 9.3 Encoder evaluation unit... 27 10 Declaration of Conformity... 28 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 3

1 General Information How to use the operating instructions 1 General Information 1.1 How to use the operating instructions This addendum to the operating instructions "Functional Safety for Synchronous Servomotors" contains special information about the safety-rated encoder of the CMP motor. The operating instructions "CMP Synchronous Servomotors" contain information about CMP motors without safety-rated mount-on components. The documentation for a motor with safety-rated mount-on components comprises the "CMP Synchronous Servomotors" operating instructions, and the addendum to the "Functional Safety for Synchronous Servomotors" operating instructions. The operating instructions and the addendum to the operating instructions are an integral part of the product and contain important information for operation and service. They are intended for staff responsible for the assembly, installation, startup and maintenance of the product. The operating instructions and the addendum to the operating instructions must be legible and accessible at all times. Make sure that staff responsible for the plant and its operation, as well as persons who work independently on the unit, have read the operating instructions and the addendum to 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, contact SEW-EURODRIVE. Make sure you always use the latest documentation and software version. Our documentation is available in various languages for download from the SEW homepage (www.sew-eurodrive.com). Consult SEW-EURODRIVE if you are unclear about any of the information in this documentation, or if you require further information. You can also order the printed documentation from SEW-EURODRIVE. 1.2 Underlying standards The safety assessment of the encoder is based on the following standards and safety classes: Underlying standards for safety-rated encoders Safety class / standard Safety Integrity Level (SIL) according to EN 62061:2005 / IEC 61508:2011 Performance Level (PL) according to EN ISO 13849-1:2008 4 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

General Information Structure of the safety notes 1 1.3 Structure of the safety notes 1.3.1 Meaning of the signal words The following table shows the grading and meaning of the signal words for safety notes, notes on potential risks of damage to property, and other notes. Signal word Meaning Consequences if disregarded DANGER Imminent danger Severe or fatal Injuries WARNING Possible dangerous situation Severe or fatal Injuries CAUTION Possible dangerous situation Minor injuries NOTICE Possible damage to property Damage to the drive system or its environment INFORMATION Useful information or tip: Simplifies the handling of the drive system. 1.3.2 Structure of the section-related safety notes Section safety notes do not apply to a specific action, but to several actions pertaining to one subject. The used symbols indicate either a general or a specific hazard. This is the formal structure of a section safety note: SIGNAL WORD Type and source of danger. Possible consequence(s) if disregarded. Measure(s) to prevent the danger. 1.3.3 Structure of the embedded safety notes Embedded safety notes are directly integrated in the instructions just before the description of the dangerous action. This is the formal structure of an embedded safety note: SIGNAL WORD Nature and source of hazard. Possible consequence(s) if disregarded. Measure(s) to prevent the danger. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 5

1 General Information Rights to claim under limited warranty 1.4 Rights to claim under limited warranty Compliance with the provisions in the addendum to the operating instructions "Functional Safety for Synchronous Servomotors" is a prerequisite for maintaining the guaranteed functional safety properties for this drive. Performing any actions that go beyond those described in the addendum to the operating instructions, or failure to comply with the requirements, will shift the responsibility for the traceability of the safety components and the liability for functional safety to the operator. 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 operating instructions and the addendum to the operating instructions. Read the operating instructions and the addendum to the operating instructions before you start working with the unit. 1.5 Exclusion of liability You must comply with the information contained in these operating instructions to ensure safe operation of the electric motors and to achieve the specified product characteristics and performance features. SEW-EURODRIVE does not assume liability for injury to persons or damage to equipment or property resulting from non-observance of these operating instructions. In such cases, any liability for defects is excluded. 1.6 Motor type notation These operating instructions cover the motor types CMP and CMPZ. If information refers to both CMP and CMPZ motors, the notation CMP. motors is used. If information refers to either CMP or CMPZ motors, the motor type is stated explicitly. 1.7 Copyright 2011 - SEW-EURODRIVE. All rights reserved. Copyright law prohibits the unauthorized duplication, modification, distribution, and use of this document, in whole or in part. 1.8 Product name and trademarks The brands and product names contained within this publication are trademarks or registered trademarks of the titleholders. 6 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Safety Notes Preliminary information 2 2 Safety Notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The operator must ensure that the basic safety notes are read and adhered to. 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 and the addendum to 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 Preliminary information The following safety notes are concerned with the use of motors. If using gearmotors, please also refer to the safety notes for gear units in the corresponding operating instructions. 2.2 General notes DANGER Servomotors, gearmotors and gear units may have live, uninsulated (in case of open connector/terminal boxes), and sometimes moving or rotating parts as well as hot surfaces during operation. Severe or fatal injuries. All work related to transportation, storage, setup/mounting, connection, startup, maintenance and repair may only be carried out by qualified personnel, in strict observance of: The relevant detailed operating instructions The warning and safety signs on the motor/gearmotor All other project planning documents, operating instructions and wiring diagrams related to the drive The specific regulations and requirements for the system The national/regional regulations governing safety and the prevention of accidents Never install damaged products Submit a complaint to the shipping company immediately in the event of damage. Removing the required protection cover or the housing without authorization, improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to property. Refer to the detailed operating instructions for additional information. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 7

2 Safety Notes Target group 2.3 Target group Any mechanical work may only be performed by adequately qualified personnel. Qualified personnel in this context are persons who are familiar with the setup, mechanical installation, trouble shooting and maintenance for this product. Further, they are qualified as follows: Completed apprenticeship in the field of mechanical engineering (e.g. mechanic or mechatronic technician). The content of the detailed operating instructions. Any electric work may only be performed by adequately qualified personnel. Qualified electricians in this context are persons who are familiar with the electronic installation, startup, trouble shooting and maintenance for this product. Further, they are qualified as follows: Completed apprenticeship in the field of electrical engineering (e.g. electric or mechatronic technician). The content of the detailed operating instructions. Any activities regarding transportation, storage, operation, and disposal must be carried out by persons who have been instructed appropriately. All qualified personnel must wear appropriate protective clothing. 2.3.1 Functional safety 04 If you perform any work on safety-rated encoders (identified by the FS logo on the nameplate) yourself, note that disassembly and assembly work on the safety-rated encoder may only be performed by qualified personnel, and that the responsibility for the traceability of the safety-rated encoder and the liability for functional safety shifts to the operator. In addition to the qualifications listed above, these persons must be familiar with: Functional safety The relevant safety regulations and laws, especially with the requirements of EN ISO 13849-1 and all other standards, directives and laws specified in this documentation. The content of the publication "Addendum to the Operating Instructions: Functional Safety for Synchronous CMP Servomotors". The content of the detailed operating instructions. 8 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Safety Notes Designated use 2 2.4 Designated use The designated use refers to the procedure specified in the operating instructions and the addendum to the operating instructions. CMP and CMPZ synchronous servomotors are drive motors designed for use in industrial and commercial systems. Motor utilization other than that specified and areas of application other than industrial and commercial systems can only be used after consultation with SEW-EURODRIVE. Using these products in potentially explosive atmospheres is prohibited, unless specifically designated otherwise. The CMP and CMPZ synchronous servomotors meet the requirements of the low voltage directive 2006/95/EC. Do not take the unit into operation until you have established that the end product complies with the Machinery Directive 2006/42/EC. You must observe the technical data and information on the connection requirements as provided on the nameplate and in the documentation. When using a CMP motor with BP holding brake and BY working brake, note that the designated use is applying the brake at standstill (< 50 rpm). Operating the motor outside the area of designated use can cause permanent damage to the encoder. Occasional emergency braking operations, e.g. in case of a power failure or emergency off, are possible without adversely affecting the encoder. The BY brake cannot be used in conjunction with AK0H. 2.5 Functional safety (FS) Observe the notes and measures described below. 2.5.1 Labeling If functional safety is integrated in the motor, this is indicated with a FS symbol on the nameplate. 2.5.2 Encoder mounting The connection between the encoder and the motor is a safety-rated frictional connection. The mechanics and the corresponding connections can be included in the safety consideration as fault elimination. Observe the mechanical limits in section "Technical Data". 2.5.3 Encoders The described safety-rated encoders can only be used in conjunction with this motor. It is not possible to adapt them to other motors. The safety-related use of encoder systems is necessary for implementing safety-related functions regarding speed, direction of rotation and standstill from the encoder that is coupled with the motor shaft. A higher-level, safe evaluation unit is required in addition, as the encoder with its encoder-internal diagnostic function is not able to trigger responses such as initiating a safe status on its own initiative. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 9

2 Safety Notes Transportation/storage Increased demands are placed on the electrical and mechanical coupling, e.g. the shielded connection lead stranded in pairs with correct wiring in line with EMC directives. AK0H, AK1H The RS485 interface (Hiperface ) cannot be used in connection with safety technology for transferring absolute position data and other data (nameplate, diagnostics). This information can be used for general diagnostic purposes. Type Part number Safety class Safety function AK0H 1335 6615 SIL2 according to EN 62061 / IEC 61508 Up to PL d according to EN ISO 13849-1 SLS, SDI, SLA, SS1, SS2, SOS, SLI AK1H 1335 8065 SIL2 according to EN 62061 / IEC 61508 Up to PL d according to EN ISO 13849-1 SLS, SDI, SLA, SS1, SS2, SOS, SLI 2.5.4 Encoder evaluation Monitoring of the encoder temperature is mandatory if operation within the specified limits (page 26) cannot be guaranteed. The encoder status is cyclically queried via the parameter channel of the encoder interface, so that a relevant signal can be read out and processed. 2.5.5 BY brake When a BY brake is used, the working air gap of the brake must be measured at regular intervals, which are specified in the "Synchronous Servomotors" operating instructions in chapter "Inspection/Maintenance". A working air gap that exceeds the permitted maximum value can cause encoder errors or destroy the encoder. 2.6 Transportation/storage Follow the instructions on transportation, storage and proper handling. Inspect the shipment for any damage that may have occurred in transit as soon as you receive the delivery. Inform the shipping company immediately. If you notice any transport damage, do not startup the motor, consult the SEW-EURO- DRIVE Service. Remove securing devices used for transportation prior to startup. Tighten installed transportation eyebolts. They are designed to only carry the weight of the motor/gearmotor; do not attach any additional loads. The installed lifting eyebolts comply with DIN 580. The loads and regulations specified in this standard must always be observed. If the gearmotor has 2 suspension eye lugs or lifting eyebolts, then you should also use both suspension eye lugs for attaching transport ropes. In this case, the tension force vector of the slings must not exceed a 45 angle according to DIN 580. 10 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Safety Notes Installation/assembly 2 INFORMATION Screw in the lifting eyes all the way. Make sure that the lifting eyes carry only a reduced load, as the angle of the load exceeds 45. Due to the angle of the load, the lifting eyes are oversized. Note that the lifting eyes are not designed to hold the entire load of the gear unit. Store the servomotor in a dry, dust-free environment if it is not to be installed straight away. The servomotor can be stored for one year without requiring any special measures before startup. 2.7 Installation/assembly Observe the instructions in chapter "Mechanical Installation" and chapter "Electrical Installation" of the detailed operating instructions. The units must be installed and cooled according to the regulations and specifications in the corresponding documentation. Protect the synchronous servomotors from excessive strain. Ensure that components are not deformed, particularly during transportation and handling. 2.8 Electrical connection Perform electrical installation according to the pertinent regulations (e.g. cable cross sections, fusing, protective conductor connection). For any additional information, refer to the applicable documentation. Observe the wiring information and differing data on the nameplate. Observe the instructions in chapter "Electrical Installation" of the detailed operating instructions. 2.9 Startup/operation Whenever changes to normal operation occur, such as increased temperatures, noise, vibrations, determine the cause and consult the manufacturer. See the notes in chapter "Startup" of the detailed operating instructions. 2.10 Inspection/maintenance Observe the notes in section 8, "Inspection/Maintenance". Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 11

2 Safety Notes Disposal 2.11 Disposal This product consists of: Iron Aluminum Copper Plastics Electronic components Dispose of all components in accordance with applicable regulations. 12 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Scope of Delivery and Unit Structure Functional safety technology (FS) 3 3 Scope of Delivery and Unit Structure 3.1 Functional safety technology (FS) SEW-EURODRIVE drives can be supplied with safety-rated components. MOVIMOT, encoders or brakes, or other accessories, can be integrated in the AC motor as safety-relevant components either individually or in combination. SEW-EURODRIVE indicates such an integration by the FS mark and a number on the nameplate. The number is a code that indicates which components in the drive are safety-related. See the following code table for all products: Functional safety MOVIMOT Brake Manual brake release Brake monitoring function Motor protection Encoder 01 x 02 x 03 x 04 x 05 x x 06 x x 07 x x 08 x x 09 x x 10 x x 11 x x 12 x x 13 x x x 14 x x x 15 x x x 16 x x x 17 x x x 18 x x x x 19 x x x x 20 x x x x 21 x x x x 22 x x x x 23 x x x x x 24 x x x x x 25 x x x x x x 26 x x x 27 x x x x 28 x x x 29 x x x 30 x x x x 31 x x x x 32 x x x x 33 x x x x x 34 x x x 35 x x x 36 x x x x 37 x x x x x Table continued on next page. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 13

3 Scope of Delivery and Unit Structure Functional safety technology (FS) Functional safety MOVIMOT Brake Manual brake release Brake monitoring function Motor protection Encoder 38 x x x 39 x x x x x 40 41 x 42 x 43 x 44 x 45 x x 46 x x 47 x x 48 x x 49 x x 50 x x 51 x x 52 x x 53 x x x 54 x x x 55 x x x 56 x x x 57 x x x 58 x x x x 59 x x x x 60 x x x x 61 x x x x 62 x x x x 63 x x x x x 64 x x x x x 65 x x x x x x 66 x x x x x 67 x x x x 68 x x x 69 x x x 70 x x x x 71 x x x x 72 x x x x 73 x x x x x 74 x x x 75 x x x 76 x x x x 77 x x x x 78 x x x 79 x x x x x If the FS logo on the nameplate contains the code "FS 04", for example, the motor is equipped with a safe encoder. You can determine the safety level of machines and plants using the safety parameters provided in chapter "Technical Data" The characteristic safety values of SEW components are also available on the SEW homepage on the Internet and in the SEW library for the Sistema software of the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA, formerly BGIA). 14 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Scope of Delivery and Unit Structure Nameplate 3 3.2 Nameplate 3.2.1 FS logo on the nameplate on the servomotor The following figure shows a nameplate: [2] 04 [1] BMV [1] FS mark including number [2] Motor identification number The labels on the upper edge of the nameplate are only present if the motor has been designed accordingly or if it includes at least one safety-rated component. The FS logo on the nameplate is based on the combination of safety-related components that is installed, see code table above. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 15

4 Mechanical Installation Retrofitting a safe encoder 4 Mechanical Installation This chapter contains no special information about safety-rated components. 4.1 Retrofitting a safe encoder Only SEW-EURODRIVE may retrofit a safety-rated encoder. 16 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Electrical Installation 5 5 Electrical Installation DANGER Danger of electric shock. Severe or fatal injuries! It is essential to comply with the safety notes in chapter 2 during installation! Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for switching the motor and the brake. Use switch contacts in utilization category DC-3 according to EN 60947-4-1 for switching the brake with DC 24 V. When motors are powered by inverters, you must adhere to the wiring instructions issued by the inverter manufacturer. Observe the operating instructions of the servo inverter. The wiring diagram for motor and brake is supplied in a bag attached to the motor. INFORMATION A bag containing the following information is attached to the motor: Safety notes Wiring diagram Observe these notes. Note the information and explanations about correct wiring in the corresponding operating instructions. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 17

6 I 0 Startup Prerequisites for startup 6 Startup 6.1 Prerequisites for startup DANGER Danger of electric shock. Severe or fatal injuries! Observe the safety notes in section 2 during installation. Use switch contacts in utilization category AC-3 according to EN 60947-4-1 for switching the motor and the brake. When motors are powered by inverters, you must adhere to the wiring instructions issued by the inverter manufacturer. Observe the operating instructions of the servo inverter. DANGER Disabling functional safety devices. Severe or fatal injuries. Only qualified personnel is allowed to carry out work on functional safety components. Any work on functional safety components must be carried out by strictly observing the specifications in the operating instructions at hand and the respective addendum to the operating instructions. Else, the right to claim under warranty will become invalid. INFORMATION The rated speed of the motor in a gearmotor can be higher than the permitted, input speed of the gear unit. Limit the maximum speed at the servo inverter. For information on the procedure, refer to the documentation of the servo inverter. 18 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Malfunctions Servomotor malfunctions 7 7 Malfunctions For any work performed on the motor during which the sealed screw fittings of the safety-rated encoder are loosened, you must observe the notes in chapter 2 (page 8). 7.1 Servomotor malfunctions Malfunction Possible cause Remedy Supply cable interrupted Check connections, correct if necessary Fuse has blown Replace fuse Motor does not start up Check motor protection for correct setting, correct fault if Motor protection has triggered necessary Inverter faulty, overloaded, incorrectly wired or incorrectly set Check inverter, check wiring Incorrect direction of rotation Incorrect setpoint polarity Check inverter, check setpoints Motor hums and has high current consumption Drive is blocked Brake does not release Encoder cable malfunction Wrong inverter setting Overload Ambient temperature too high Motor heats up excessively Insufficient cooling (measure temperature, significantly higher than 100 C) Forced cooling fan does not run Rated operating mode (S1 to S10, EN 60034) exceeded, e.g. caused by excessive effective torque Running noise on motor Inverter not optimized Bearing damage Vibration of rotating parts Forced cooling fan: Foreign bodies in cooling air passages Check drive Possible cause: No brake voltage Check encoder cable Check the inverter Measure power, use larger motor or reduce load if necessary, check travel profile Comply with permitted temperature range Correct cooling air supply or clear cooling air passages, retrofit forced cooling fan if necessary Check connection, correct if necessary Adjust the rated operating mode of the motor to the required operating conditions; consult a professional to determine the correct drive if necessary Check the inverter Contact SEW-EURODRIVE customer service Replace the motor Rectify cause, possible imbalance Clean the cooling air passages Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 19

7 Malfunctions Encoder malfunctions 7.2 Encoder malfunctions When a BY brake is used, the working air gap of the brake must be measured at regular intervals, which are specified in the "Synchronous Servomotors" operating instructions in chapter "Inspection/Maintenance". A working air gap that exceeds the permitted maximum value can cause encoder errors or destroy the encoder. Encoder malfunctions are displayed at the inverter with a corresponding error message. 7.3 Brake malfunctions For any work performed on the motor during which the sealed screw fittings of the safety-rated encoder are loosened, you must observe the notes in chapter 2 (page 8). 7.3.1 Brake BP Malfunction Possible cause Remedy Brake does not release Motor does not brake Noise/squeaking near the brake Brake connected incorrectly Max. permitted working air gap exceeded because brake lining worn down Incorrect voltage at brake control unit, e.g. voltage drop in the supply cable > 10% Brake coil has interturn short circuit or a short circuit to frame Brake lining worn Incorrect braking torque. Brake parameters set incorrectly in the inverter Check brake connection Consult SEW-EURODRIVE Replace the motor Check voltage at motor connection: Ensure correct connection voltage; check cable cross section Consult SEW-EURODRIVE Consult SEW-EURODRIVE Replace the motor Consult SEW-EURODRIVE Replace the motor Check brake release and application times 20 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Malfunctions Brake malfunctions 7 7.3.2 BY brake Malfunction Possible cause Remedy Brake does not release Motor does not brake Brake is applied with time lag Noise/squeaking near the brake Brake control unit failed Brake connected incorrectly Max. permitted working air gap exceeded because brake lining worn down Brake coil has interturn short circuit or a short circuit to frame Brake lining worn Incorrect braking torque. Manual brake release device not set correctly Brake is switched on AC voltage side Brake parameters set incorrectly in the inverter Install a new brake control system, check internal resistance and insulation of brake coil, check switchgear Check brake connection Consult SEW-EURODRIVE Brake disk replacement by SEW-trained staff Check switchgear Replace the entire brake and brake control system (consult SEW-EURODRIVE) Consult SEW-EURODRIVE Brake disk replacement by SEW-trained staff Consult SEW-EURODRIVE Brake spring replacement by SEW-trained staff Set the setting nuts correctly Switch both, the DC and AC voltage sides; observe wiring diagram Check brake release and application times Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 21

8 Inspection/Maintenance 8 Inspection/Maintenance DANGER Disabling functional safety devices. Severe or fatal injuries. Only qualified personnel is allowed to carry out work on functional safety components. Any work on functional safety components must be carried out by strictly observing the specifications in the operating instructions at hand and the respective addendum to the operating instructions. Else, the right to claim under warranty will become invalid. DANGER The servomotor has live parts during and after operation. Severe or fatal injuries from electric shock. De-energize all power, brake and signal cables before unplugging the power or signal plug connector. Secure the motors against unintended power-up. The motor can generate a voltage when the shaft is rotated. Do not touch the connector pins. CAUTION Only use original spare parts, otherwise the motor can be damaged. Possible damage to property Use only genuine spare parts in accordance with the valid parts list. CAUTION The servomotor can have a surface temperature of more than 100 C during operation. Risk of burns and fire. Never touch the CMP synchronous servomotor during operation or in the cool down phase once it has been switched off. 22 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Inspection/Maintenance 8 NOTICE Working air gap at BY brake too large. Possible damage to property. When a BY brake is used, the working air gap must be measured at regular intervals, which are specified in the "Synchronous Servomotors" operating instructions in chapter "Inspection/Maintenance". A working air gap that exceeds the permitted maximum value can cause encoder errors or destroy the encoder. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 23

8 Inspection/Maintenance Functional safety 8.1 Functional safety Certain demands on the mechanical coupling of the encoder system to the motor must be met so that the encoder can be used for safety-relevant tasks. SEW-EURODRIVE assumes responsibility for the delivered motor with safety-rated encoder in terms of compliance with the functional safety regulations. Safety-relevant connection elements are sealed in order to be able to ensure that the delivery condition is not changed, see following figures. CMP40 CMP50/63 [1] [1] AK0H CMP71/80/100 CMPZ71/80/100 CMP71/80/100 /BP [1] [1] CMP71/80/100 CMPZ71/80/100 CMPZ71/80/100 /BP CMPZ71/80/100 /BY AK1H [1] Sealed screw connections of the encoder [1] [1] 24 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Inspection/Maintenance Functional safety 8 There are two options for performing work on the encoder or motor during which these sealed screw connections must be opened: Ask SEW-EURODRIVE Service to perform this work. If you perform any work on safety-rated encoders yourself, note that disassembly and assembly work on the safety-rated encoder may only be performed by qualified personnel. All work on the safety-rated encoder and its mechanical coupling are performed at your own risk, and the responsibility for the traceability of the safety-rated encoder and the liability for functional safety shifts to the operator. In addition to the qualifications listed above, these persons must be especially familiar with: Functional safety The relevant safety regulations and laws, especially with the requirements of EN ISO 13849-1 and all other standards, directives and laws specified in this documentation. The content of the publication "Addendum to the Operating Instructions: Functional Safety for Synchronous CMP Servomotors". The content of the detailed operating instructions. 8.1.1 Retraceability Products with functional safety, indicated by the FS logo on the motor nameplate, are subject to an extensive market observation/retraceability by SEW-EURODRIVE. This allows SEW-EURODRIVE to inform the respective customers/operators in the event of product defects. Consistent retraceability by SEW-EURODRIVE is no longer ensured if you perform work on safety-rated encoder system, e.g. if you replace or retrofit encoders. This is why we strongly suggest that you establish your own retraceability procedure and/or to support the SEW-EURODRIVE measures. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 25

9 kva i P n f Hz Technical Data of the Safety-Rated Encoder Systems Encoder 9 Technical Data of the Safety-Rated Encoder Systems 9.1 Encoder Designation Value AK0H AK1H Ambient temperature of motor -20 C to +60 C Operating temperature of encoder -20 C to +110 C -20 C to +115 C Storage temperature of encoder -40 C to +125 C Maximum speed 9000 rpm 12000 rpm Vibration resistance to EN 60068-2-6 500 m/s 2 50 g (10 Hz to 2 khz) 200 m/s 2 20 g (10 Hz to 2 khz) Shock resistance to EN 60068-2-27 1000 m/s 2 100 g (6 ms) Maximum angular acceleration 5 10 5 rad/s 2 2 10 5 rad/s 2 Degree of protection according to EN 60529 IP50 IP40 Operating voltage DC +7 to +12 V Current consumption without load 60 ma 80 ma Incremental section Absolute part Interface sin/cos Periods / revolution 128 1024 Accuracy ±0.0222 (±80 angular seconds) ±0.0125 (±45 angular seconds) Interface RS485 (Hiperface ) Increments/revolution (single-turn) 12 bit = 4096 15 bit = 32768 Revolution (multi-turn) 12 bit = 4096 12 bit = 4096 Accuracy ±0.0888 (±320 angular seconds) ±0.025 (±90 angular seconds) 9.2 Safety characteristics 9.2.1 Characteristic safety values for AK0H encoders The following table shows the characteristic safety values of the safety-rated AK0H encoders: Characteristic values according to EN 62061 / IEC 61508 EN ISO 13849-1 Classification/underlying standards SIL2 according to EN 62061 PL d according to EN ISO 13849-1 Structure HFT = 1 Probability of a dangerous failure per hour (PFH d value) 1) 1.3 10-8 1/h 2 channels (corresponds to category 3 according to EN ISO 13849-1) Mean time to dangerous failure (MTTF d value) 2) - 100 years Mission time / service life 20 years Proof test interval Not required - Safe fault coverage (SSF) 95 % - Motor/encoder connection In the drive with FS identification, exclusion of errors according to EN ISO 13849 1) The specified value refers to a diagnostics coverage of 90% that must be achieved by an encoder evaluation unit. Diagnostics must be performed within the process response time. 2) Ambient temperature 40 C 26 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

Technical Data of the Safety-Rated Encoder Systems Encoder evaluation unit kva i P n f Hz 9 9.2.2 Characteristic safety values for AK1H encoders The following table shows the characteristic safety values of the safety-rated AK1H encoder: Characteristic values according to EN 62061 / IEC 61508 EN ISO 13849-1 Classification/underlying standards SIL2 according to EN 62061 PL d according to EN ISO 13849-1 Structure HFT = 1 2 channels (corresponds to category 3 according to EN ISO 13849-1) Probability of a dangerous failure per hour (PFH d value) 1) 1.0 10-8 1/h Mean time to dangerous failure (MTTF d value) 2) - 1073 years Mission time / service life 20 years Proof test interval Not required - Safe fault coverage (SSF) 95 % - Motor/encoder connection In the drive with FS identification, exclusion of errors according to EN ISO 13849 1) The specified value refers to a diagnostics coverage of 90% that must be achieved by an encoder evaluation unit. Diagnostics must be performed within the process response time. 2) Ambient temperature 40 C 9.3 Encoder evaluation unit Designation Value Safety requirements SIL 2 according to EN 62061 / IEC 61508 Error detection rate 1) DC 90 % Error presumptions according to EN 61800-5-2:2007, table D.16 Signal amplitude monitoring 2) DC 0.5 V SS to 1.5 V SS (peak-peak) Safety functions that can be implemented SS1, SS2, SOS, SLA, SAR, SLS, SSR, SSM, SDI, SLI 1) Diagnostics must be performed within the process response time. 2) In the encoder evaluation unit, signals A, A, B and B must be high-resistance (> 1 kω) to the supply voltage and 0 V. Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100 27

10 Declaration of Conformity 10 Declaration of Conformity EC Declaration of Conformity Bruchsal Johann Soder Place Date Managing Director Technology a) b) a) Authorized representative for issuing this declaration on behalf of the manufacturer b) Authorized representative for compiling the technical documents 28 Functional Safety Synchronous Servomotors CMP40-100, CMPZ71-100

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