Operating Instructions MOVISAFE UCS.B Safety Modules

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services Operating Instructions MOVISAFE UCS.B Safety Modules Edition 05/ / EN

2 SEW-EURODRIVE Driving the world

3 Contents Contents 1 General Information How to use the operating instructions Structure of the safety notes Meaning of the signal words Structure of section safety notes Structure of the embedded safety notes Right to claim under warranty Exclusion of liability Copyright Other applicable documentation Safety Notes General information Target group Designated use Transportation and storage Installation Electrical connection Operation Definitions Integrated Safety Technology General structure and safety technology architecture Safety functions STO (Safe Torque Off) SS1b (Safe Stop 1) SS1c (Safe Stop 1) SS2b (Safe Stop 2) SS2c (Safe Stop 2) SOS (Safe Operating Stop) SLA (Safely Limited Acceleration) SAR (Safe Acceleration Range) SLS (Safely Limited Speed) SSR (Safe Speed Range) SDI (Safe Direction) SLI (Safely Limited Increment) SLP (Safely Limited Position) SCA (Safe Cam) SBC (Safe Brake Control) Limitations Operating Instructions MOVISAFE UCS.B 3

4 Contents 4 Unit Design Unit properties Scope of delivery Nameplate of UCS.B Unit design of basic modules UCS10B UCS11B UCS12B Unit design of expansion module UCS23B Unit design of diagnostic module UCS25B Mechanical Installation General installation notes Installation notes Dimension drawing for support rail Installation clearance Expansion options Backplane bus connectors Registration of an expansion module Step-by-step installation of MOVISAFE UCS.B Step-by-step disassembly of MOVISAFE UCS.B Electrical Installation Connection and terminal description of the basic modules Part numbers Terminal description Connection and terminal description for expansion module UCS23B Part number Terminal description Connection and terminal description for diagnostic module Part number Terminal description Measures for electromagnetic compatibility (EMC) External DC 24 V supply External encoder voltage supply Binary input connection Use of the pulse outputs Single-channel sensor, not monitored Single-channel sensor, monitored Dual-channel sensor, not monitored Dual-channel sensor, monitored Wiring of the outputs General information Connection of outputs at the basic module Connection of outputs at the expansion module Operating Instructions MOVISAFE UCS.B

5 Contents 6.9 Connection of position and velocity sensors Before you start General installation notes for encoders Combination of various encoder types Technical requirements on suitable encoder types Voltage supply for encoder systems Connection of HTL proximity sensors Prefabricated cables Startup General startup information Requirements Startup steps Communication and establishing a connection RS485 interface X Operating states Switch-on sequences LED display on the basic module LED display on the expansion module Configuration of measuring sections Conversion example Conversion factors Measuring error during speed measurement Validation Procedure Configuration report for validation Structure of the configuration report Creation of the configuration report Entries in the configuration report Function test Determining/checking the response times for validation Validation of the performance level according to EN ISO Maintenance Servicing Modification/changes to the unit Disposal Replacement of the basic module Preparations Replacing the basic module Concluding measures Replacing the expansion module Preparation Replacing the expansion module Concluding measures Operating Instructions MOVISAFE UCS.B 5

6 Contents 9.6 Replacing the diagnostic module Preparation Replacing the diagnostic module Concluding measures Replacing an SSI absolute encoder Replacing an SSI absolute encoder when position processing is inactive Replacing an SSI absolute encoder when position processing is active Diagnostics Meaning of the 7-segment display Meaning of the status LED Diagnostic module UCS23B with CAN interface Structure of CAN telegram Structure of CAN telegram Error and alarm messages Display of error or alarm messages List of error messages List of alarm messages List of ECS messages Technical Data General technical data Characteristic safety values of MOVISAFE UCS10B Characteristic safety values of MOVISAFE UCS11B Characteristic safety values of MOVISAFE UCS12B Characteristic safety values of MOVISAFE UCS23B Plug connectors of basic module Connector assignment X Connector assignment X7/X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Operating Instructions MOVISAFE UCS.B

7 Contents 11.7 Plug connectors of expansion module Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Plug connectors of diagnostic module Connector assignment X Technical data of SEW encoders TTL incremental encoder SIN/COS encoder Combination encoders Hiperface and sin/cos Combination encoders RS485 and sin/cos Combination encoders SSI and sin/cos Dimension drawing Appendix Description of input elements General information Operating mode selection switch Light curtain Emergency stop Start/reset Sensor Door monitoring Confirmation button Two-hand button Diagnostic values Binary inputs Binary outputs Encoder interface Response times of MOVISAFE Calculating the response time of MOVISAFE with overspeed distance monitoring Fast channel IL code list of MOVISAFE UCS.B Abbreviations used Declaration of conformity for MOVISAFE Address List Index Operating Instructions MOVISAFE UCS.B 7

8 1 General Information How to use the operating instructions 1 General Information 1.1 How to use the operating instructions The operating instructions are an integral part of the product and contain important information for operation and service. Programming and parameterization is described in the online help of the MOVISAFE Config UCS software. The operating instructions are written for all employees who assemble, install, startup, and service this product. 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 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. 1.2 Structure of the safety notes 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 Structure of section 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 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. 8 Operating Instructions MOVISAFE UCS.B

9 General Information Right to claim under warranty Right to claim under warranty 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 documentation. Therefore, read the manual before you start operating the device. Make sure that the manual is available to persons responsible for the plant and its operation, as well as to persons who work independently on the device. You must also ensure that the documentation is legible. 1.4 Exclusion of liability You must observe this documentation and the documentation of the connected devices from SEW-EURODRIVE to ensure safe operation 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 these operating instructions. In such cases, any liability for defects is excluded. 1.5 Copyright 2010 SEW-EURODRIVE. All rights reserved. Copyright law prohibits the unauthorized duplication, modification, distribution, and use of this document, in whole or in part. 1.6 Other applicable documentation Installation and startup only by trained personnel observing the relevant accident prevention regulations and the following documents: Online help in the MOVISAFE Config UCS software (MOVISAFE software ROM, edition 04/2009, part number ). Configuration report of the MOVISAFE Config UCS software. Is used as acceptance protocol during validation. TÜV certificate for the MOVISAFE UCS10B/11B/12B/23B safety modules (MOVISAFE software ROM, edition 04/2009, part number ). Read through these publications carefully before you commence installation and startup of the MOVISAFE UCS.B safety modules. You must adhere to the information in the documentation as a prerequisite to faultfree operation and fulfillment of warranty claims. INFORMATION For the current version of the MOVISAFE Config UCS software and the "MOVISAFE UCS.B Safety Modules" operating instructions, refer to the homepage of SEW-EURODRIVE. Operating Instructions MOVISAFE UCS.B 9

10 2 Safety Notes General information 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 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, please contact SEW-EURODRIVE. 2.1 General information Never install or start up damaged products. Submit a complaint to the shipping company immediately in the event of damage. During operation, safety modules can have live parts depending on their degree of protection. Removing covers 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 documentation for additional information. 2.2 Target group Only qualified electricians can perform installation, startup, fault repair and servicing (observe IEC or CENELEC HD 384 or DIN VDE 0100 and IEC or DIN VDE 0110 as well as national accident prevention regulations). Qualified personnel in the context of these basic safety notes are all persons familiar with installation, assembly, startup, programming, parameterization and operation of the product who possess the necessary qualifications. They must also be familiar with the relevant safety regulations and laws, especially with the requirements of category 4/performance level e according to EN ISO and all other standards, directives and laws specified in this documentation. The persons mentioned must have the authorization expressly issued by the company, to operate, program, configure, label and ground units, systems and circuits in accordance with the standards of safety technology. Any activities regarding transportation, storage, operation, and disposal must be carried out by persons who have been instructed appropriately. 10 Operating Instructions MOVISAFE UCS.B

11 Safety Notes Designated use Designated use MOVISAFE UCS.B safety modules are components intended for installation in electrical systems or machines. When a MOVISAFE UCS.B safety module is to be installed in a machine (i.e. start of designated operation) do not startup the unit until it has been determined that the machine meets the requirements stipulated in the directive 2006/42/EC (machine guideline); observe EN Startup (i.e. the start of designated use) is only permitted under observance of the EMC (2004/108/EC) directive. The EMC test specifications EN , EN , EN , EN and EN must be taken into account during startup. You must observe the technical data and information on the connection requirements as provided on the nameplate and in the documentation. 2.4 Transportation and storage You must observe the notes on transportation, storage and proper handling. Observe the climatic conditions as stated in chapter "Technical data". 2.5 Installation The units must be installed and cooled according to the regulations and specifications in the corresponding documentation. Protect the MOVISAFE UCS.B safety modules from improper strain. Ensure that components are not deformed and/or insulation spaces are maintained, particularly during transportation. Avoid contact with electronic components and contacts. MOVISAFE UCS.B safety modules contain components that can be damaged by electrostatic energy and could suffer irreparable damage in case of improper handling. Prevent mechanical damage or destruction of electric components (may pose health risk). The following applications are prohibited unless the unit is explicitly designed for such use: Use in potentially explosive atmospheres Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc. Operating Instructions MOVISAFE UCS.B 11

12 2 Safety Notes Electrical connection 2.6 Electrical connection Observe the applicable national accident prevention guidelines when working on live MOVISAFE UCS.B safety modules (e.g. BGV A3). 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. 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 module. The manufacturer of the system or machine is responsible for maintaining the limits established by EMC legislation. Preventive measures and protection devices must meet the regulations in force (e.g. EN 60204). 2.7 Operation Systems with integrated MOVISAFE UCS.B safety modules 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 supply system 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 may result in the drive restarting automatically. If, for safety reasons, this is not permitted for the driven machine, disconnect the unit from the supply system before correcting the error. 2.8 Definitions The designation MOVISAFE is used as a generic term for all derivatives of the MOVISAFE UCS.B product series. If a particular design variant is referred to in the operating instructions, the complete designation is used. The term "safe" in this document refers to the classification as a safe function up to category 4/performance level e (Pl e) according to EN ISO and SIL3 according to EN The "MOVISAFE Config UCS" parameter setting software is a programming and configuration tool for the MOVISAFE UCS.B unit series. Internally, the components of the MOVISAFE unit series consist of 2 independent processing units. They are referred to as system A and system B in this document. 12 Operating Instructions MOVISAFE UCS.B

13 Integrated Safety Technology General structure and safety technology architecture kva i P f n Hz 3 3 Integrated Safety Technology The safety technology of MOVISAFE UCS.B described below meets the following safety requirements: Category 4 and performance level e according to EN ISO SIL 3 according to IEC INFORMATION This product was certified by TÜV. Copies of the TÜV certificate are available from SEW-EURODRIVE. 3.1 General structure and safety technology architecture The internal structure of MOVISAFE UCS.B consists of two separate channels with mutual comparison of results. High-quality diagnostic mechanisms for fault detection are executed in both channels. The structure corresponds to the architecture and operating principle of category 4 according to EN ISO m I A L A O A c m I B L B O B PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B O A = Output channel A O B = Output channel B c = cross comparison m = Monitoring Operating Instructions MOVISAFE UCS.B 13

14 3 kva i P f n Hz Integrated Safety Technology General structure and safety technology architecture The means the overall architecture has the following structure: Sensor Logistics Actuator Double reading of every input and diagnostics by cross comparison. The specific safety technology characteristics of the respective component (sensor, actuator) are listed in the respective technical data chapters. To assess the overall system in terms of safety, you can use the characteristic safety values specified in the "Technical Data" chapter for the subsystem UCS.B (PES). INFORMATION When using several sensors of different functions (e.g. access door position indicator and speed detection) for a safety function (e.g. safely reduced speed with open access door), these sensors have to be regarded as series connection for the safety-relevant evaluation of the overall system. See also BGIA report 02/ 2008 "Functional Safety of Machine Controls Application of EN ISO 13849". For fault exclusions, refer to the tables under D in the appendix of EN ISO The examples and their characteristic architecture depicted in this manual are decisive for the assignment to a category according to EN ISO The resulting maximum possible performance levels according to EN ISO depend on the following factors of the external components: Structure, simple or redundant (category) Measures against common cause failure (CCF) Diagnostics coverage (DC avg ) Mean time to failure of a channel (MTTF d ) 14 Operating Instructions MOVISAFE UCS.B

15 Integrated Safety Technology Safety functions kva i P f n Hz Safety functions The following drive-related safety functions can be implemented depending on the module STO (Safe Torque Off) If the STO function is activated, the drive inverter no longer supplies power to the motor. As a result, the drive cannot generate torque. This safety function corresponds to a noncontrolled stop according to EN , stop category 0. Safety function trips v t t 1 = Speed = Time = Point of time when STO is triggered INFORMATION The STO function does not monitor the stopping of the drive. Controlled standstill is preferred, if possible. Operating Instructions MOVISAFE UCS.B 15

16 3 kva i P f n Hz Integrated Safety Technology Safety functions SS1b (Safe Stop 1) When the SS1b function is active, the inverter brings the motor to a standstill electrically. The deceleration is monitored. The STO safety function is triggered when the monitored deceleration is exceeded and at standstill. This safety function corresponds to a controlled stop of the drive according to EN , stop category 1. V t 1 t 2 t Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SS1b is activated and motor deceleration is triggered = Point of time when STO is triggered 16 Operating Instructions MOVISAFE UCS.B

17 Integrated Safety Technology Safety functions kva i P f n Hz SS1c (Safe Stop 1) When the SS1c function is active, the drive inverter brings the motor to a standstill electrically. The STO safety function will be triggered after a specified, safety-relevant time. This safety function corresponds to a controlled stop of the drive according to EN , stop category 1. Safety function monitors Safety function trips v t t 1 t 2 t = Speed = Time = Point of time when SS1c is activated and motor deceleration is triggered = Point of time when STO is triggered = Safety-relevant period of time INFORMATION The SS1c function does not monitor the stopping of the drive. The safety-relevant period of time t allows the drive to come to a stop. In the event of a fault, the drive does not come to a stop. It will not be de-energized until the time t 2 (STO). Operating Instructions MOVISAFE UCS.B 17

18 3 kva i P f n Hz Integrated Safety Technology Safety functions SS2b (Safe Stop 2) When the SS1b function is active, the drive inverter brings the motor to a standstill electrically. The deceleration is monitored. The STO safety function will be triggered if the deceleration is exceeded. At standstill, the drive inverter delivers the power to keep the motor in position. The position must be safely monitored (SOS function according to EN ). This safety function corresponds to a controlled stop of the drive according to EN , stop category 2. Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SS2b is activated and motor deceleration is triggered = Point of time when SOS is triggered 18 Operating Instructions MOVISAFE UCS.B

19 Integrated Safety Technology Safety functions kva i P f n Hz SS2c (Safe Stop 2) When the SS2c function is active, the drive inverter brings the motor to a standstill electrically. At standstill, the drive inverter delivers the power to keep the motor in position. The position must be safely monitored after a specified, safety-relevant time has elapsed (SOS function according to EN ). This safety function corresponds to a controlled stop of the drive according to EN , stop category 2. Safety function monitors Safety function trips v t t 1 t 2 t = Speed = Time = Point of time when SS2c is activated and motor deceleration is triggered = Point of time when SOS is triggered = Safety-relevant period of time INFORMATION The SS2c function does not monitor the stopping of the drive. The safety-relevant period of time t allows the drive to come to a stop. In the event of a fault, the drive does not come to a stop. It will not be de-energized until the time t 2 (STO). Operating Instructions MOVISAFE UCS.B 19

20 3 kva i P f n Hz Integrated Safety Technology Safety functions SOS (Safe Operating Stop) The SOS function prevents the motor from deviating from the stop position by more than a specified value. The drive inverter delivers the power to keep the motor in position. If the specified value is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SOS is triggered = Point of time when SOS is deactivated 20 Operating Instructions MOVISAFE UCS.B

21 Integrated Safety Technology Safety functions kva i P f n Hz SLA (Safely Limited Acceleration) The SLA function prevents a movement from exceeding a specified acceleration value. If the specified acceleration limit is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SLA is activated = Point of time when SLA is deactivated Operating Instructions MOVISAFE UCS.B 21

22 3 kva i P f n Hz Integrated Safety Technology Safety functions SAR (Safe Acceleration Range) The SAR function prevents the acceleration of the drive from exceeding a specified value. If the specified value is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips t t t v t t 1 t 2 = Speed = Time = Point of time when SAR is activated = Point of time when SAR is deactivated 22 Operating Instructions MOVISAFE UCS.B

23 Integrated Safety Technology Safety functions kva i P f n Hz SLS (Safely Limited Speed) The SLS function prevents the drive from exceeding a specified velocity. If the specified velocity limit is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SLS is activated = Point of time when SLS is deactivated Operating Instructions MOVISAFE UCS.B 23

24 3 kva i P f n Hz Integrated Safety Technology Safety functions SSR (Safe Speed Range) The SSR function prevents the speed of the drive from exceeding a specified range. If the specified value is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. V Safety function monitors Safety function trips t t t v t t 1 t 2 = Speed = Time = Point of time when SSR is activated = Point of time when SSR is deactivated 24 Operating Instructions MOVISAFE UCS.B

25 Integrated Safety Technology Safety functions kva i P f n Hz SDI (Safe Direction) The SDI function prevents movement in an unintended direction. If this condition is violated, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips v t t 1 t 2 = Speed = Time = Point of time when SDI is activated = Point of time when SDI is deactivated Operating Instructions MOVISAFE UCS.B 25

26 3 kva i P f n Hz Integrated Safety Technology Safety functions SLI (Safely Limited Increment) The SLI function prevents that a movement exceeds a specified increment. If the limit value of the increment is exceeded, an error message will be issued and an error response (usually STO or SS1) will be triggered. Safety function monitors Safety function trips v S s 1, s 2 s 2, s 3 s = Speed = distance = Point of time when SLI is activated = Point of time when SLI is deactivated = Safe increment 26 Operating Instructions MOVISAFE UCS.B

27 Integrated Safety Technology Safety functions kva i P f n Hz SLP (Safely Limited Position) The SLP function prevents that a movement exceeds a specified absolute position. If the limit value of the absolute position is exceeded, an error message will be issued and a fault response (usually STO or SS1) will be triggered. Safety function trips v t X 1 X 2 = Speed = Time = Point of time when SLP is activated = Point of time when SLP is deactivated Operating Instructions MOVISAFE UCS.B 27

28 3 kva i P f n Hz Integrated Safety Technology Safety functions SCA (Safe Cam) The SCA function provides a safe signal to indicate whether the drive is located in a specific area or position range. This signal can be displayed or used for programming. In addition, a message is issued. Safety function trips v = velocity s = distance x 1 = lower limit of range x 2 = upper limit of range Operating Instructions MOVISAFE UCS.B

29 Integrated Safety Technology Safety functions kva i P f n Hz SBC (Safe Brake Control) The SBC function provides a safe output signal for controlling an external brake. This means no power is supplied to release the brake electrically. Safety function trips v t t 1 t 2 t = Speed = Time = Point of time when the drive is stopped = Point of time when SBC is triggered = Safety-relevant period of time Operating Instructions MOVISAFE UCS.B 29

30 3 kva i P f n Hz Integrated Safety Technology Limitations 3.3 Limitations INFORMATION The system/machine manufacturer must perform a system/machine-specific risk analysis. The use of the drive system must be considered for the analysis. The safety concept is only suitable for performing mechanical work on the system/ machine components. Before carrying out work on the electrical section of the drive system, the supply voltage must be disconnected using an external maintenance switch/main switch. When the DC 24 V voltage supply is disconnected, mains voltage is still present on the drive inverter's DC link. When using a thermistor, protection against restart is not guaranteed when the thermistor is triggered. This must be taken into account during project planning for the system/machine. Suitable measures might have to be implemented in addition. If the brake control and/or the motor brake fails, the drive can coast for much longer (depending on the friction and inertia of the system). In case of regenerative loads (e.g. lifting axes, declining conveying lines), the drive can even accelerate. This must be taken into account for the risk analysis of the system/machine and prevented by safety-relevant additional measures (e.g. safety braking system), if required. The inverter cannot be used without an additional brake system for applicationspecific safety functions that require active deceleration (braking) of the dangerous movement. When using the above described functions SS1c/SS2c, the deceleration of the drive is not monitored with respect to safety. In the event of a fault, the drive might not be braked during the deceleration time, or it might even accelerate. In this case, the STO function is only activated after the set time delay has passed. The resulting danger must be taken into account for the risk analysis of the system/machine. Additional safety measures have to be implemented if required. 30 Operating Instructions MOVISAFE UCS.B

31 Unit Design Unit properties 4 4 Unit Design 4.1 Unit properties Speed monitoring Speed monitoring Standstill monitoring Direction monitoring Emergency stop monitoring Position monitoring Position range monitoring Travel range monitoring Target position control 14 safe digital inputs Can be expanded to max. 70 inputs/outputs 2 2 safe digital outputs 1 2 safe relay outputs 2 auxiliary outputs 2 pulse outputs for crossfault monitoring Encoder interface: SSI / TTL incremental / SIN/COS 2 HTL counting inputs (only with UCS11B/12B) Freely programmable logic up to 800 IL instructions 4.2 Scope of delivery MOVISAFE UCS.B module Connector for all signal terminals without encoder connection Only for UCS23B/25B: Backplane bus connector (part number: ) Operating Instructions MOVISAFE UCS.B 31

32 4 Unit Design Nameplate of UCS.B 4.3 Nameplate of UCS.B The nameplate is attached to the side of the unit and contains the following information: Type designation Part number (P/N) Serial number (S/N) Hardware version (HW release) Software version (SW release) Date of manufacture (here: week 18/2010) Permitted standards Input data Output data Degree of protection Information about response times Operating Instructions MOVISAFE UCS.B

33 Unit Design Unit design of basic modules Unit design of basic modules UCS10B [1] [2] [17] X11 X21 X12 X22 [3] [16] [15] IN1314 P1 P2 ENTER STATUS IN [4] [5] [14] [13] X6 [12] OUTK1K IN IN [6] [7] UCS10B [11] X31 X41 X32 X42 [8] [10] [9] [1] X11: Terminal for DC 24 V voltage supply [2] X12: Terminal for voltage supply encoder and binary outputs DO 0.0, DO 0.1 [3] X22: Terminal for binary inputs DI 0.01 DI 0.04 [4] LED STATUS: Display of the system status [5] LED 01 04: Status of binary inputs DI 0.01 DI 0.04 [6] LED 05 08: Status of binary inputs DI 0.05 DI 0.08 [7] LED 09 12: Status of binary inputs DI 0.09 DI 0.12 [8] X32: Terminal for binary inputs DI 0.05 DI 0.08 [9] X42: Terminal for binary inputs DI DI 0.12 [10] X41: Terminal for relay outputs K 0.1, K 0.2 [11] X31: Terminal for binary outputs DO 0.2, DO 0.3 [12] LED K1, K2: Status of relay outputs K 0.1, K 0.2 LED 02, 03: Status of binary outputs DO 0.2, DO 0.3 [13] X6: Terminal for service interface [14] Status of 7-segment display [15] ENTER button [16] LED 13, 14: Status of binary inputs DI 0.13, DI 0.14 LED P1, P2: Status of pulse signals P1, P2 [17] X21: Terminal for binary inputs DI 0.13, DI 0.14 and pulse signals P1, P2 Operating Instructions MOVISAFE UCS.B 33

34 4 Unit Design Unit design of basic modules UCS11B [1] [2] [18] X11 X21 X12 X22 [3] [17] [16] IN 1314 P1 P2 ENTER STATUS IN [4] [5] [15] X7 [6] [14] X6 [13] OUTK1K IN IN [7] [8] UCS11B [12] X31 X41 X32 X42 [9] [11] [10] [1] X11: Terminal for DC 24 V voltage supply [2] X12: Terminal for voltage supply encoder and binary outputs DO 0.0, DO 0.1 [3] X22: Terminal for binary inputs DI 0.01 DI 0.04 [4] LED STATUS: Display of the system status [5] LED 01 04: Status of binary inputs DI 0.01 DI 0.04 [6] X7: Terminal for incremental, sin/cos or absolute encoder [7] LED 05 08: Status of binary inputs DI 0.05 DI 0.08 [8] LED 09 12: Status of binary inputs DI 0.09 DI 0.12 [9] X32: Terminal for binary inputs DI 0.05 DI 0.08 [10] X42: Terminal for binary inputs DI 0.09 DI 0.12 [11] X41: Terminal for relay outputs K 0.1, K 0.2 [12] X31: Terminal for binary outputs DO 0.2, DO 0.3 [13] LED K1, K2: Status of relay outputs K 0.1, K 0.2 LED 02, 03: Status of binary outputs DO 0.2, DO 0.3 [14] X6: Terminal for service interface [15] Status of 7-segment display [16] ENTER button [17] LED 13, 14: Status of binary inputs DI 0.13, DI 0.14 LED P1, P2: Status of pulse signals P1, P2 [18] X21: Terminal for binary inputs DI 0.13, DI 0.14 and pulse signals P1, P2 34 Operating Instructions MOVISAFE UCS.B

35 Unit Design Unit design of basic modules UCS12B [1] [2] [20] X11 X21 X12 X22 X13 [3] [4] [19] [18] IN 1314 P1 P2 ENTER STATUS IN [5] [6] [17] X7 X8 [7] [8] [16] X6 [15] OUTK1K IN IN [9] [10] UCS12B [14] X31 X41 X32 X42 [11] [13] [12] [1] X11: Terminal for DC 24 V voltage supply [2] X12: Terminal for voltage supply encoder and binary outputs DO 0.0, DO 0.1 [3] X13: Terminal for voltage supply for encoder (X8) [4] X22: Terminal for binary inputs DI 0.01 DI 0.04 [5] LED STATUS: Display of the system status [6] LED IN 01 04: Status of binary inputs DI 0.01 DI 0.04 [7] X7: Terminal for incremental, sin/cos or absolute encoder [8] X8: Terminal for incremental, sin/cos or absolute encoder [9] LED IN 05 08: Status of binary inputs DI 0.05 DI 0.08 [10] LED IN 09 12: Status of binary inputs DI 0.09 DI 0.12 [11] X32: Terminal for binary inputs DI 0.05 DI 0.08 [12] X42: Terminal for binary inputs DI 0.09 DI 0.12 [13] X41: Terminal for relay outputs K 0.1, K 0.2 [14] X31: Terminal for binary outputs DO 0.2, DO 0.3 [15] LED K1, K2: Status of relay outputs K 0.1, K 0.2 LED 02, 03: Status of binary outputs DO 0.2, DO 0.3 [16] X6: Terminal for service interface [17] Status of 7-segment display [18] ENTER button [19] LED IN 13, 14: Status of binary inputs DI 0.13, DI 0.14 LED P1, P2: Status of pulse signals P1, P2 [20] X21: Terminal for binary inputs DI 0.13, DI 0.14 and pulse signals P1, P2 Operating Instructions MOVISAFE UCS.B 35

36 4 Unit Design Unit design of expansion module 4.5 Unit design of expansion module UCS23B [1] [2] [15] X15 X25 X16 X26 [3] [14] STATUS I/O 0102 P1 P2 IN [4] [5] [13] [12] I/O I/O IN IN [6] [7] UCS23B [11] X35 X45 X36 X46 [8] [10] [9] [1] X15: Terminal for DC 24 V voltage supply [2] X16: Terminal for binary outputs DO X.0, DO X.1 [3] X26: Terminal for binary inputs DI X.01 DI X.04 [4] LED STATUS: Display of the system status [5] LED IN 01 04: Status of binary inputs DI X.01 DI X.04 [6] LED IN 05 08: Status of binary inputs DI X.05 DI X.08 [7] LED IN 09 12: Status of binary inputs DI X.09 DI X.12 [8] X36: Terminal for binary inputs DI X.05 DI X.08 [9] X46: Terminal for binary inputs DI X.09 DI X.12 [10] X45: Terminal for binary inputs/outputs DIO X.07 DIO X.10 [11] X35: Terminal for binary inputs/outputs DIO X.03 DIO X.06 [12] LED I/O: 07 10: Status of binary inputs/outputs DIO X.07 DIO X.10 [13] LED I/O: 03 06: Status of binary inputs/outputs DIO X.03 DIO X.06 [14] LED I/O: 01, 02: Status of binary inputs DIO X.01, DIO X.02 LED I/O: P1, P2: Status of pulse signals P1, P2 [15] X25: Terminal for binary inputs/outputs DIO X.01, DIO X.02 Terminal for pulse signals P1, P2 INFORMATION X = 1: 1. expansion module X = 2: 2. expansion module Operating Instructions MOVISAFE UCS.B

37 Unit Design Unit design of diagnostic module Unit design of diagnostic module UCS25B UCS25B X49 [1] [1] X49: CAN connection Operating Instructions MOVISAFE UCS.B 37

38 5 Mechanical Installation General installation notes 5 Mechanical Installation 5.1 General installation notes INFORMATION Install the units vertically only. Do not install the units horizontally, tilted or upside down. Ensure the correct unit enclosure (IP20) when installing MOVISAFE UCS.B in a control cabinet. The control cabinet must have have at least degree of protection IP54. Leave 10 mm clearance above and below for optimum cooling. Make sure air can circulate freely. There is no need for clearance at the sides of the unit. Route the cables for connecting digital inputs and contact monitoring functions separately from each other. Always route power cables separately from signal cables. 5.2 Installation notes NOTICE Observe the following points to prevent MOVISAFE UCS.B from being damaged: Switch off the power supply before you insert or remove MOVISAFE UCS.B. INFORMATION The individual safety modules are mounted directly to a support rail. When adding an expansion or diagnostic module to the basic module, a backplane bus connection is required. The necessary backplane bus connectors are installed in the support rail before mounting the modules. The safety modules that are to be connected via backplane bus must be mounted right next to each other. Gaps between the modules are not permitted, else the backplane bus will be interrupted. A safety module is not properly installed and electrically connected until it locks in place in the backplane connector. 38 Operating Instructions MOVISAFE UCS.B

39 Mechanical Installation Installation notes Dimension drawing for support rail You can use the following 35 mm standard profile rail (see following figure) for installation. SEW-EURODRIVE recommends to use version II to ensure sufficient space for the retaining screws under the backplane bus connector. I 35 (1.38) (0.04) (0.30) II 35 (1.38) (0.06) 15 (0.59) 27 (1.06) 27 (1.06) All dimensions in mm (ft) Installation clearance Ensure a minimum clearance of 110 mm above and 60 mm below the middle of the backplane connector when installing the components. 60 (2.36) 110 (4.33) All dimensions in mm (ft) Operating Instructions MOVISAFE UCS.B 39

40 5 Mechanical Installation Installation notes Expansion options You can add a maximum of 2 expansion modules [2] and 1 diagnostic module [3] horizontally next to 1 basic module [1] (see following figure). [1] [2] [3] X11 X21 X12 X22 X13 X15 X25 X16 X26 X15 X25 X16 X26 STATUS STATUS STATUS IN 1314 P1 P2 IN I/O 0102 P1 P2 IN I/O 0102 P1 P2 IN ENTER X7 X8 X6 OUT K1K20203 IN I/O IN I/O IN IN I/O IN I/O IN UCS12B UCS23B UCS23B UCS25B X31 X41 X32 X42 X35 X45 X36 X46 X35 X45 X36 X46 X INFORMATION You must register the expansion modules in the MOVISAFE Config software (see chapter "Registration of the expansion module"). Observe the permitted ambient temperature of 0 C to 50 C. When using expansion modules, the PFH value of the overall logic must be determined for a safety assessment. For the PFH values of the modules, refer to chapter "Technical Data". 40 Operating Instructions MOVISAFE UCS.B

41 Mechanical Installation Installation notes Backplane bus connectors The backplane bus connectors (see following figure) are expandable, 5-pole plug connectors with spring contacts. When mounting the safety modules to the support rail, contact is established with the backplane bus. The individual safety module slots are indicated by guide rails. If an expansion module and/or a diagnostic module is added to a basic module, communication between the safety modules is routed via the backplane bus. Install the backplane bus connectors in the support rail before mounting the safety modules In case of an extension, all backplane bus slots of the modules to be connected must be used. When using a basic module without expansion, the backplane bus connection is not required. Several basic modules cannot be connected. INFORMATION The scope of delivery of the basic module does not include backplane bus connectors. You can order the backplane bus connectors as accessories (5 pieces per package, part number ). When ordering a basic module with expansion and/or diagnostic module, the required number of backplane bus connectors is already included. Operating Instructions MOVISAFE UCS.B 41

42 5 Mechanical Installation Installation notes Registration of an expansion module Before you can use an expansion module, you have to assign an address to it and register this address in the MOVISAFE Config UCS software. The address is assigned via the address switch at the bottom of the expansion module (see following figure). Use the following addresses: Basic module: Address 0 (reserved) 1. Expansion module: Address 1 2. Expansion module: Address For registration of the address in MOVISAFE Config UCS, the window "UCS23B multiunit configuration" opens during the configuration of an expansion module (see following figure). INFORMATION If the set address does not correspond to the configured address, MOVISAFE UCS.B triggers an alarm. 42 Operating Instructions MOVISAFE UCS.B

43 Mechanical Installation Installation notes Step-by-step installation of MOVISAFE UCS.B Proceed as follows: NOTICE Observe the following points to prevent MOVISAFE UCS.B from being damaged: Switch off the power supply before you insert or remove MOVISAFE UCS.B. 1. Install the mounting rail. Ensure the minimum clearance of at least 110 mm above and 60 mm below the middle of the profile rail. 2. Insert the backplane bus connector into the profile rail until it locks in place. The bus connections protrude from the rail. 3. Plug in the basic module farthest left. Next plug in the required expansion modules to the right of the basic module. 4. Place the module you want to install from top at an angle of approx. 45 onto the mounting rail. Move the safety module downwards until it locks in place on the mounting rail (see following figure). Only then will the module be properly connected with the backplane bus. CLACK Operating Instructions MOVISAFE UCS.B 43

44 5 Mechanical Installation Installation notes Step-by-step disassembly of MOVISAFE UCS.B Proceed as follows to remove modules: NOTICE Observe the following points to prevent MOVISAFE UCS.B from being damaged: Switch off the power supply before you insert or remove MOVISAFE UCS.B. INFORMATION The backplane bus is interrupted by when MOVISAFE UCS.B is removed. 1. The housing of the safety module is fitted with a spring-loaded clip at the bottom by which the module can be removed from the rail. 2. Insert a suitable screwdriver into the slot. The safety module is unlocked (see following figure, pos. I). 3. First pull the safety module forward and then upward away from the mounting rail (see following figure, pos. II). I II Operating Instructions MOVISAFE UCS.B

45 Electrical Installation Connection and terminal description of the basic modules 6 6 Electrical Installation 6.1 Connection and terminal description of the basic modules Part numbers MOVISAFE UCS10B: MOVISAFE UCS11B: MOVISAFE UCS12B: INFORMATION MOVISAFE UCS.B must be supplied with DC 24 V. MOVISAFE UCS10B MOVISAFE UCS11B MOVISAFE UCS12B X11 X21 X12 X22 X11 X21 X12 X22 X11 X21 X12 X22 X13 STATUS STATUS STATUS IN1314 P1 P2 IN IN 1314 P1 P2 IN IN 1314 P1 P2 IN ENTER ENTER ENTER X7 X7 X8 X6 X6 X6 OUTK1K IN OUTK1K IN OUTK1K IN IN IN IN UCS10B UCS11B UCS12B X31 X41 X32 X42 X31 X41 X32 X42 X31 X41 X32 X Operating Instructions MOVISAFE UCS.B 45

46 6 Electrical Installation Connection and terminal description of the basic modules Terminal description Description LED/ Terminal Function LED STATUS: STATUS The LED shows the status of MOVISAFE UCS.B (see chapter "Operating states"). LED IN The LEDs show the status of the binary input (see chapter "Operating states"). LED P1, P2 P1, P2 The LEDs show the status of the pulse output (see chapter "Operating states"). LED K1, K2 K1, K2 The LEDs show the status of the relay output (see chapter "Operating states"). LED OUT , 03 The LEDs show the status of the binary output (see chapter "Operating states"). 7-segment display The number show the status of the module (see chapter "Operating states and diagnostics"). Function key ENTER Error reset and in status "4" display of the CRC. X6: Connection for service interface X6 Service interface, baud rate 38.4 kbaud. For point-to-point connection only. X7, X8: Terminal for incremental, sin/cos or absolute encoder X7 (X8):1 9 Assignment depends on connected encoder (See chapter "Electrical Installation"). X11: Terminal for DC 24 V voltage supply X11:1 DC 24 V X11:2 DC 24 V X11:3 Reference potential 0V24 X11:4 Reference potential 0V24 X12: Connection for encoder supply voltage X12:1 U_ENC_1 Encoder supply voltage for encoder interface X7 for encoder interface X7 Terminal for signal and auxiliary outputs X12:2 GND_ENC_1 Reference potential for encoder supply voltage DO 0.0, DO 0.1 X12:3 DO 0.0 Signal and auxiliary output DO 0.0 X12:4 DO 0.1 Signal and auxiliary output DO 0.1 X13: Connection for encoder supply voltage X13:1 U_ENC_2 Encoder supply voltage for encoder interface X8 for encoder interface X8 (only UCS12B) X13:2 GND_ENC_2 Reference potential for encoder supply voltage X13:3 N.C. X13:4 N.C. X21: Terminal for binary inputs DI 0.13, DI X21:1 DI 0.13 Binary input 13 (suitable for OSSD) 0.14 and pulse outputs P1, P2 X21:2 DI 0.14 Binary input 14 (suitable for OSSD) X21:3 P1 Pulse signal 1 for safe inputs; DC+24 V clocked X21:4 P2 Pulse signal 2 for safe inputs; DC+24 V clocked X22: Terminal for binary inputs DI 0.01 X22:1 DI 0.01 Binary input 1 (suitable for OSSD) DI 0.04 X22:2 DI 0.02 Binary input 2 (suitable for OSSD) X22:3 DI 0.03 Binary input 3 (suitable for OSSD) X22:4 DI 0.04 Binary input 4 (suitable for OSSD) X31: Terminal for binary outputs DO 0.02, X31:1 DO 0.02_P HISIDE output 2 DO 0.03 X31:2 DO 0.02_M LOSIDE output 2 X31:3 DO 0.03_P HISIDE output 3 X31:4 DO 0.03_M LOSIDE output 3 X32: Terminal for binary inputs DI 0.05 X32:1 DI 0.05 Binary input 5 / HTL counting input (only with UCS11B/12B) DI 0.08 X32:2 DI 0.06 Binary input 6 / HTL counting input (only with UCS11B/12B) X32:3 DI 0.07 Binary input 7 / HTL counting input (only with UCS11B/12B) X32:4 DI 0.08 Binary input 8 / HTL counting input (only with UCS11B/12B) 46 Operating Instructions MOVISAFE UCS.B

47 Electrical Installation Connection and terminal description of the basic modules 6 Description LED/ Terminal Function X41: Connection for relay outputs X41:1 K 0.11 Relay output 1 X41:2 K 0.12 X41:3 K 0.21 Relay output 2 X41:4 K 0.22 X42: Terminal for binary inputs DI 0.09 X42:1 DI 0.09 Binary input 9 (suitable for OSSD) DI 0.12 X42:2 DI 0.10 Binary input 10 (suitable for OSSD) X42:3 DI 0.11 Binary input 11 (suitable for OSSD) X42:4 DI 0.12 Binary input 12 (suitable for OSSD) Operating Instructions MOVISAFE UCS.B 47

48 6 Electrical Installation Connection and terminal description for expansion module UCS23B 6.2 Connection and terminal description for expansion module UCS23B Part number MOVISAFE UCS23B: MOVISAFE UCS23B X15 X25 X16 X26 STATUS I/O 0102 P1 P2 IN I/O I/O IN IN UCS23B X35 X45 X36 X Operating Instructions MOVISAFE UCS.B

49 Electrical Installation Connection and terminal description for expansion module UCS23B Terminal description Description LED/ Terminal Function LED STATUS: STATUS The LED shows the status of MOVISAFE UCS23B (see chapter "Operating states"). LED IN DIO X The LEDs show the status of the binary input, the binary output, LED P1, P2 P1, P2 and the pulse output. (see chapter "Operating states"). LED I/O DIO X X15: Connection X15:1 DC 24 V DC 24 V voltage supply X15:2 DC 24 V X15:3 Reference potential 0V24 X15:4 Reference potential 0V24 X16: Connection Auxiliary outputs DO X.0, DO X.1 X16:1 N.C. X16:2 N.C. X16:3 DO X.0 Signal and auxiliary output DO X.0 and DO X.1. X16:4 DO X.1 X25: Connection X25:1 DIO X.01 Binary input/output 1 Binary inputs/outputs DIO X.01 DIO X.02 and pulse outputs P1, P2 X25:2 DIO X.02 Binary input/output 2 X25:3 P1 Pulse output 1 for safe inputs; DC+24 V clocked X25:4 P2 Pulse output 2 for safe inputs; DC+24 V clocked X26: Connection X26:1 DI X.01 Binary input 1 (suitable for OSSD) Binary inputs DI X.01 DI X.04 X26:2 DI X.02 Binary input 2 (suitable for OSSD) X26:3 DI X.03 Binary input 3 (suitable for OSSD) X26:4 DI X.04 Binary input 4 (suitable for OSSD) X35: Connection X35:1 DIO X.03 Configurable binary input/output 3 Binary inputs/outputs DIO X.03 DIO X.06 X35:2 DIO X.04 Configurable binary input/output 4 X35:3 DIO X.05 Configurable binary input/output 5 X35:4 DIO X.06 Configurable binary input/output 6 X36: Connection X36:1 DI X.05 Binary input 5 Binary inputs DIX0.5 DIX0.8 X36:2 DI X.06 Binary input 6 X36:3 DI X.07 Binary input 7 X36:4 DI X.08 Binary input 8 X45: Connection X45:1 DIO X.07 Configurable binary input/output 7 Binary inputs/outputs DIO X.07 DIO X.10 X45:2 DIO X.08 Configurable binary input/output 8 X45:3 DIO X.09 Configurable binary input/output 9 X45:4 DIO X.10 Configurable binary input/output 10 X46: Connection X46:1 DI X.09 Binary input 9 (suitable for OSSD) Binary inputs DI X0.9 DI X.12 X46:2 DI X.10 Binary input 10 (suitable for OSSD) X46:3 DI X.11 Binary input 11 (suitable for OSSD) X46:4 DI X.12 Binary input 12 (suitable for OSSD) INFORMATION X = 1: 1. expansion module X = 2: 2. expansion module Operating Instructions MOVISAFE UCS.B 49

50 6 Electrical Installation Connection and terminal description for diagnostic module 6.3 Connection and terminal description for diagnostic module Part number MOVISAFE UCS25B: MOVISAFE UCS25B UCS25B X Terminal description The UCS25B diagnostic module has a terminating resistor with 120 Ω. Description LED/ Terminal Function X49: CAN connection X49:1 DGND CAN reference potential X49:2 CAN_High CAN High X49:3 CAN_Low CAN Low X49:4 N.C Operating Instructions MOVISAFE UCS.B

51 Electrical Installation Measures for electromagnetic compatibility (EMC) Measures for electromagnetic compatibility (EMC) MOVISAFE is designed for use in industrial applications (based on the EMC test specifications EN , EN , EN , EN and EN ). MOVISAFE can be installed in a control cabinet together with inverter technology without any problems. Prerequisite for safe installation is that the electromagnetic compatibility of the entire system must be ensured by taking appropriate measures. The following measures must be taken to comply with the designated operation of MOVISAFE : Make sure that the MOVISAFE voltage supply cables and the converter's "switching cables" are routed separately. Route the converter's signal cables and power cables in separate cable ducts. The minimum distance between the cable ducts should be 10 mm. All contactors in the immediate vicinity of MOVISAFE must be equipped with appropriate suppressors or protective diodes. Make sure that the converter technology in the immediate vicinity of MOVISAFE complies with the EMC guidelines. Check the routing and design of the shielding for the motor cable and braking resistor connection. Follow the installation guidelines of SEW-EURODRIVE for inverters technology. Only use shielded cables to connect the position and velocity sensors. The cable for transmitting signals must be suitable for EIA485 standard (previously RS485). Make sure the shield is connected correctly in the 9-pole D-sub connectors of the position and velocity sensors and on the sensor end of the cable. Only use metal or metalized connectors. Use prefabricated cables from SEW-EURODRIVE for splitting the signals of position and speed sensors (see chapter "Prefabricated cables"). 6.5 External DC 24 V supply The MOVISAFE UCS.B safety modules require a voltage supply of DC 24 V (see SELV or PELV, EN 50178). The following conditions must be taken into account for project planning and installation of the power supply unit: It is essential that you observe 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 achieve a rather low residual ripple of the supply voltage, we recommend using a 3-phase power supply unit or an electronically controlled unit. The power supply unit must satisfy the requirements of EN (voltage dip). The external DC 24 V supply of MOVISAFE supplies the internal electronics. When using encoders, the encoder voltage supply must be provided separately. Operating Instructions MOVISAFE UCS.B 51

52 6 Electrical Installation External encoder voltage supply Always ensure safe electrical isolation against the voltage supply system (e.g. AC 230 V). For this purpose, select power supply units that comply with DIN VDE0551, EN and DIN VDE0160. When selecting the unit, make sure it has equipotential bonding between PE and DC 0 V on the secondary side. Provide external protection for MOVISAFE by installing a 2 A fuse (single-pole, thermal-magnetic circuit breaker, "fast-acting"). Observe local regulations when dimensioning the connection cables. The maximum external voltage that can be connected to MOVISAFE UCS.B is DC 32 V. 6.6 External encoder voltage supply MOVISAFE UCS11B X12 X7 L-_ENC1 L+_ENC A A Voltage monitoring of encoder supply voltage MOVISAFE UCS12B X12 X7 L-_ENC1 L+_ENC X13 A X8 L-_ENC2 L+_ENC A Voltage monitoring of encoder supply voltages The basic modules UCS11B and UCS12B support encoder voltages of DC 5 V, 8 V, 10 V, 12 V and 24 V at the encoder terminals X7 and X8. The voltage configured in MOVISAFE Config UCS is monitored internally with a tolerance of ±10 %. If an encoder system is not powered via the UCS.B safety modules, the encoder voltage supply must still be connected to terminals X12 or X13 and configured accordingly for monitoring purposes. INFORMATION Monitoring of the encoder supply voltage cannot be deactivated. 52 Operating Instructions MOVISAFE UCS.B

53 Electrical Installation Binary input connection Binary input connection MOVISAFE UCS.B is equipped with binary inputs that can be used to connect singleor dual-channel sensors, some of them with output signal switching device (OSSD) according to EN type 2. The OSSD capability of an input is listed in chapters "Plug connectors of basic module" and Plug connectors of expansion module". INFORMATION The following sample circuits assume that the switching elements are configured in accordance with the required performance level to EN ISO and that safety approval has been granted for the application in question. UCS.B 1 P1 2 DI The connected signals must have a "High" level of DC 24 V (DC +15 V to DC +30 V) and a "Low" level of DC 0 V (DC 3 V to DC +5 V). The inputs are fitted with input filters. For project planning, note that connected cables must not exceed 30 m. For cables that are longer than 30 m, suitable measures must be taken to prevent a voltage flashover, e.g. due to a high power density (elimination of faults). This can be achieved, for example, by choosing suitable cables and/or cable routing. The internal pulse voltages can be used to detect a cross fault in the connected signal lines. They can be connected with the binary inputs as described in chapter "Using pulse outputs P1 and P2". An internal diagnostic function checks cyclically whether the binary functions, including the input filters, are working properly. When a fault is detected, MOVISAFE goes into alarm status. At the same time, all MOVISAFE outputs are deactivated (see chapter "Diagnostics"). INFORMATION Triggered safety functions or alarm messages can be acknowledged via the "ENTER" button on MOVISAFE or via a configurable reset at the binary input. Error messages can only be acknowledged by switching MOVISAFE off and then on again (see chapter "Error and alarm messages"). Operating Instructions MOVISAFE UCS.B 53

54 6 Electrical Installation Binary input connection Depending on the required performance level, you can use binary inputs individually or combined in groups. The MOVISAFE Config UCS software interface provides various, predefined input elements for this purpose (see chapter "Description of input elements"). MOVISAFE UCS.B is equipped with completely separate signal processing paths for each safety input (DI 0.01 DI 0.14). m I A L A O A c m I B L B O B Sensor PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring 54 Operating Instructions MOVISAFE UCS.B

55 Electrical Installation Binary input connection 6 Example: Signal processing in two channels and diagnostics by means of cross comparison in MOVISAFE UCS.B (PES). S A I A L A m O A c S B I B L B m O B Sensor PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B S A = Sensor channel A S B = Sensor channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring Example: Double reading and signal processing in two channels and diagnostics by means of cross comparison in MOVISAFE UCS.B (PES). S A=K1 I A L A m O A c S B=K2 m I B L B O B Sensor PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B S A = Sensor channel A S B = Sensor channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring Operating Instructions MOVISAFE UCS.B 55

56 6 Electrical Installation Binary input connection MOVISAFE UCS.B ensures comprehensive diagnostic functions for the input subsystem to achieve as high as possible DC values (Diagnostic Coverage). This functions are executed permanently or optionally (cross fault monitoring by means of pulse detection). You can use the DC values for the input sensors given in chapter "Diagnostic values" for a safety-relevant evaluation of the overall system. Inputs of the basic module DI 0.01 to 0.04 DI 0.05 to 0.08 DI 0.09 to 0.12 DI 0.13 to 0.14 Inputs of the 1st expansion module DI 1.01 to 1.04 DI 1.05 to 1.08 DI 1.09 to 1.12 DIO 1.01 to 1.10 Inputs of the 2nd expansion module DI 2.01 to 2.04 DI 2.05 to 2.08 DI 2.09 to 2.12 DIO 2.01 to 2.10 Comment Up to performance level e Up to performance level d Up to performance level e Up to performance level e Comment Up to performance level e Up to performance level d Up to performance level e Auxiliary input for DC 24 V signal Up to performance level d For category 1 structure with cross fault monitoring through pulse detection Up to performance level e For category 3 structure with cross fault monitoring through pulse detection Comment Up to performance level e Up to performance level d Up to performance level e Auxiliary input for DC 24 V signal Up to performance level d For category 1 structure with cross fault monitoring through pulse detection Up to performance level e For category 3 structure with cross fault monitoring through pulse detection 56 Operating Instructions MOVISAFE UCS.B

57 Electrical Installation Binary input connection Use of the pulse outputs In addition to the binary inputs, MOVISAFE UCS.B offers two pulse outputs (P1 and P2) at the basic module and at each expansion module. The pulse outputs are DC 24 V outputs that are intended exclusively for monitoring the binary inputs of the respective module. The pulse outputs must not be used for other functions within the application. There is a phase shift of 180 between pulse P1 and P2. The frequency of both pulse outputs is 125 Hz. Observe the following points during project planning: The connected cables must not exceed the maximum length of 30 m, and the maximum permitted total current for the pulse outputs must not exceed 250 ma. Pulse P1 and pulse P2 must be used for one specific module each. It is not possible to mix the pulses of basic and expansion modules. INFORMATION Without using pulsing, the binary inputs can be connected as follows: With single-channel, self-monitoring sensors, you can establish structures up to category 2. This means you can achieve a performance level in accordance with EN ISO With dual-channel sensors without function test within 24 hours, you can establish structures up to category 3. This means you can achieve a performance level in accordance with EN ISO With dual-channel sensors and function test within 24 hours, you can establish structures up to category 4. This means you can achieve a performance level in accordance with EN ISO 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 MOVISAFE UCS.B. Each binary input of MOVISAFE can be configured separately for the following signal sources: Digital input is assigned to pulse P1 of the same module Digital input is assigned to pulse P2 of the same module Digital input is assigned to DC 24 V continuous voltage Operating Instructions MOVISAFE UCS.B 57

58 6 Electrical Installation Binary input connection Single-channel sensor, not monitored DI 0.01 DI 0.02 DI 0.03 DI X22 L+ L INFORMATION The single-channel sensor is connected to MOVISAFE without pulsing. MOVISAFE cannot detect cross faults or interruptions in the signal line. Note that this configuration is not permitted for safe applications unless external measures are taken. A category 1 structure according to EN ISO can be achieved with this circuit. 58 Operating Instructions MOVISAFE UCS.B

59 Electrical Installation Binary input connection Single-channel sensor, monitored DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 P1 P2 L+ L When using a single-channel sensor with pulsing, the sensor must be connected to the pulse output P1 or P2. The pulse cycle must then be assigned on MOVISAFE. The following faults are detected if you use a single-channel sensor with pulsing: Short circuit against 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 DI 0.01 is also not detected. INFORMATION A category 2 structure according to EN ISO can be achieved if the short circuit between DI 0.01 and P1, and the short circuit between the sensor connections can be excluded. Faults can be excluded in accordance with EN ISO , table D8. Operating Instructions MOVISAFE UCS.B 59

60 6 Electrical Installation Binary input connection Dual-channel sensor, not monitored DI 0.01 DI 0.02 DI 0.03 DI X22 L+ L Using dual-channel homogeneous sensors without 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. DI 0.01 DI 0.02 DI 0.03 DI X22 L+ L MOVISAFE can operate safely with dual-channel diversified sensors without pulsing. INFORMATION A category 3 structure according to EN ISO can be achieved with both circuits. 60 Operating Instructions MOVISAFE UCS.B

61 Electrical Installation Binary input connection Dual-channel sensor, monitored DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 P1 P2 L+ L All cross fault connections and connections to DC 24 V and DC 0 V can be detected when 2 independent pulse signals are used on a homogeneous sensor. Only use NC contacts for safety applications. DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 P1 P2 L+ L Note that when connecting a diversified sensor (see above figure), only the NO contact is tested regularly. As with the homogeneous sensor, all types of faults are detected in the supply line. INFORMATION A category 4 structure according to EN ISO can be achieved with both circuits. Operating Instructions MOVISAFE UCS.B 61

62 6 Electrical Installation Wiring of the outputs 6.8 Wiring of the outputs General information MOVISAFE UCS.B offers the following outputs at the basic module and at the expansion modules. Module Quantity Type of output Comment Basic module 1. expansion module 2. expansion module 4 Binary P switching 2 Binary M switching 2 Relay 2 Binary P switching 10 Binary P switching, can be configured as input or output 2 Binary P switching 10 Binary P switching, can be configured as input or output MOVISAFE UCS.B ensures comprehensive diagnostic functions for the output subsystem to achieve as high as possible diagnostic coverage values. Make sure that elements for switching amplification, such as relays, contactors, etc., are included in the switch-off circuit. You can use the DC values for the output sensors in chapter "Diagnostic values" for a safety-relevant evaluation of the overall system. If the unit-internal diagnostic function is enabled, it will cyclically check the binary outputs for proper functioning. During this plausibility check, the binary output is switched to its inverse value for the duration of the check (< 500 μs). This means a P binary output is briefly switched to DC 0 V potential, and an M binary output is briefly switched to DC 24 V potential. The signal outputs are not tested. You can configure the 10 safe binary outputs of the expansion modules as auxiliary output in MOVISAFE Config UCS. The relay outputs are checked for plausibility during each switching cycle. The relay outputs have to be tested (switched) cyclically to maintain the safety function. A test should be performed at least once per year. For increased demands, the test cycle is to be determined based on the application. Auxiliary outputs at the basic or expansion module are not tested and are not permitted for safety technology applications. 62 Operating Instructions MOVISAFE UCS.B

63 Electrical Installation Wiring of the outputs 6 INFORMATION Due to the diagnostic function, the safe binary outputs of the basic and expansion modules must not be connected to fast-processing touch-probe inputs. The diagnostic function can cause unintentional switching operations. This includes, for example, the binary inputs of the frequency inverters. Cross and short circuits in the external wiring of the binary outputs are not detected. For safe outputs, cross faults and short circuit have therefore to be prevented according to EN ISO table D.4. For a safety assessment of switching amplifiers in the switch-off circuit, e.g. relay or contactor, the manufacturer's specification (MTTF d value, FIT value, B10 d value, etc.) must be used. When used for safety purposes, the proper functioning of switching amplifiers, e.g. relays or contactors, must be monitored via suitable feedback contacts. Fault exclusions are permitted according to the relevant standards. The effective peripheral conditions must be permanently ensured. If an error is detected, MOVISAFE UCS.B switches to alarm/error status and indicates this status (see chapter "Diagnostics"). Example: Signal processing in two channels and redundant output in MOVISAFE UCS.B (PES). m I A L A O A c K1 m PES I B L B O B K2 Actuator PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring K1 = Actuator 1 K2 = Actuator 2 Operating Instructions MOVISAFE UCS.B 63

64 6 Electrical Installation Wiring of the outputs Example: Signal pattern of an individual P binary output (e.g. DO 0.2_P). High DO 0.2_P Low t t 1 < 500μs t 1 < 500μs Example: Signal pattern of two binary outputs at the basic module, configured as redundant output (e.g. DO 0.2_P with DO 0.2_M). High DO 0.2_P Low t t 1 < 500μs t 1 < 500μs DO 0.2_M High Low t t 1 < 500μs t 1 < 500μs Operating Instructions MOVISAFE UCS.B

65 Electrical Installation Wiring of the outputs Connection of outputs at the basic module The following sample circuits assume that the switching elements are configured in accordance with the required performance level to EN ISO and that safety approval has been granted for the application in question. Depending on the required performance level, you can use the binary or relay outputs individually or combined in groups. For project planning, note that connected cables must not exceed 30 m. P switching binary output P and M switching binary output Relay output Relay output UCS.B DO 0.2_P UCS.B DO 0.2_P UCS.B K 0.11 UCS.B K 0.11 K 0.12 K 0.12 DO 0.2_M K 0.21 K Output Comment Output voltage Max. current DO 0.0 Auxiliary output, only functional DC 24 V 0.1 A DO 0.1 Auxiliary output, only functional DC 24 V 0.1 A DO 0.2_P with DO 0.2_M Safe output, up to performance level e DC 24 V with DC 0 V 0.5 A DO 0.2_P Auxiliary output, only functional DC 24 V 0.5 A DO 0.2_M Auxiliary output, only functional DC 0 V 0.5 A DO 0.3_P with DO 0.3_M Safe output, up to performance level e DC 24 V with DC 0 V 0.25 A DO 0.3_P Auxiliary output, only functional DC 24 V 0.25 A DO 0.3_M Auxiliary output, only functional DC 0 V 0.25 A K 0.1 with K 0.2 Safe output, up to performance level DC 24 V or AC 230 V 2 A e K 0.1 Auxiliary output, only functional DC 24 V or AC 230 V 2 A K 0.2 Auxiliary output, only functional DC 24 V or AC 230 V 2 A INFORMATION The total current load of the basic module may not exceed DC 1.9 A. For safety-relevant applications, use only external switching elements with a minimum holding current of > 1.2 ma. Cross and short circuits in the external wiring of the binary outputs are not detected. For safe outputs, cross faults and short circuit have therefore to be prevented according to EN ISO table D.4. Operating Instructions MOVISAFE UCS.B 65

66 6 Electrical Installation Wiring of the outputs Single-pole switching binary output, not monitored DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M X31 L+ L DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M X31 L+ L Similar to the previous wiring example, the above sample circuits show a single-pole P or M binary output without test. 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, one or more external MOVISAFE contacts will not be detected. INFORMATION The sample circuits are not suitable for safety applications. 66 Operating Instructions MOVISAFE UCS.B

67 Electrical Installation Wiring of the outputs 6 Single-pole switching binary output, monitored DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M X31 DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 L+ L DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X31 X22 X21 L+ L Similar to the previous wiring example, the above sample circuits show a single-pole P or M binary output with external monitoring. The prerequisite for this solution is a switching element with monitored forced contacts and test contact (NC contact). The monitoring contact is fed via clock output P1 and read via any input. The EMU (Emergency Monitoring Unit) must be configured correctly in MOVISAFE Config UCS for this solution to function properly. INFORMATION A category 2 structure according to EN ISO can be achieved with the circuit. Operating Instructions MOVISAFE UCS.B 67

68 6 Electrical Installation Wiring of the outputs Dual-channel switching binary output, not monitored Similar to the previous wiring example, the following sample circuit shows a dual-channel switching P binary output (P and M switching). The complementary binary outputs are wired as a group and redundantly control an external actuator [1]. The actuator [1] is not monitored in this wiring example. X31 DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M [1] INFORMATION Two-pole disconnection without monitoring of the external actuator is permitted for safety applications up to category 3 / performance level d according to EN ISO Note that when you connect external actuators without monitoring, errors occurring in the switch-off circuit are not detected by MOVISAFE UCS.B. 68 Operating Instructions MOVISAFE UCS.B

69 Electrical Installation Wiring of the outputs 6 Dual-channel switching binary output, monitored DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M X31 DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X For safety applications with category 4 / performance level e according to EN ISO , two complementary binary outputs are connected as a group to control two external power contactors. The two external monitoring contacts are connected in series, supplied by pulse signal P1 and read via binary input DI Binary input DI 0.01 is used as read-back input, but any other binary input can also be assigned instead. INFORMATION For applications with increased demands, note that a switching operation must take place at least every 24 hours to test the switching capability of the external power contactor. Operating Instructions MOVISAFE UCS.B 69

70 6 Electrical Installation Wiring of the outputs Single-pole switching relay output, not monitored K 0.11 K 0.12 K 0.21 K X41 L+ L Note that when connecting multi-phase applications or in case of increased current consumption, welding of one or more external contacts is not detected by MOVISAFE. INFORMATION The example above is not suitable for safety applications. 70 Operating Instructions MOVISAFE UCS.B

71 Electrical Installation Wiring of the outputs 6 Single-pole switching relay output, monitored K K K 0.21 K X41 DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 L+ L The two external monitoring contacts are connected in series, supplied by pulse signal P1 and read by binary input DI 0.01 (configured as EMU input). INFORMATION For applications with increased demands, note that a switching operation must take place at least every 24 hours to test the switching capability of the external power contactor. A category 2 structure according to EN ISO can be achieved with the circuit. Operating Instructions MOVISAFE UCS.B 71

72 6 Electrical Installation Wiring of the outputs Dual-channel switching relay output, monitored K 0.11 K 0.12 K 0.21 K X41 DI 0.01 DI 0.02 DI 0.03 DI 0.04 DI 0.13 DI 0.14 P1 P X22 X21 L+ L External monitoring contact 1 is fed by pulse signal P1 and read by binary input DI External monitoring contact 2 is fed by pulse signal P2 and read by binary input DI This operating mode allows specific feedback to identify which external switching element has triggered an error. INFORMATION For applications with increased demands, note that a switching operation must take place at least every 24 hours. A category 4 structure according to EN ISO can be achieved with the circuit. 72 Operating Instructions MOVISAFE UCS.B

73 Electrical Installation Wiring of the outputs 6 Connection of an auxiliary output X12 U_ENC_1 GND_ENC_1 DO 0.0 DO L+ L Both auxiliary outputs implemented on MOVISAFE UCS.B can be connected for functional applications. The auxiliary outputs are not pulsed. INFORMATION Applications with auxiliary outputs are not permitted for safety applications. Operating Instructions MOVISAFE UCS.B 73

74 6 Electrical Installation Wiring of the outputs Using the safe outputs to control the safe stop The safe binary outputs or the safe relay outputs can be used to control the safe stop function of MOVIDRIVE B, MOVITRAC B (X17) and MOVIAXIS (X7/X8) (see following figures). NOTICE Power input at terminal X17 of MOVIDRIVE B and MOVITRAC B too high. Parts of MOVISAFE could be destroyed, or malfunctions of the safe stop could be the result. Note the specific power input at terminal X17 of MOVIDRIVE B and MOVITRAC B. It is listed in the "Functional Safety" manual for the respective product. Use of the safe binary outputs MOVISAFE UCS.B MOVIDRIVE B / MOVITRAC B DO 0.2_P 1 DO 0.2_M 2 DO 0.3_P 3 DO 0.3_M 4 X31 X17 4 SVI24 3 SOV24 2 VO24 1 DGND MOVISAFE UCS.B MOVIAXIS MXA81 X31 DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M DI 0.13 DI 0.14 P1 P X X7 +24V RGND C NC DI 0.01 DI 0.02 DI 0.03 DI X Operating Instructions MOVISAFE UCS.B

75 Electrical Installation Wiring of the outputs 6 MOVISAFE UCS.B MOVIAXIS MXA82 DO 0.2_P DO 0.2_M DO 0.3_P DO 0.3_M X X7 +24V RGND C NC DI 0.13 DI 0.14 P1 P X X8 +24V RGND C NC DI 0.01 DI 0.02 DI 0.03 DI X Use of the safe relay outputs MOVISAFE UCS.B MOVIDRIVE B / MOVITRAC B K 0.11 K 0.12 K 0.21 K X41 X17 4 SVI24 3 SOV24 2 VO24 1 DGND Operating Instructions MOVISAFE UCS.B 75

76 6 Electrical Installation Wiring of the outputs Connection of outputs at the expansion module You can configure the binary outputs in MOVISAFE Config UCS as safety outputs or as standard outputs (auxiliary outputs). When configured as safety outputs, they are subjected to an internal diagnostic procedure. When the unit is switched on, the proper functioning of the safety outputs is tested cyclically by switching the output to its inverse value for the duration of the test (t < 500 μs), that means a P binary output is switched to DC 0 V potential for a short time. No diagnostics is performed when the outputs are configured as standard outputs. Example: Different signal patterns at the binary output when this is configured as safety output (following figure, top) or as standard output (following figure, bottom). High DIO 1.01 Low t t 1 < 500μs t 1 < 500μs DIO 1.01 High Low t INFORMATION When configured as safety outputs, the outputs may not be connected to fast processing touch probe inputs due to the diagnostic function. The diagnostic function can cause unintentional switching operations. This includes, for example, the binary inputs of the frequency inverters. No diagnostics is performed when the outputs are configured as standard outputs (auxiliary outputs). This allows for using the outputs with touch probe inputs. The following sample circuits assume that the switching elements are configured in accordance with the required performance level to EN ISO and that safety approval has been granted for the application in question. 76 Operating Instructions MOVISAFE UCS.B

77 Electrical Installation Wiring of the outputs 6 Depending on the required performance level, you can connect binary outputs via one or two channels. For project planning, note that connected cables must not exceed 30 m. P switching binary output UCS.B DIO Output Output type Performance level that can be achieved Output voltage DO 1.0 Auxiliary output Only functional DC 24 V 0.1 A DO 1.1 Auxiliary output Only functional DC 24 V 0.1 A DIO 1.01 DIO 1.02 DIO 1.03 DIO 1.04 DIO 1.05 DIO 1.06 DIO 1.07 DIO 1.08 DIO 1.09 DIO 1.10 Max. current Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A Auxiliary output Only functional DC 24 V 0.25 A Safety output Up to performance level e DC 24 V 0.25 A INFORMATION The total current load of the expansion module may not exceed DC 1.9 A. For safety-relevant applications, use only external switching elements with a minimum holding current of > 1.2 ma. Cross and short circuits in the external wiring are not detected. For safety outputs, cross faults and short circuit must be excluded according to EN ISO , table D.4. Operating Instructions MOVISAFE UCS.B 77

78 6 Electrical Installation Wiring of the outputs Single-channel switching binary output, not monitored DIO X.01 DIO X.02 P1 P X25 L+ L You can use external contactors to connect multi-phase applications or in applications with an increased current consumption. Note that with a single-channel connection without monitoring, welding of one or several contacts is not detected by MOVISAFE. INFORMATION The sample circuit is not suitable for safety applications. 78 Operating Instructions MOVISAFE UCS.B

79 Electrical Installation Wiring of the outputs 6 Single-channel switching binary output, monitored DIO X.03 DIO X DIO X.05 3 DIO X.06 4 DI X.01 DI X.02 DI X.03 DI X X35 X26 DIO X.01 DIO X.02 P1 P X25 L+ L The example above shows single-channel switching of an external relay/contactor with monitoring. The monitoring contact must have force-guided contacts. It is supplied via pulse 1 and read in at any binary input. The proper functioning of the external relay/contactor must be monitored via an emergency monitoring unit (EMU). INFORMATION With this example, a category 2 structure up to performance level d according to EN ISO can be achieved. Operating Instructions MOVISAFE UCS.B 79

80 6 Electrical Installation Wiring of the outputs Dual-channel switching binary output, not monitored DIO X.03 DIO X DIO X.05 3 DIO X.06 4 DI X.01 DI X.02 DI X.03 DI X.04 DIO X.01 DIO X.02 P1 P X35 X26 X25 [1] [1] L+ L The example above shows dual-channel control of external actuators [1] without monitoring. This connection is permitted for safety applications up to category 3 / performance level d according to EN ISO Note that occurring faults in the switch-off circuit are not detected by MOVISAFE UCS.B. INFORMATION With this example, a category 3 structure up to performance level d according to EN ISO can be achieved. 80 Operating Instructions MOVISAFE UCS.B

81 Electrical Installation Wiring of the outputs 6 Dual-channel switching binary output, monitored DIO X.03 DIO X.04 DIO X.05 DIO X X35 X26 DI X.01 DI X.02 DI X.03 DI X DIO X.01 DIO X.02 P1 P2 L+ L X The example above shows dual-channel connection of external power contactors with monitoring. The two external monitoring contacts are connected in series, supplied by pulse signal P1 and read via a binary input. INFORMATION With this example, a category 4 structure up to performance level e according to EN ISO can be achieved. For applications with increased demands, note that a switching operation must take place at least every 24 hours. DIO X.03 DIO X.04 DIO X.05 DIO X X35 X26 DI X.01 DI X.02 DI X.03 DI X DIO X.01 DIO X.02 P1 P2 L+ L X Operating Instructions MOVISAFE UCS.B 81

82 6 Electrical Installation Wiring of the outputs Analog to the previous example, this connection features a separate supply of monitoring contacts with P1 and P2. This allows for independent error detection in the respective switch-off channel. The pulses are read at the inputs that were configured as binary inputs. INFORMATION With this example, a category 4 structure up to performance level e according to EN ISO can be achieved. For applications with increased demands, note that a switching operation must take place at least every 24 hours. Connection of an auxiliary output X12 U_ENC_1 1 GND_ENC_1 2 DO X.0 3 DO X.1 4 L+ L The example above shows the connection of an auxiliary output. The auxiliary outputs are not pulsed. INFORMATION Auxiliary outputs are not permitted for safety applications. 82 Operating Instructions MOVISAFE UCS.B

83 Electrical Installation Connection of position and velocity sensors Connection of position and velocity sensors Before you start NOTICE Do not plug in or remove encoder connections during operation. Doing so can cause irreparable damage to the electrical components on the encoder. De-energize connected encoders and MOVISAFE UCS.B before you plug in or remove the encoder connections. MOVISAFE UCS.B option has up to two encoder interfaces for connecting standard TTL incremental, sin/cos, and SSI absolute encoders. TTL incremental, sin/cos, or SSI absolute encoders (binary or Gray Code) can be connected and operated via the same encoder interface. The encoder parameters are set using the MOVISAFE Config UCS software interface. Different safety levels can be achieved depending on the encoder type and combination. The following system view applies to the respective subsystem. Example: Dual-channel sensor system with separate signal processing in two channels and diagnostics by means of cross comparison in MOVISAFE UCS.B (PES). m I A L A O A S A c m I B L B O B Sensor S B PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring S A = Sensor 1 channel A S B = Sensor 2 channel B Operating Instructions MOVISAFE UCS.B 83

84 6 Electrical Installation Connection of position and velocity sensors Example: Sensor system with single- and dual-channel subsystem (e.g. incremental encoder, single-channel mechanics, dual-channel signal generation). Diagnostics by means of separate signal processing in two channels and cross comparison in MOVISAFE UCS.B (PES) as well as further specific diagnostics. Sig A I A L A m O A S A c Sig B I B L B m O B Sensor S B PES PES = Programmable Electronic System I A = Input channel A I B = Input channel B L A = Logic channel A L B = Logic channel B O A = Output channel A O B = Output channel B c = Cross comparison m = Monitoring S A = Sensor 1 channel A S B = Sensor 1 channel B Sig A = Signal track A of the incremental encoder Sig B = Signal track B of the incremental encoder Depending on the selected encoder type and encoder combination, several diagnostic measures have been implemented in MOVISAFE UCS.B to detect faults in the sensor system. They are activated automatically when selecting the encoder type in the MOVISAFE Config UCS software interface. You can use the diagnostic coverage values for the encoder sensors in chapter "Diagnostic values" for a safety-relevant evaluation of the overall system. Observe the following notes: Observe the notes in chapter "General installation notes for encoders" and "Voltage supply for encoder systems". To activate position processing, you must use at least one SSI absolute encoder. An internal number format is used in the input fields "Position", "Velocity" and "Acceleration" when the monitoring functions are configured. This can lead to rounding of the entered values. 84 Operating Instructions MOVISAFE UCS.B

85 Electrical Installation Connection of position and velocity sensors General installation notes for encoders Maximum length of encoder cables: 100 m (328 ft) with a capacitance per unit length 120 nf/km. Core cross section: mm (AWG25 AWG21) Use shielded cables with twisted pair conductors and make sure they are grounded on both ends over a large surface area: At the encoder in the cable gland or in the encoder plug To the inverter in the housing of the D-sub connector, or To the metal clamp / strain relief on the bottom of the inverter Observe the notes in chapter "Measures for electromagnetic compatibility (EMC)" Combination of various encoder types You always have to provide MOVISAFE UCS.B with two encoder signals. Whether the signals come from one or two encoders depends on the required performance level. Encoder types can be combined depending on the specific application. Observe the following notes. If position processing is enabled, at least one of the two encoder signals must come from an SSI absolute encoder. When using SSI absolute encoders it is important that velocities are calculated from the position signals. For this purpose, the encoder must have the respective resolution and reproducibility of the accuracy. If position processing is not used, the reference sensor is automatically adjusted to the process sensor. The following values apply for the sensor adjustment: Measuring section User-defined unit Adjustment Linear Rotational mm/s m/s 2500 mm 12.5 m Degree/s 125 degrees 1/s 125 revolutions 1/min 125 revolutions SEW-EURODRIVE recommends not to exceed a maximum resolution ratio of 1:10000 between "encoder 1" and "encoder 2". If you change the encoder configuration at a later date in the MOVISAFE Config UCS software interface, the existing parameters for the monitoring functions might 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. Operating Instructions MOVISAFE UCS.B 85

86 6 Electrical Installation Connection of position and velocity sensors Encoder 1 Encoder 2 (only UCS12B) Counting input Safe speed Safe direction Safe absolute position HTL + 1 HTL X TTL incremental - - X TTL incremental TTL incremental - X X TTL incremental - 1 HTL X TTL incremental - 2 HTL 90 X X TTL incremental SIN/COS - X X TTL incremental SSI absolute - X X X SIN/COS - - X X SIN/COS TTL incremental - X X SIN/COS - 1 HTL X X SIN/COS - 2 HTL 90 X X SIN/COS SSI absolute - X X X SSI absolute - 2 HTL 90 X X X SSI absolute SIN/COS - X X X SSI absolute SSI absolute - X X X - SIN/COS - X X - SSI absolute 2 HTL 90 X X X Technical requirements on suitable encoder types SSI absolute encoder: SSI data interface with a data length of 10 to 28 bit Data format binary or Gray Code Signal level to RS422 If the measuring channel is operated in master mode, the clock rate is 150 khz. If the measuring channel is operated in slave mode, the maximum external clock rate is 200 khz. The pulse break between the clock pulse trains must be greater than 30 μs and less than 2 ms. TTL incremental encoder: Signal level to RS422 Measuring signal A/B track with 90 degree phase difference Maximum frequency of input pulses: 200 khz SIN/COS encoder: AC 1 V pp Measuring signal A/B track with 90 degree phase difference Maximum frequency of input pulses: 200 khz HTL counting inputs: Signal level DC 24 V / 0 V. Standard and complementary track (e.g. A/B) with 90 degree phase offset. Maximum pulse frequency 10 khz. 86 Operating Instructions MOVISAFE UCS.B

87 Electrical Installation Connection of position and velocity sensors Voltage supply for encoder systems NOTICE The encoder system is connected to more than one voltage supply. More than one voltage supply can result in a destruction of the encoder. Undetected voltage dips can lead to a failure of the safety functions. The encoder system may only be connected to one voltage supply. The basic modules MOVISAFE UCS11B and UCS12B support encoder voltages of DC 5 V, 8 V, 10 V, 12 V and 24 V at the encoder terminals X7 and X8. The voltage configured in MOVISAFE Config UCS is monitored internally by a diagnostic function with a tolerance of ±10 %. The following connection variants are possible: Encoder voltage supply via MOVISAFE UCS.B The encoder voltage supply is connected to terminals X12 and X13. The voltage is routed internally to the encoder terminals X7 or X8 and monitored as parameterized in MOVISAFE UCS.B. External encoder voltage supply (also see chapter "External encoder voltage supply") The voltage supply for the encoders is routed from the outside to the encoder terminals X7/X8. This connected voltage must be parameterized in MOVISAFE Config UCS and is monitored internally. With this connection variant, the terminals X12 and X13 are not connected. The encoders are supplied with voltage externally. To be able to monitor the encoder supply voltage, it must also be connected to terminals X12 and X13 and parameterized accordingly in MOVISAFE Config UCS. INFORMATION The encoder voltage that is to be monitored can be set independently for X7 and X8 in MOVISAFE Config UCS. It is not possible to deactivate voltage monitoring in MOVISAFE Config UCS. When using an external encoder voltage supply, it must be verified that an undervoltage in the encoder supply voltage is detected and excluded Connection of HTL proximity sensors HTL proximity sensors can only be connected to MOVISAFE UCS11B/12B via terminal X32 (DI0.05 DI0.08). The inputs are debounced accordingly. When using HTL encoders, make sure that tracks A and B, and A and B must be combined with one another accordingly. Signal tracks A and B must have a phase difference of 90. A maximum counting frequency of 10 khz can be read in. Terminal HTL / Proxy 1Z 1) X32:5 A A X32:6 - B X32:7 B A X32:8 - B HTL / Proxy 2Z 1) 1) Designation according to the MOVISAFE Config UCS software interface Operating Instructions MOVISAFE UCS.B 87

88 6 Electrical Installation Connection of position and velocity sensors Prefabricated cables Overview For connecting an encoder to both a MOVIDRIVE B / MOVIAXIS and MOVISAFE UCS11B/12B, you can order the following prefabricated cables from SEW- EURODRIVE. Encoder cable Type designation Part number DAE50B DAE51B DAE52B DAE53B DAE54B DAE55B DAE56B DAE57B DAE58B DAE59B DAE60B DAE61B Operating Instructions MOVISAFE UCS.B

89 Electrical Installation Connection of position and velocity sensors 6 Connecting a motor encoder SIN/COS or TTL incremental encoder (parallel connection) The following figure shows the parallel connection of a sin/cos or TTL incremental encoder to MOVIDRIVE B or MOVIAXIS. In this case, the signal outputs of the encoder are distributed to X15 (with MOVIDRIVE B) or X13/X63/X64 (with MOVIAXIS ) and to X7/X8 of MOVISAFE UCS11B/12B (see following figure). A/COS + A/COS - B/SIN + B/SIN - C C DATA + DATA - TF+ TF- Us GND RD BU YE GN BN WH BK VT GY PK RDBU GYPK max. 100 m (328 ft) MOVIDRIVE B DEH11B/21B:X15 DEU21B:X MOVIAXIS MXA:X13 XGH:X63 XGS:X MOVISAFE UCS11B/12B X7/X INFORMATION An individual sin/cos or TTL encoder can be used for applications up to performance level d. The following limitations must be considered: Mechanical faults, such as shaft breakage or slip, are not detected and have to be ruled out by appropriate measures in the system design. The design of the mechanical system and the encoder must be subjected to an FMEA based on the system to ensure that the encoder has a positive connection with the movement. Sin/cos encoders, TTL, encoders, or encoders that provide such signal tracks must be used. The encoders must be designed in such a way that the output signals of both tracks are generated independently of one another and that common cause failure can be ruled out. Operating Instructions MOVISAFE UCS.B 89

90 [III] [II] [I] 6 Electrical Installation Connection of position and velocity sensors The following prefabricated cables are available from SEW-EURODRIVE for the safe connection of motor encoders. [A] [B] [A] A-side with fixed length (200 mm) [B] B-side with variable length (200 mm to 6 m) Type Part number Connection [I] [II] [III] D-sub socket, DA15 D-sub plug, DA15 D-sub plug, DE9 DAE52B DAE53B MOVIDRIVE B: DEH11B:X15 DEH21B:X15 DEU21B:X15 MOVIAXIS : MXA:X13 XGH:X63 XGS:X64 Motor encoder DAE52B Connecting encoder cables without TF line DAE53B Connection of encoder cables with integrated TF line. UCS.B:X7/X8 The following encoders can be connected: TTL incremental encoders SIN/COS encoder Hiperface encoder (only the sin/cos tracks are evaluated in UCS.B) RS485 combination encoder (only the sin/cos tracks are evaluated in UCS.B) SSI combination encoder (only the sin/cos tracks are evaluated in UCS.B) 90 Operating Instructions MOVISAFE UCS.B

91 Electrical Installation Connection of position and velocity sensors 6 Connection of an external encoder SIN/COS or TTL incremental encoder (parallel connection) The following figure shows the parallel connection of a sin/cos or TTL incremental encoder to MOVIDRIVE B. A/COS + A/COS - B/SIN + B/SIN - CLK+ CLK- DATA + DATA - TF+ TF- Us GND RD BU YE GN BN WH BK VT GY PK RDBU GYPK max. 100 m (328 ft) MOVIDRIVE B DEH11B:X14 DER11B:X14 DEU21B:X MOVISAFE UCS11B/12B X7/X INFORMATION An individual sin/cos or TTL encoder can be used for applications up to performance level d. The following limitations must be considered: Mechanical faults, such as shaft breakage or slip, are not detected and have to be ruled out by appropriate measures in the system design. The design of the mechanical system and the encoder must be subjected to an FMEA based on the system to ensure that the encoder has a positive connection with the movement. Sin/cos encoders, TTL, encoders, or encoders that provide such signal tracks must be used. The encoders must be designed in such a way that the output signals of both tracks are generated independently of one another and that common cause failure can be ruled out. Operating Instructions MOVISAFE UCS.B 91

92 6 Electrical Installation Connection of position and velocity sensors The following prefabricated cables are available from SEW-EURODRIVE for the safe connection of external encoders. [A] [B] [I] [II] [III] [A] A-side with fixed length (200 mm) [B] B-side with variable length (200 mm to 6 m) Type Part number Connection [I] [II] [III] D-sub socket, DA15 D-sub socket, DA15 D-sub plug, DE9 DAE50B DAE51B MOVIDRIVE B: DEH11B:X14 DER11B:X14 DEU21B:X14 External encoder UCS.B:X7/X8 MOVIDRIVE B: DEU21B:X14 DAE50B Connecting encoder cables without TF line DAE51B Connection of encoder cables with integrated TF line. The following encoders can be connected: TTL incremental encoders SIN/COS encoder Hiperface encoder (only the sin/cos tracks are evaluated in UCS.B) RS485 combination encoder (only the sin/cos tracks are evaluated in UCS.B) SSI combination encoder (only the sin/cos tracks are evaluated in UCS.B) 92 Operating Instructions MOVISAFE UCS.B

93 Electrical Installation Connection of position and velocity sensors 6 Connecting an absolute encoder SSI absolute encoder in slave mode (parallel connection) The following figure shows the parallel connection of an SSI absolute encoder in slave mode to MOVIDRIVE B. max. 100 m (328 ft) MOVIDRIVE B DIP11B/DEH21B:X62 DATA + DATA - CLK + CLK - DC 24 V GND BK VT BN WH RDBU GYPK MOVISAFE UCS11B/12B X7/X INFORMATION In this connection variant, the pulse signals and data are read. In this example, the encoder is not supplied with voltage from MOVISAFE UCS.B. Observe the following limitation: Maximum clock rate: 200 khz (see chapter "Technical requirements on suitable encoder types") Operating Instructions MOVISAFE UCS.B 93

94 [III] [II] [I] 6 Electrical Installation Connection of position and velocity sensors The following prefabricated cable is available from SEW-EURODRIVE for the safe connection of motor encoders. [A] [B] [A] A-side with fixed length (200 mm) [B] B-side with variable length (200 mm to 6 m) Type Part number Connection [I] [II] [III] D-sub plug, DE9 D-sub socket, DE9 D-sub plug, DE9 DAE54B MOVIDRIVE B: DIP11B:X62 DEH21B:X62 SSI absolute encoder UCS.B:X7/X8 94 Operating Instructions MOVISAFE UCS.B

95 Electrical Installation Connection of position and velocity sensors 6 SSI absolute encoder in slave mode (parallel connection) The following figure shows the parallel connection of an SSI absolute encoder in slave mode to MOVIDRIVE B and MOVIAXIS. A/COS + A/COS - B/SIN + B/SIN - CLK+ CLK- DATA + DATA - TF+ TF- Us GND RD BU YE GN BN WH BK VT GY PK RDBU GYPK max. 100 m (328 ft) MOVIDRIVE B DEU21B:X15 MOVIAXIS XGS:X MOVISAFE UCS11B/12B X7/X INFORMATION In this connection variant, the pulse signals and data are read. In this example, the encoder is not supplied with voltage from MOVISAFE UCS.B. Observe the following limitation: Maximum clock rate: 200 khz (see chapter "Technical requirements on suitable encoder types") Operating Instructions MOVISAFE UCS.B 95

96 6 Electrical Installation Connection of position and velocity sensors The following prefabricated cable is available from SEW-EURODRIVE for the safe connection of motor encoders. [A] [B] [I] [II] [III] [A] A-side with fixed length (200 mm) [B] B-side with variable length (200 mm to 6 m) Type Part number Connection [I] [II] [III] D-sub plug, DA15 D-sub socket, DA15 D-sub plug, DE9 DAE61B MOVIDRIVE B: DEU21B:X15 MOVIAXIS : XGS:X64 SSI absolute encoder UCS.B:X7/X8 INFORMATION With MOVIAXIS, voltage is supplied to the encoder via the option XGS11B (DC 12 V or 24 V), with MOVIDRIVE B via option DEU21B (DC 12 V). Voltage supply monitoring must be set accordingly in MOVISAFE Config UCS. 96 Operating Instructions MOVISAFE UCS.B

97 Electrical Installation Connection of position and velocity sensors 6 SSI absolute encoder in slave mode (parallel connection) The following figure shows the parallel connection of an SSI absolute encoder in slave mode to MOVIDRIVE B. A/COS + A/COS - B/SIN + B/SIN - CLK+ CLK- DATA + DATA - TF+ TF- Us GND RD BU YE GN BN WH BK VT GY PK RDBU GYPK max. 100 m (328 ft) MOVIDRIVE B DEU21B:X MOVISAFE UCS11B/12B X7/X INFORMATION In this connection variant, the pulse signals and data are read. In this example, the encoder is not supplied with voltage from MOVISAFE UCS.B. Observe the following limitation: Maximum clock rate: 200 khz (see chapter "Technical requirements on suitable encoder types") Operating Instructions MOVISAFE UCS.B 97

98 6 Electrical Installation Connection of position and velocity sensors The following prefabricated cable is available from SEW-EURODRIVE for the safe connection of motor encoders. [A] [B] [I] [II] [III] [A] A-side with fixed length (200 mm) [B] B-side with variable length (200 mm to 6 m) Type Part number Connection [I] [II] [III] D-sub plug, DA15 D-sub socket, DA15 D-sub plug, DE9 DAE55B MOVIDRIVE B: DEU21B:X15 SSI absolute encoder UCS.B:X7/X8 INFORMATION The encoder is supplied with DC 24 V via the DEU21B option. 98 Operating Instructions MOVISAFE UCS.B

99 Electrical Installation Connection of position and velocity sensors 6 Direct connection of an encoder SIN/COS or TTL incremental encoder (direct connection) The following figure shows the direct connection of a sin/cos or TTL incremental encoder to MOVISAFE UCS.B. max. 100 m (328 ft) MOVISAFE UCS11B/12B X7/X8 A/COS+ 1 (RD) A/COS- 9 (BU) B/SIN+ 2 (YE) B/SIN- 10 (GN) 7 (WH) Us 15 (GY) GND 8 (PK) R R R = 120 Ω The following prefabricated cable is available from SEW-EURODRIVE for direct connection of an encoder to MOVISAFE UCS11B/12B. [I] [II] Type Part number Connection D-sub socket, DA15 DAE57B SIN/COS encoder TTL incremental encoders Encoder simulation [I] D-sub plug, DE9 UCS.B:X7/8 [II] INFORMATION In this connection variant, MOVISAFE UCS.B supplies voltage to the encoder. The cable DAE57B is also used for connecting the encoder simulation of MOVIDRIVE B (terminal X14 of options DEH11B, DER11B or DEU21B) with MOVISAFE UCS11B/12B, terminal X7/8. Operating Instructions MOVISAFE UCS.B 99

100 6 Electrical Installation Connection of position and velocity sensors 9-pole SSI absolute encoder in master mode (direct connection) The following figure shows the direct connection of a 9-pole SSI absolute encoder to MOVISAFE UCS11B/12B. max. 100 m (328 ft) MOVISAFE UCS11B/12B X7/X8 CLK + CLK - DATA+ DATA - Us GND 3 (BN) 8 (WH) 1 (RD) 6 (BU) 9 (GY) 5 (PK) R R = 120 Ω The following prefabricated cable is available from SEW-EURODRIVE for direct connection of a 9-pole SSI absolute encoder to MOVISAFE UCS11B/12B. [I] [II] Type Part number Connection [I] [II] D-sub socket, DE9 D-sub plug, DE9 DAE58B SSI absolute encoder, 9-pole UCS.B:X7/X8 INFORMATION In this connection variant, clocking is provided by MOVISAFE UCS.B. In this example, MOVISAFE UCS.B supplies voltage to the encoder. Observe the following limitation: Maximum clock rate: 150 khz (see chapter "Technical requirements on suitable encoder types") 100 Operating Instructions MOVISAFE UCS.B

101 Electrical Installation Connection of position and velocity sensors 6 15-pole SSI absolute encoder in master mode (direct connection) The following figure shows the direct connection of a 15-pole SSI absolute encoder to MOVISAFE UCS11B/12B. max. 100 m (328 ft) MOVISAFE UCS11B/12B X7/X8 CLK + 3 (BN) CLK - 11 (WH) DATA+ 4 (RD) DATA - 12 (BU) Us GND (GY) 8 (PK) R R = 120 Ω U s = DC 24 V encoder voltage supply at pin 13 with cable DAE59B U s = DC 12 V encoder voltage supply at pin 15 with cable DAE60B The following prefabricated cables are available from SEW-EURODRIVE for direct connection of a 15-pole SSI absolute encoder to MOVISAFE UCS11B/12B. [I] [II] Type Part number Connection [I] [II] D-sub socket, DA15 D-sub plug, DE9 DAE59B DAE60B SSI absolute encoder, 15-pole UCS.B:X7/X8 INFORMATION In this connection variant, clocking is provided by MOVISAFE UCS.B. In this example, MOVISAFE UCS.B supplies voltage to the encoder. Observe the following limitation: Maximum clock rate: 150 khz (see chapter "Technical requirements on suitable encoder types") Operating Instructions MOVISAFE UCS.B 101

102 6 Electrical Installation Connection of position and velocity sensors TTL incremental encoder simulation TTL incremental encoder simulation (direct connection) The following figure shows the direct connection of the TTL incremental encoder simulation of MOVIDRIVE A to MOVISAFE UCS11B/12B. max. 100 m (328 ft) MOVISAFE UCS11B/12B X7/X8 A 1 (RD) A 6 (BU) B 2 (YE) B 7 (GN) 4 (WH) Us 9 (GY) GND 5 (PK) R R R = 120 Ω The following prefabricated cable is available from SEW-EURODRIVE for direct connection of the TTL incremental encoder simulation to MOVISAFE UCS11B/12B. [I] [II] Type Part number Connection [I] [II] D-sub socket, DE9 D-sub plug, DE9 DAE56B MOVIDRIVE A:X14 UCS.B:X7/X8 INFORMATION In this connection variant, a DC 24 V supply is routed from MOVIDRIVE A to MOVISAFE UCS.B. Note the following: Set voltage monitoring in MOVISAFE Config UCS to 24 V. The number of pulses of the TTL incremental encoder simulation is: MDV60A: as X15, motor encoder input MDS60A: 1024 pulses/revolution 102 Operating Instructions MOVISAFE UCS.B

103 Startup General startup information I Startup 7.1 General startup information Requirements The following prerequisites must be fulfilled to ensure successful startup The system must be configured correctly The MOVISAFE Config UCS software must be installed. The latest software release is available on the Internet on the SEW homepage or on the MOVISAFE Software ROM, part number For detailed configuration notes and a description of the parameters, refer to the online help in the MOVISAFE Config UCS parameterization software. Prerequisites for using the MOVISAFE Config UCS parameterization software: MOVISAFE Config UCS must be activated with a USB dongle (part number ) Operating system: Microsoft Windows 2000, XP or Vista Required hard disk space: approx. 100 MB RAM: 512 MB or more recommended Startup steps Make sure that the MOVISAFE UCS.B installation the wiring the terminal assignment and the safety cut-outs have been configured correctly and are suited to the application. Prevent unintentional starting of the motor using suitable measures. Take additional safety measures depending on the application to prevent possible injuries and damage to machines. Switch on the mains voltage and, if necessary, the DC 24 V supply voltage. Configure and program MOVISAFE UCS.B to suit your application. Perform a validation (see chapter "Validation"). Create a validation report (see chapter "Configuration report for validation"). Operating Instructions MOVISAFE UCS.B 103

104 7 I 0 Startup Communication and establishing a connection 7.2 Communication and establishing a connection RS485 interface X6 The RS485 interface X6 of MOVISAFE UCS.B is implemented as RJ10 socket. It allows parameterization and diagnostics of the basic modules using the Windows -based software interface MOVISAFE Config UCS. The PC can be connected with the parameterization and diagnostic interface X6 of MOVISAFE UCS.B using, for example, the interface adapter UWS21B (RS232 to RS485) or USB11A (USB to RS485). In RUN mode, the logic is processed in MOVISAFE UCS.B. Parameterization/programming is only possible in STOP mode. You can set MOVISAFE back to RUN mode once you have sent the configuration and the message "Configuration successfully written to flash" has appeared. 7.3 Operating states Switch-on sequences Each time MOVISAFE UCS.B is restarted successfully, the following phases are run through and displayed in the 7-segment display on the front of the unit. 7-segment display Mode Description 1 STARTUP Synchronization between both processor systems and check of the configuration/firmware data. 2 SEND CONFIG Distribution of the configuration/firmware data and another check of this data. Range check of the configuration data. 3 STARTUP BUS If applicable, the bus system is initialized (PROFIsafe). 4 RUN Watchdog is active, i.e. all outputs can be switched. INFORMATION The firmware automatically disables the outputs for all operating modes except for RUN. In "RUN" mode (display "4"), access is possible via the implemented PLC program or fieldbus LED display on the basic module Status LED LED display Flashing green Flashing yellow Flashing red Flashing red Description System ok, configuration validated System ok, configuration not validated yet Alarm Fatal error LED IN LED display Flashing green Description Signal present at binary input. 104 Operating Instructions MOVISAFE UCS.B

105 Startup Operating states I 0 7 LED P1, P2 LED display Flashing green Description The pulse output is available. LED OUT K1, K2 LED display Flashing green Description The relay output has switched LED display on the expansion module Status LED LED display Flashing green Flashing yellow Flashing red Flashing red Description System ok, configuration validated System ok, configuration not validated yet Alarm Fatal error LED IN LED display Flashing green Description Signal present at binary input. LED P1, P2 LED display Flashing green Description The pulse output is available. LED I/O LED display Flashing green Description Signal present at binary input or binary output. Operating Instructions MOVISAFE UCS.B 105

106 7 I 0 Startup Configuration of measuring sections 7.4 Configuration of measuring sections The most important input parameters for the monitoring functions of MOVISAFE UCS.B are: Position Speed Acceleration These input parameters are generated in a dual-channel from the connected encoder systems. To achieve performance level e according to EN ISO , always two independent encoder systems are required. To achieve performance level d according to EN ISO , one encoder system can be sufficient for certain applications. Measuring sections A and B must be configured accordingly for internal signal processing. This is done in the encoder configuration of the MOVISAFE Config UCS software interface. Note the following parameters when configuring the measuring section: Parameters of the measuring section You can choose "linear" or "rotary" as the measuring section. Measuring section units For a linear measuring section, you can choose "mm/s" or "m/s" as the unit for speed. For a rotatory measuring section, you can choose "rev/min", "rev/s" or "deg/s" as the unit for speed. The selected resolution should correspond to the physics of the measuring section to prevent rounding problems in the configuration. Position processing The position processing of MOVISAFE UCS.B can be selected by ticking the "Activate position processing" checkbox. The measuring length determines the permitted position range for position processing. It is important that the present position of the drive is within the measuring length window. If this position range is left, MOVISAFE UCS.B switches off and issues alarm A3307. The measuring length has a range of and is normalized with the unit specified for the measuring section. If position processing is not activated, only monitoring functions with velocity processing are permitted for parameter setting. This means monitoring functions with position processing are disabled in the MOVISAFE Config UCS software. Sensor information To have selection data and result data of the currently used encoder settings displayed, press the [Sensor information] button. Selection and result data are not applied until you have confirmed the set parameters with [OK]. The displayed values are used by technical support staff to configure the encoder. They are also used for the scaling calculation in the MOVISAFE UCS.B. 106 Operating Instructions MOVISAFE UCS.B

107 Startup Configuration of measuring sections I 0 7 Sensor information Meaning/setting Cycle time Displays the cycle time of MOVISAFE UCS.B. UCS.B = 8 ms V_Max Maximum speed value that can be entered during the parameterization of the safety functions. When V_Max is exceeded, an alarm is triggered and the outputs are switched off. V_MinUsed Minimum speed for internal scaling calculation. V_Min Minimum speed value that can be entered during the parameterization of the safety functions. Shiftval speed Internal operand to scale the speed. Integer exponent to base 2. V_Standardization Scaling value for the velocity (internal calculation data) FactorSpeed Factor for calculating the velocity (scaling) Measuring length Measuring length to determine the position from the encoder screen. If no measuring length is activated, the following value is entered by default: Linear = mm / 50 m Rotatory = 500 revolutions / 500 degrees Pos_MinUsed Minimum position for internal scaling calculation. Pos_Min Minimum position that can be entered for parameterizing the monitoring dialogs. Shiftval Pos Internal operand to scale the position. Integer exponent to base 2. Pos_Standardizatio Scaling value for the position (internal calculation data). n FactorPos Factor for position calculation (scaling). Maximum speed In the "Maximum velocity" edit box, you can set the maximum velocity of the application in the set reference unit. It is used to determine internal calculations. Safety-related cut-off thresholds The basic check is to perform a plausibility test between the two measuring channels A and B of MOVISAFE UCS.B to compare the current position and velocity values with the configured thresholds. The "cut-off threshold incr." describes the tolerable position offset between encoder 1 and encoder 2 in the unit of the measuring section. The "cut-off threshold velocity" describes the tolerable velocity offset between encoder 1 and encoder 2 in the unit of the velocity. Diagnostic functions are provided in the SCOPE function of the MOVISAFE Config UCS software interface to determine the optimum parameter values of this application. Operating Instructions MOVISAFE UCS.B 107

108 7 I 0 Startup Configuration of measuring sections Encoder type The following encoder types are available: SSI absolute TTL incremental SIN/COS HTL Direction of rotation In the "Direction" edit box, you can choose between the options "increasing" and "decreasing" to adjust different counting directions of the encoders. SSI data format The data format of the connected SSI absolute encoder can be selected as data format. Binary and Gray code data formats are supported. SSI clock In the "SSI clock" selection field, you can choose between "Master mode" and "Slave mode". The selection is only enabled for SSI absolute encoders. If the option "Master mode" is enabled, MOVISAFE UCS.B pulses automatically. This option can only be used if the SSI absolute encoder is connected directly to MOVISAFE UCS.B. "Slave mode" option must be selected if the SSI absolute encoder is connected both with an option, e.g. DEH21B, and MOVISAFE UCS.B. In this case, MOVISAFE UCS.B monitors the signals, and the option generates the clock pulses. SSI processing For the SSI, the default bit width of the data transfer is set to 24 bits when the SSI absolute encoder is activated. You can set other data width from 10 bits to 28 bits. Resolution In the "Resolution" edit box, you can enter the resolution of the encoder or the value converted to the distance in the configuration unit of the measuring section per revolution. Double-clicking on the "(i)" icon opens a conversion tool that will help you with the conversion (see chapter "Conversion example"). Value range: 1 to 2 6 Offset An offset can only be entered when position processing is activated. It lets you scale the value of the SSI absolute encoder to the actual position of the application. Clicking the "(i)" icon opens a conversion tool to support you in calculating the offset. Value range: 1.67 x 10 7 to 1.67 x Operating Instructions MOVISAFE UCS.B

109 Startup Configuration of measuring sections I Conversion example The ramp times of the MOVIDRIVE B inverter are based on a setpoint step change of n = 3000 rpm. The acceleration value a is calculated using the following equation: v a = t 3000[ 1 min] a = t12 [ min] Example: In MOVITOOLS MotionStudio, P137 Emergency ramp is set to 2 seconds. [ ] [ ] min a = 2 min 60 Conversion to 1/s 2 : = min min a = min = 60 s 60 s 2 [ ] [ ] = s The values that are entered in the MOVISAFE Config software interface are based on the measuring section. This means that the motor revolutions still have to be converted to the measuring section. Operating Instructions MOVISAFE UCS.B 109

110 7 I 0 Startup Configuration of measuring sections Rotary system: Calculating the speed: v = i G v M i VG v M Motor speed [1/min] (rpm) i G Gear unit ratio i VG Gear ratio of the additional gear Calculating the acceleration: a = i G a M i VG a M Motor acceleration i G Gear unit ratio i VG Gear ratio of the additional gear Operating Instructions MOVISAFE UCS.B

111 Startup Configuration of measuring sections I 0 7 Linear system: Calculating the speed: v = i G v M i VG D π A v Speed [m/min] v M Motor speed [1/min] (rpm) i G Gear unit ratio i VG Gear ratio of the additional gear D A Drive wheel diameter [m] Calculating the acceleration: a = i G a M i VG D π A a Acceleration [m/min 2 ] a M Motor acceleration [1/min 2 ] i G Gear unit ratio i VG Gear ratio of the additional gear D A Drive wheel diameter [m] Conversion: In many cases, the data in millimeters or minutes exceed the input s value range. In this case, you have to scale the values from millimeters to meters (for linear systems) or from minutes to seconds (for rotatory systems). Operating Instructions MOVISAFE UCS.B 111

112 7 I 0 Startup Configuration of measuring sections Velocity: v mm s v[ [ ] m s]= 1000 vumin vus [ ]= [ ] Acceleration: a mm s a 2 m s = a U min a U min 2 a U s = = a U min a U s 3600 = Conversion factors To check whether limit values are complied with, the displayed value is compared in MOVISAFE Config UCS (Scope) with the speed specified in parameter 000 (for MDX B). In the encoder interface, you can preset the following units that have to be converted to rpm (standard in MDX B). 1/min 1/s m/s mm/s Degree/s For this purpose, the following conversion factors are provided. Conversion from rpm to 1/min: No conversion required. Conversion from 1/s to 1/min: 1 1/s = 60 1/min Conversion from mm/s to 1/min: 1 mm/s = /min Conversion from m/s to 1/min: 1 m/s = 60 1/min Conversion from degree/s to 1/min: 1 degree/s /min 112 Operating Instructions MOVISAFE UCS.B

113 Startup Configuration of measuring sections I Measuring error during speed measurement MOVISAFE UCS.B measures the speed up to a frequency of 500 steps/s using the time measuring method. Frequencies higher than 500 steps/second are measured using the frequency measuring method. Both measuring methods are subject to a measuring error as shown below. If you are operating your application in this velocity range, you must take the measuring error into account when dimensioning the switch-off limits of the safety functions. The measuring error can be reduced by selecting a suitable encoder or making suitable encoder settings. 30% Measuring error in % 25% 20% 15% 10% 5% 0% Steps/s Example 1: Velocity monitoring PPR count: 256 steps/rev Requested switch-off limit: 120 rpm Steps per second for the required switch-off limit: 256 steps/rev 120 rev/min 1/60 min/s = 512 steps/s Resulting measuring error according to the illustration: approx. 25 % Required switch-off limit: 120 rev/min 1.25 = 150 rev/min Example 2: Reducing the measuring error with a higher PPR count: PPR count: 1024 steps/rev Requested switch-off limit: 120 rpm Steps per second for the required switch-off limit: 1024 steps/s 120 1/min 1/60 min/s = 2048 steps/s Resulting measuring error according to the illustration: approx. 6.5 % Required switch-off limit: 120 1/min /min Operating Instructions MOVISAFE UCS.B 113

114 8 Validation Procedure 8 Validation 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 in the MOVISAFE Config UCS software in the form of a configuration report. The MOVISAFE concept relies on the following basic assumptions: Parameter and PLC data stored in the flash memory of MOVISAFE UCS.B cannot change automatically. Online tests and corresponding signatures ensure this by implementing basic measures on the subassembly. However, the configuration cannot be evaluated by the subassembly. This affects parameters for the sensors, thresholds and limit values. Once the configuration has been transferred to MOVISAFE UCS.B, the status LED of the basic module flashes yellow. This means that the configuration has not been validated before transfer. Validation is performed via plan management in MOVISAFE Config UCS. Here, the configuration can be inhibited. An inhibited configuration is indicated by a yellow, flashing status LED. 8.1 Procedure After successful startup, the user must confirm that the data of the test report matches the parameters of the module. The user must validate and protocol the parameterized values for the measuring section, sensors and monitoring functions individually by performing a function test. In addition, the user must validate and protocol the connection of each programmed PLC function in MOVISAFE Config UCS by inspecting the code. SEW-EURODRIVE recommends to design the controller in such a way that the limit values of MOVISAFE UCS.B can be tested. 8.2 Configuration report for validation Structure of the configuration report The file contains the following information: Three pages with header data that can be edited Encoder configuration Parameters of the monitoring functions The IL code of the programmed PLC functions Creation of the configuration report The MOVISAFE Config UCS software interface lets you generate an individual configuration report and save it as a text file (.txt). The text file is created using the file name and the path of the current parameter/programming data set. Depending on the application software, the text file can be printed in DIN A4 landscape format. 114 Operating Instructions MOVISAFE UCS.B

115 Validation Function test Entries in the configuration report Before you generate the configuration report, you can enter general information on the application (header data) which will then also appear in the configuration report. You can use the first page of the configuration report to enter general information on the system (system designation, customer, supplier, setup operator, etc.). On the second page of the configuration report, you can enter more detailed information about the system/machine. This data is for information only, but the content and scope should be checked with the approval authorities / inspector. The last page of the configuration report contains the itemization for the safety check. The MOVISAFE Config UCS software automatically enters the following information in the text file: Manufacturer: SEW-EURODRIVE GmbH & Co KG Type: MOVISAFE UCS.B Parameterized values of the safety functions All the other entries must be entered manually by the inspector: Date: of the day when the configuration data set was created CRC signature: of the verified data set Read-off serial number identical to the serial number on the nameplate The inspector responsible confirms that the read-off serial number in MOVISAFE Config UCS is identical with the serial number on the nameplate attached to MOVISAFE UCS.B. Identical to option: Here, the responsible inspector confirms that the CRC displayed in MOVISAFE Config UCS is identical to the one stored in MOVISAFE UCS.B. This CRC signature consists of a five-digit number that is displayed in the connection dialog of the software interface when a connection has been established with MOVISAFE UCS.B. Signature of the inspector Approval of the function INFORMATION The correct program data and parameter data must be loaded to create the configuration report for validation. All listed parameters and program instructions must be validated at the system/ machine and confirmed in writing on the configuration report The inspector must validate all the configured data in the printed configuration report. To do so he/she must verify all the set limit values of the monitoring functions used by performing a function test. The printed out IL code must be validated, see chapter "Appendix", subchapter "IL instruction list". 8.3 Function test The proper functioning of the safety functions has to be checked once a year to ensure the safety of the subassembly. This is done by testing the function of the modules used in the parameterization. Operating Instructions MOVISAFE UCS.B 115

116 8 Validation Determining/checking the response times for validation 8.4 Determining/checking the response times for validation The total response time of the drive system has to be determined to assess the slowingdown path of the machine. For this purpose, all the response times of the affected components (electronic and mechanical) must be determined. The following example illustrates this The following components are used: MOVIDRIVE B, size 1, with the following option card: DEH21B as encoder interface Safety-relevant BST brake module DR motor with integrated BE brake and SIN/COS encoder Additional external SIN/COS encoder UCS12B safety module 116 Operating Instructions MOVISAFE UCS.B

117 Validation Determining/checking the response times for validation 8 The drive is to be monitored for safe speed (SLS safety function). If the velocity is exceeded, the drive must be switched off immediately (STO safety function). The encoders are read into MOVISAFE UCS.B. Then the safety function is activated. The total response time is calculated as follows: MOVISAFE UCS.B processing and detecting that the limit speed is exceeded (2 cycle time UCS.B): 16 ms Switch-off (STO) of the binary output DO 0.2_P/M in MOVISAFE UCS.B: 4 ms Response time of the safe disconnection X17 in MOVIDRIVE B: 100 ms The brake is disconnected via BST at the same time: Response time of the BST: 6 ms Response time of the BE brake: about 30 ms Application time of the BE brake: about 130 ms This results in a total response time of 286 ms for the SLS safety function. INFORMATION The total response time becomes longer when using overspeed distance monitoring and/or an SS1/SS2 safety function. If the filter for overspeed distance monitoring is used and the SS1 safety function is used instead of STO, the total response time will change as follows: Processing and activating any violation of the velocity limit including overspeed distance monitoring in MOVISAFE UCS.B (2 cycle time UCS.B): 16 ms Time until overspeed distance monitoring is exceeded: 120 ms Switch-off of the binary output DO 0.0_P in MOVISAFE UCS.B for enable: 4 ms Delayed disabling (SS1) of binary output DO2_P/M of the DCS21B option: 560 ms Response time of the safe disconnection X17 in MOVIDRIVE B: 100 ms The brake is disconnected via BST at the same time: Response time of the BST: 6 ms Response time of the BE brake: about 30 ms Application time of the BE brake: about 130 ms This results in a total response time of 966 ms for the SLS safety function with overspeed distance monitoring and SS1 safety function. INFORMATION For an example of how to calculate the response time of overspeed distance monitoring, refer to chapter "Calculating the response time with overspeed distance monitoring". You find the response times of the various components in the technical data of the relevant component documentation. Operating Instructions MOVISAFE UCS.B 117

118 8 Validation Validation of the performance level according to EN ISO Validation of the performance level according to EN ISO It has to be checked whether the required performance level (PL r ), which was determined in the risk assessment, is achieved by the chosen system for each safety function used. SEW-EURODRIVE recommends to check the calculation using the SISTEMA software tool (free of charge) of the employer's liability insurance association. SEW- EURODRIVE provides a component library which can be used as basis for the calculation. SEW-EURODRIVE offers corresponding services to support the system check by calculation. If you use another method to validate the performance level, you can use the characteristic safety values specified in the "Appendix" chapter. 118 Operating Instructions MOVISAFE UCS.B

119 Maintenance Servicing 9 9 Maintenance 9.1 Servicing The proper functioning of the safety functions has to be checked once a year to ensure the safety of the module. This is done by testing the function or switch-off of the modules used in the parameterization (inputs, outputs, monitoring functions, and logic modules). 9.2 Modification/changes to the unit Hardware modifications Changes to the module MOVISAFE UCS.B may only be carried out by SEW- EURODRIVE. Firmware modifications Only SEW-EURODRIVE is authorized to make changes to the firmware. Repair Only SEW-EURODRIVE is authorized to repair MOVISAFE UCS.B. INFORMATION The safety certification and any right to claim under limited warranty become void if the user manipulates the unit internally (e.g. replacing components, welding parts). 9.3 Disposal Observe the applicable national regulations. Dispose of the following materials separately in accordance with the country-specific regulations in force, as: Electronics scrap Plastic Sheet metal copper Operating Instructions MOVISAFE UCS.B 119

120 9 Maintenance Replacement of the basic module 9.4 Replacement of the basic module Preparations The following components are required to perform the necessary steps for replacing the basic module: Programming software MOVISAFE Config UCS Interface adapter for connecting the basic module with the PC, see chapter "Communication and establishing a connection". Observe the following points: The configuration report of the original startup procedure must be on hand. The configuration (original program) must be on hand. If the configuration is inhibited, you need the password to unlock it. The hardware and software version of the new basic module must be higher than or the same as that of the old basic module. The hardware and software version is listed on the nameplate of the basic module. The CRC codes (3) from the basic module must be identical with those of the configuration and the configuration report. INFORMATION There are 3 different CRC codes. They are labeled with a letter and 5 numerals. Program CRC (P XXXXX) Parameter CRC (C XXXXX) Overall CRC (L XXXXX) After pressing the <ENTER> key for more than 3 seconds, the CRC codes are displayed at the basic module. As an alternative, it is possible to display them in MOVISAFE Config UCS (menu [Connection] / [Diagnostics] / [System information]). The CRC codes of the configuration are displayed in the plan management in MOVISAFE Config UCS Replacing the basic module INFORMATION Encoder and connection cables may only be connected or disconnected while the voltage supply is switched off. When using prefabricated encoder cables, the voltage can be supplied by the frequency inverter. In this case, you must also switch off the voltage supply of the frequency inverter. Unlocking the configuration is not required for reading and transmitting the binary file. Do the following: 1. Start the MOVISAFE Config UCS software and select the respective basic module. 2. Use the PC to establish a connection with the basic module (menu [Connection] / [Connect]). 3. Read the current configuration from the basic module (menu [Connection] / [Validation] / [Read UCS binary file...]). 120 Operating Instructions MOVISAFE UCS.B

121 Maintenance Replacing the expansion module 9 4. Save the read configuration after the transmission is complete. 5. Disconnect the connection with the basic module (menu [Connection] / [Disconnect]). 6. Switch off the voltage supply of the basic module. 7. Disconnect all encoder and connection cables from the basic module. 8. Remove the basic module from the standard profile rail. 9. Install the new basic module on the standard profile rail. 10.Connect all encoder and connection cables to the new basic module. 11.Switch on the voltage supply of the new basic module. 12.Use the PC to establish a connection with the new basic module (menu [Connection] / [Connect]). 13.Send the configuration saved under point 3 to the new basic module (menu [Connection] / [Validation] / [Send UCS binary file to UCS...]). 14.After the transmission is complete, start the new basic module (menu [Connection] / [Start]) Concluding measures After the new basic module has been installed and configured, the following final measures must be taken: 1. Perform a visual check (correct installation, swapped connections, etc.) 2. Read the CRC codes (3) from the new basic module. They must be identical with those of the configuration report. 3. Enter the transmission counter in the configuration report. 4. Enter the serial number of the new basic module in the configuration report. 5. Confirm the changes in the configuration report with date, name, and signature. 9.5 Replacing the expansion module Preparation The following points must be considered for performing the necessary steps for replacing an expansion module: The configuration report of the original startup procedure must be on hand. The hardware and software version of the new expansion module must be higher than or the same as that of the old expansion module. The hardware and software version is listed on the nameplate of the expansion module Replacing the expansion module 1. Switch off the voltage supply of the basic and expansion module. 2. Disconnect all connection cables from the expansion module. 3. Remove the expansion module from the standard profile rail. This interrupts the connection to the backplane bus. 4. Read the unit address from the bottom of the expansion module. 5. Set the same unit address on the new expansion module. Operating Instructions MOVISAFE UCS.B 121

122 9 Maintenance Replacing the diagnostic module 6. Install the new expansion module on the standard profile rail. This re-establishes the connection to the backplane bus. 7. Connect all connection cables to the new expansion module. 8. Switch on the voltage supply of the basic module and the new expansion module Concluding measures After the new expansion module has been installed and connected, the following final measures must be taken: 1. Enter the serial number of the new expansion module in the configuration report. 2. Confirm the changes in the configuration report with date, name, and signature. INFORMATION When replacing an expansion module, no new CRC code is generated. This means a validation is not necessary after the replacement. 9.6 Replacing the diagnostic module Preparation The following point must be considered for performing the necessary steps for replacing a diagnostic module: The hardware version of the new diagnostic module must be higher than or the same as that of the old diagnostic module. The hardware version is listed on the nameplate of the diagnostic module Replacing the diagnostic module 1. Switch off the voltage supply of the basic module and of the expansion module, if applicable. 2. Disconnect all connection cables from the diagnostic module. 3. Remove the diagnostic module from the standard profile rail. This interrupts the connection to the backplane bus. 4. Install the new diagnostic module on the standard profile rail. This re-establishes the connection to the backplane bus. 5. Connect all connection cables to the new diagnostic module. 6. Switch on the voltage supply of the basic module and the expansion module, if applicable Concluding measures Once the new diagnostic module has been installed and connected, perform a visual check (correct installation, swapped connections, etc.). INFORMATION When replacing a diagnostic module, no new CRC code is generated. This means a validation is not necessary after the replacement. 122 Operating Instructions MOVISAFE UCS.B

123 Maintenance Replacing an SSI absolute encoder Replacing an SSI absolute encoder Two cases are distinguished when replacing an SSI absolute encoder: Position processing in UCS.B Not active Active Application Simple velocity monitoring: No encoder offset necessary Positions are monitored: Necessary to adjust/recalculate the encoder offset (usually with rotative encoders) Replacing an SSI absolute encoder when position processing is inactive Preparation An SSI absolute encoder may only be replaced by the same encoder type. Replacing an SSI absolute encoder Proceed as follows to replace an SSI absolute encoder without active position processing: 1. Before replacing the encoder, switch off the mains voltage and the DC 24 V supply voltage. 2. Disconnect terminal X17 on MOVIDRIVE B or MOVITRAC B units, or terminal X7/ X8 on MOVIAXIS. This prevents the motor or brake from being enabled unintentionally during encoder replacement. 3. Replace the encoder in the application. Make sure that the encoder type is the same. 4. Switch the DC 24 V supply voltage and the mains voltage back on. 5. Re-connect terminal X17 (on MOVIDRIVE B/MOVITRAC B) or X7/X8 (on MOVIAXIS ). 6. Connect MOVISAFE UCS.B with your PC, see chapter "Communication and establishing a connection". 7. Start the MOVISAFE Config UCS software and establish a connection with the basic module. 8. Use the SCOPE function to check the plausibility of the transmitted position and velocity of your encoder. INFORMATION An empty program is sufficient to check the plausibility with the SCOPE function. Select UCS11B or UCS12B because the full SCOPE functionality is only available for basic modules with encoder interface. Concluding measures Once the new SSI absolute encoder has been installed and connected, perform a visual check (correct installation, swapped encoder connections, etc.). Operating Instructions MOVISAFE UCS.B 123

124 9 Maintenance Replacing an SSI absolute encoder Replacing an SSI absolute encoder when position processing is active Preparation The following components are required to perform the necessary steps for replacing an SSI absolute encoder when position processing is active: Programming software MOVISAFE Config UCS Dongle for MOVISAFE Config UCS. Interface adapter for connecting the basic module with the PC, see chapter "Communication and establishing a connection". Observe the following points: The SSI absolute encoder may only be replaced by the same encoder type. The configuration report of the original startup procedure must be on hand. The configuration (original program) must be on hand. If the configuration is inhibited, you need the password to unlock it. The CRC codes (3) from the basic module must be identical with those of the configuration and the configuration report. Replacing an SSI absolute encoder Proceed as follows to replace an SSI absolute encoder with active position processing: 1. Before replacing the encoder, switch off the mains voltage and the DC 24 V supply voltage. 2. Disconnect terminal X17 on MOVIDRIVE B or MOVITRAC B units, or terminal X7/ X8 on MOVIAXIS. This prevents the motor or brake from being enabled unintentionally during encoder replacement. 3. Replace the encoder in the application. Make sure that the encoder type is the same. 4. Switch the DC 24 V supply voltage and the mains voltage back on. 5. Re-connect terminal X17 (on MOVIDRIVE B/MOVITRAC B) or X7/X8 (on MOVIAXIS ). 6. Connect MOVISAFE UCS.B with your PC, see chapter "Communication and establishing a connection". 7. Start the MOVISAFE Config UCS software and establish a connection with the basic module. 8. Use the SCOPE function to check the transmitted position and velocity of your encoder. If the displayed position is identical with the position in the application, no adjustments are necessary and you can proceed with step If the position of the application is not identical with the displayed position, open the original program in the MOVISAFE Config UCS software. The following changes cause the CRC to be calculated again. 10.Open the encoder dialog and enter the value "0" in the "Offset" entry field. 11.Save this new configuration under another name. 12.Send the new configuration to the basic module. 13.Start the sent configuration. 14.Use the SCOPE function to check the displayed position of the encoder. 124 Operating Instructions MOVISAFE UCS.B

125 Maintenance Replacing an SSI absolute encoder 9 15.Re-open the encoder dialog and calculate the offset of the new SSI absolute encoder for the application. 16.Save the adjusted configuration and send it to the basic module. 17.Start the sent configuration and check the displayed position and speed of the SSI encoder again using the SCOPE function. 18.Check the displayed values for plausibility with the real values of the application. INFORMATION MOVISAFE Config UCS offers a calculation aid for calculating the offset. You can start in in the dialog for the encoder setting, next to the offset entry. Concluding measures Once the new SSI absolute encoder has been installed and connected, take the following measures: 1. Perform a visual check (correct installation, swapped connections, etc.) 2. Read the CRC codes (3) from the basic module. Enter the CRC codes in the configuration report. 3. Enter the transmission counter in the configuration report. 4. Enter the new offset in the configuration report. 5. Archive the changed configuration together with the original configuration. 6. Confirm the changes in the configuration report with date, name, and signature. Operating Instructions MOVISAFE UCS.B 125

126 10 kva i P f n Hz Diagnostics Meaning of the 7-segment display 10 Diagnostics 10.1 Meaning of the 7-segment display The 7-segment display is used to indicate the status of MOVISAFE. Status of 7- segment display Mode Description 1 STARTUP Synchronization between both processor systems and check of the configuration/firmware data. 2 SEND CONFIG Distribution of the configuration/firmware data and another check of this data. Range check of the configuration data. 3 STARTUP BUS If applicable, the bus system is initialized (PROFIsafe). 4 RUN Standard operation of the MOVISAFE assembly. The program is executed cyclically. 5 STOP In STOP mode, parameters and program data can be loaded externally. F FAILURE A fault can only be reset by switching the subassembly off and then on again (see chapter "Error and alarm messages"). A ALARM An alarm can be reset via a binary input or by pressing the "ENTER" button on the front panel (see chapter "Error and alarm messages"). E ECS-ALARM An ECS alarm can be reset via binary inputs or by pressing the "ENTER" button on the front panel (see chapter "Error and alarm messages"). INFORMATION In states 1, 2, 3 and 5, the outputs are automatically switched off by the firmware. In status 4, the implemented MOVISAFE program assumes control. In states F and A, all outputs are disabled. If MOVISAFE UCS.B is restarted after a reset, the outputs are enabled in status 4 and switched as programmed. If a reason for an error or alarm is still present, the outputs are disabled again and a corresponding error or alarm message is issued. In status E, only a message is issued. The outputs are not disabled Meaning of the status LED The LED status indicates the system status of MOVISAFE. LED display Flashing green Flashing yellow Flashing red Flashing red Description System ok, configuration validated System ok, configuration not validated yet Alarm Failure 126 Operating Instructions MOVISAFE UCS.B

127 Diagnostics Diagnostic module UCS23B with CAN interface kva i P f n Hz Diagnostic module UCS23B with CAN interface The UCS25B diagnostic module can be used for non-safe communication via CAN with a higher-level controller. In the software configuration, you can set the transmission of up to 2 CAN telegrams with 8 Bytes each. The first CAN telegram is always sent and contains variable logic data from the logic plan. The second CAN telegram can be transmitted optionally and contains configurable process data. The CAN ID assigned to the data frame can be freely configured. A data frame is structured as follows: Byte 7 Byte 6 Byte 5 Byte 4 Byte 3 Byte 2 Byte 1 Byte Structure of CAN telegram 1 Configuration in status Byte Bit 2, 3, 4 6, 7 1 = STARTUP 2 = SEND CONFIG 3 = STARTUP BUS = RUN 7 5 = STOP 6 = FAILURE 7 = ALARM 4 0x1 (fixed value) 5 7 Life bit Logic data (data bit: 48 55) Logic data (data bit: 40 47) Logic data (data bit: 32 39) Logic data (data bit: 8 15) Logic data (data bit: 0 7) 0 6 Logic data (data bit: 24 30) Error code high byte 1 7 "0" (status bit) "1" (status bit) 0 Logic data (data bit: 16 23) Error code low byte Byte 7 (bits 0 3) of the logic data always contains the current status of the basic modules. This status is also indicated on the 7-segment display. INFORMATION If the unit is in alarm status, the error message is displayed in byte 0 and 1 (data bit 16 30). The status bit (byte 1, bit 7) changes to "1". This means that any configured logic data information is overwritten. Operating Instructions MOVISAFE UCS.B 127

128 10 kva i P f n Hz Diagnostics Diagnostic module UCS23B with CAN interface Structure of CAN telegram 2 Byte Bit Configuration in status 2, 3, 4, 6, Process data (data bit: 56 63) Process data (data bit: 48 55) Process data (data bit: 40 47) Process data (data bit: 32 39) Process data (data bit: 24 31) Process data (data bit: 16 23) Process data (data bit: 8 15) Process data (data bit: 0 7) The following information can be chosen as process data in the MOVISAFE Config UCS software: Process data Axis Data length in bits Current position 16, 20, 24 Current velocity 08, 12, 16 SLP position (teach-in) 16, 20, 24 1 or 2 Analog value of input 08 Analog value of filter 08 Analog value of adder 08 You can freely set the parameters for the frequency at which CAN telegrams will be updated. You can choose between cyclic and acyclic transmission. Cyclic transmission is carried out based on the cycle time of the basic module (see chapter "Response times of MOVISAFE ") plus a freely selectable factor X (X: 1-255). Acyclic transmission means a new CAN telegram will be transmitted if the data content of the entire telegram is changed. The CAN telegrams are resent every 500 ms even if no change was made. 128 Operating Instructions MOVISAFE UCS.B

129 Diagnostics Error and alarm messages kva i P f n Hz Error and alarm messages MOVISAFE UCS.B basically distinguishes between 3 types of messages as follows. Message Description Impact on the system Reset condition UCS.B Error The last active process is the operation of the 7-segment display via system A. System B is in stop mode. 1) Switching MOVISAFE off and then on again. Alarm ECS Functional error caused by the external process. Both systems (A, B) continue to run cyclically. When using the ECS function in the programming interface, encoder alarm messages will be identified with "E" instead of "A". 1) All outputs are disabled The ECS function block returns "0" as result. 1) Error detection in system A (odd-numbered) and system B (even-numbered). INFORMATION Through parameterizable input or <ENTER> button on MOVISAFE. If you receive error or alarm messages that are not described here, proceed as follows: Under what circumstances did the error/alarm occur? Save the current configuration set Document the error or alarm code Contact SEW-EURODRIVE Service Display of error or alarm messages Errors should not occur during normal operation of the module. Error messages on MOVISAFE UCS.B are distinguished as shown in the following overview. Error message Meaning F, A, E A 4-digit error message is issued if only one MOVISAFE basic module is used. F, A, E _ A 5-digit error message is issued if one MOVISAFE basic module and additional expansion modules are used. The first digit of the error code has the following meaning: 0: Basic module 1: Expansion module with logic address 1 2: Expansion module with logic address 2 Operating Instructions MOVISAFE UCS.B 129

130 10 kva i P f n Hz Diagnostics Error and alarm messages List of error messages Fatal error code F 1001 Error message Error during transfer of configuration data to the monitoring unit Interruption in connection during program download Remedy Send the configuration files again Fatal error code F 1003 Error message Configuration data for software version of the subassembly is invalid. Subassembly configured with incorrect software version of the programming interface. Remedy Configure subassembly with permitted version of the programming interface. Then switch subassembly off and on again. Fatal error code F 1007 Error message Unit was programmed with incorrect programming interface. Program or configuration data was loaded into the unit with an incorrect programming interface. Remedy Check the design of the subassembly. Configure again with a valid programming interface. Then switch the unit off and on again. Fatal error code F 1307 Error message Error when deleting the configuration data in the flash memory. Fatal error code Error message F 1311 / F1312 Internal error, please contact the manufacturer. Fatal error code F 1314 Error message Internal error, please contact the manufacturer. Fatal error code F 1330 Error message Internal error, please contact the manufacturer. Fatal error code Error message F 1401 / F1402 Internal error, please contact the manufacturer. Fatal error code Error message Remedy F 1403 / F1404 CRC of configuration data invalid. Faulty transmission of configuration data. Transmit configuration data again. Fatal error code F 1406 Error message Internal error, please contact the manufacturer. 130 Operating Instructions MOVISAFE UCS.B

131 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code Error message F 1407 / F1408 Internal error, please contact the manufacturer. Fatal error code Error message F 1501 / F1502 Internal error, please contact the manufacturer. Fatal error code Error message F 1503 / F1504 Internal error, please contact the manufacturer. Fatal error code Error message F 1505 / F1506 Internal error, please contact the manufacturer. Fatal error code Error message F 1601 / F1602 Faulty range check of the unit description. Fatal error code Error message F 1603 / F1604 Faulty range check of access data. Fatal error code Error message F 1605 / F1606 Faulty EMU range check. Fatal error code Error message F 1607 / F1608 Faulty SCA range check. Fatal error code Error message F 1609 / F1610 Faulty SSX range check. Fatal error code Error message F 1611 / F1612 Faulty SEL range check. Fatal error code Error message F 1613 / F1614 Faulty SLP range check. Fatal error code Error message F 1615 / F1616 Faulty SOS range check. Fatal error code Error message F 1617 / F1618 Faulty SLS range check. Operating Instructions MOVISAFE UCS.B 131

132 10 kva i P f n Hz Diagnostics Error and alarm messages Fatal error code Error message F 1619 / F1620 Faulty SDI range check. Fatal error code Error message F 1621 / F1622 Faulty SLI range check. Fatal error code Error message F 1623 / F1624 Faulty PLC range check. Fatal error code Error message F 1625 / F1626 Faulty shutdown channel range check. Fatal error code Error message F 1627 / F1628 Faulty output range check. Fatal error code Error message F 1629 / F1630 Faulty digital input range check. Fatal error code Error message F 1633 / F1634 Faulty encoder type range check. Fatal error code Error message F 1635 / F1636 Faulty range check of encoder processing. Fatal error code Error message F 1637 / F1638 Faulty encoder position range check. Fatal error code Error message F 1639 / F1640 Faulty PDM range check. Fatal error code Error message F 1645 / F1646 Faulty range check of axis management. Fatal error code Error message F 1647 / F1648 Faulty range check of expansion modules. Fatal error code Error message F 1649 / F1650 Faulty PLC timer range check. 132 Operating Instructions MOVISAFE UCS.B

133 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code Error message F 1651 / F1652 Faulty system range check. Fatal error code Error message F 1653 / F1654 Faulty range check of connection table. Fatal error code Error message F 1655 / F1656 Faulty SAC range check. Fatal error code Error message F 1657 / F1658 Faulty diagnostics range check. Fatal error code Error message F 2001 / F2002 Internal error, please contact the manufacturer. Fatal error code Error message F 2003 / F2004 Timeout during transmission of configuration and firmware data. Fatal error code F 2005 Error message Internal error, please contact the manufacturer. Fatal error code F 2007 Error message Internal error, please contact the manufacturer. Fatal error code F 2009 Error message Internal error, please contact the manufacturer. Fatal error code F 2011 Error message Internal error, please contact the manufacturer. Fatal error code Error message F 2013 / F2014 Internal error, please contact the manufacturer. Fatal error code Error message F 3001 / F3002 Internal error, please contact the manufacturer. Operating Instructions MOVISAFE UCS.B 133

134 10 kva i P f n Hz Diagnostics Error and alarm messages Fatal error code F 3201 / F3202 Error message Processor voltage 2.5 V outside defined range. Faulty DC 24 V supply voltage of the module. Faulty component in the module. Remedy Check supply voltage of module Switch unit off and on again Fatal error code F 3203 Error message Faulty DC 24 V supply voltage of the subassembly. Faulty DC 24 V supply voltage of the module. Faulty component in the module. Remedy Check supply voltage of module Switch units off and on again Fatal error code F 3306 Error message Plausibility error in the position changeover of axis 1 For the position changeover, SOS, SLI or SDI is permanently activated Remedy Check SOS activation Check SLI activation Check SDI activation (only for monitoring via position) Fatal error code F 3316 Error message Error encoder alignment of axis 1. Faulty position triggered by system A. Remedy Check encoder configuration Switch unit off and on again Fatal error code F 3326 Error message Error encoder alignment of axis 2. For the position changeover, SOS, SLI or SDI is permanently activated. Remedy Check SOS activation Check SLI activation Check SDI activation (only for monitoring via position) Fatal error code F 3336 Error message Error encoder alignment of axis 2. Faulty position triggered by system A. Remedy Check encoder configuration Switch unit off and on again Fatal error code Error message Remedy F 3603 / F3604 Faulty switching of K 0.1 relay Programming via SCA outputs can cause the relay to flutter Check the activation of relay K 0.1 in the user program 134 Operating Instructions MOVISAFE UCS.B

135 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code Error message Remedy F 3605 / F3606 Faulty switching of K 0.2 relay Programming via SCAS outputs can cause the relay to flutter Check the activation of relay K 0.2 in the user program Fatal error code F 3609 Error message Faulty writing of the "0 V" driver DO 0.2_M. Faulty output switching status. Remedy Switch unit off and on again. Fatal error code F 3610 Error message Faulty switching of the "24 V" driver DO 0.2_P. Faulty output switching status. Remedy Switch unit off and on again. Fatal error code F 3611 Error message Faulty switching of the "0 V" driver DO 0.3_M. Faulty output switching status. Remedy Switch unit off and on again. Fatal error code F 3612 Error message Faulty switching of the "24 V" driver DO 0.3_P. Faulty output switching status. Remedy Switch unit off and on again. Fatal error code F 3613 Error message Faulty testing of the "0 V" driver DO 0.2_M. Short circuit of the output with "0 V". Remedy Switch unit off and on again. Fatal error code F 3614 Error message Faulty testing of the "24 V" driver DO 0.2_P. Short circuit of the output with "24 V". Remedy Switch unit off and on again. Fatal error code F 3615 Error message Faulty testing of the "0 V" driver DO 0.3_M. Short circuit of the output with "0 V". Remedy Switch unit off and on again. Operating Instructions MOVISAFE UCS.B 135

136 10 kva i P f n Hz Diagnostics Error and alarm messages Fatal error code F 3616 Error message Faulty testing of the "24 V" driver DO 0.3_P. Short circuit of the output with "24 V". Remedy Switch unit off and on again. Fatal error code F 3617 Error message Internal error, please contact the manufacturer. Fatal error code F 3618 Error message Internal error, please contact the manufacturer. Fatal error code F 3619 Error message Internal error, please contact the manufacturer. Fatal error code F 3620 Error message Internal error, please contact the manufacturer. Fatal error code F 3621 Error message Internal error, please contact the manufacturer. Fatal error code F 3622 Error message Internal error, please contact the manufacturer. Fatal error code Error message F 3701 / F3702 Internal error, please contact the manufacturer. Fatal error code F 3821 Error message Faulty switching of output DIO X.01. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3823 Error message Faulty switching of output DIO X.02. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3825 Error message Faulty switching of output DIO X.03. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. 136 Operating Instructions MOVISAFE UCS.B

137 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code F 3827 Error message Faulty switching of output DIO X.04. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3829 Error message Faulty switching of output DIO X.05. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3831 Error message Faulty switching of output DIO X.06. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3833 Error message Faulty switching of output DIO X.07. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3835 Error message Faulty switching of output DIO X.08. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3837 Error message Faulty switching of output DIO X.09. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code F 3839 Error message Faulty switching of output DIO X.10. Short circuit of the output with "24 V" or "0 V". Remedy Switch unit off and on again. Fatal error code Error message Remedy F 3841 / F3842 Faulty testing of output DIO X.01. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Operating Instructions MOVISAFE UCS.B 137

138 10 kva i P f n Hz Diagnostics Error and alarm messages Fatal error code Error message Remedy F 3843 / F3844 Faulty testing of output DIO X.02. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3845 / F3846 Faulty testing of output DIO X.03. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3847 / F3848 Faulty testing of output DIO X.04. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3849 / F3850 Faulty testing of output DIO X.05. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3851 / F3852 Faulty testing of output DIO X.06. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3853 / F3854 Faulty testing of output DIO X.07. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3855 / F3856 Faulty testing of output DIO X.08. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code Error message Remedy F 3857 / F3858 Faulty testing of output DIO X.09. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. 138 Operating Instructions MOVISAFE UCS.B

139 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code Error message Remedy F 3859 / F3860 Faulty testing of output DIO X.10. Short circuit of the output with "24 V" or "0 V". Switch unit off and on again. Fatal error code F 3872 Error message Internal error, please contact the manufacturer. Fatal error code F 3874 Error message Internal error, please contact the manufacturer. Fatal error code F 3892 Error message Internal error, please contact the manufacturer. Fatal error code F 3894 Error message Internal error, please contact the manufacturer. Fatal error code F 4501 / F4502 Error message Faulty calculation of SSX brake ramp. Faulty configuration. Remedy Check the configuration Contact the manufacturer Fatal error code F 4503 / F4504 Error message Faulty calculation of SSX limit curve. Faulty calculation of SSX limit curve. Remedy Check the configuration Contact the manufacturer Fatal error code Error message F 6801 / F6802 Internal error, please contact the manufacturer. Fatal error code Error message F 6803 / F6804 Internal error, please contact the manufacturer. Fatal error code Error message F 6805 / F6806 Internal error, please contact the manufacturer. Fatal error code Error message F 6807 / F6808 Internal error, please contact the manufacturer. Operating Instructions MOVISAFE UCS.B 139

140 10 kva i P f n Hz Diagnostics Error and alarm messages Fatal error code Error message F 6809 / F6810 Internal error, please contact the manufacturer. Fatal error code Error message F 6811 / F6812 Internal error, please contact the manufacturer. Fatal error code Error message F 6813 / F6814 Internal error, please contact the manufacturer. Fatal error code Error message F 8205 / F8206 Internal error, please contact the manufacturer. Fatal error code Error message F 8207 / F8208 Internal error, please contact the manufacturer. Fatal error code Error message F 8213 / F8214 Internal error, please contact the manufacturer. Fatal error code F 8220 Error message Internal error, please contact the manufacturer. Fatal error code Error message F 8221 / F8222 Internal error, please contact the manufacturer. Fatal error code Error message F 8223 / F8224 Internal error, please contact the manufacturer. Fatal error code F 8225 Error message Internal error, please contact the manufacturer. Fatal error code F 8227 Error message Internal error, please contact the manufacturer. Fatal error code F 8228 Error message Internal error, please contact the manufacturer. Fatal error code Error message F 9001 / F9002 Internal error, please contact the manufacturer. 140 Operating Instructions MOVISAFE UCS.B

141 Diagnostics Error and alarm messages kva i P f n Hz 10 Fatal error code Error message F 9007 / F9008 Internal error, please contact the manufacturer. Fatal error code Error message F 9009 / F9010 Internal error, please contact the manufacturer. Fatal error code Error message F 9011 / F9012 Internal error, please contact the manufacturer. Fatal error code Error message F 9013 / F9014 Internal error, please contact the manufacturer. Fatal error code Error message F 9015 / F9016 Internal error, please contact the manufacturer. Fatal error code Error message F 9017 / F9018 Internal error, please contact the manufacturer List of alarm messages Alarm code A 2101 / A2102 Alarm message Timeout receive telegram UCS23B (address 1). Expansion module has received telegram too late. Remedy Check connection with expansion module. Alarm code A 2105 / A2106 Alarm message CRC error in the send telegram of UCS23B (address 1). Faulty send telegram. Remedy Check configuration of serial number of UCS23B option. Alarm code A 2107 / A2108 Alarm message CRC error in the send telegram. Faulty send telegram. Remedy Check configuration of serial number of UCS23B option. Check connection with expansion module. Alarm code A 2109 / A2110 Alarm message CRC error in the receive telegram. Faulty receive telegram. Remedy Check configuration of serial number of UCS23B option. Check connection with expansion module. Operating Instructions MOVISAFE UCS.B 141

142 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 2111 Alarm message Timeout of communication with expansion module UCS23B (address 1). Expansion module installed incorrectly. Remedy Check connection with expansion module. Alarm code A 2113 Alarm message Expansion module UCS23B (address 1) installed but not configured. Faulty configuration. Remedy Check configuration. Alarm code A 2115 / 2116 Alarm message Incorrect address of expansion module UCS23B. Faulty configuration. Remedy Check configuration. Alarm code A 2121 / A2122 Alarm message Timeout receive telegram UCS23B (address 2). Expansion module has received telegram too late. Remedy Check connection with expansion module. Alarm code A 2125 / A2126 Alarm message CRC error in the send telegram of UCS23B (address 2) Faulty send telegram. Remedy Check configuration of UCS23B serial number. Alarm code A 2131 Alarm message Timeout of communication with expansion module UCS23B (address 2). Expansion module installed incorrectly. Remedy Check connection with expansion module. Alarm code A 2133 Alarm message Expansion module UCS23B (address 2) installed but not configured. Faulty configuration. Remedy Check configuration. Alarm code A 3031 / A3032 Alarm message Pulse 1 plausibility error at expansion input DIO X.01. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring 142 Operating Instructions MOVISAFE UCS.B

143 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3033 / A3034 Alarm message Pulse 2 plausibility error at expansion input DIO X.01. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3035 / A3036 Alarm message Faulty 24 V signal at DIO X.01. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3037 / A3038 Alarm message Pulse 1 plausibility error at expansion input DIO X.02. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3039 / A3040 Alarm message Pulse 2 plausibility error at expansion input DIO X.02. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3041 / A3042 Alarm message Faulty 24 V signal at DIO X.02. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3043 / A3044 Alarm message Pulse 1 plausibility error at expansion input DIO X.03. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3045 / A3046 Alarm message Pulse 2 plausibility error at expansion input DIO X.03. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Operating Instructions MOVISAFE UCS.B 143

144 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3047 / A3048 Alarm message Faulty 24 V signal at DIO X.03. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3049 / A3050 Alarm message Pulse 1 plausibility error at expansion input DIO X.04. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3051 / A3052 Alarm message Pulse 2 plausibility error at expansion input DIO X.04. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3053 / A3054 Alarm message Faulty 24 V signal at DIO X.04. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3055 / A3056 Alarm message Pulse 1 plausibility error at expansion input DIO X.05. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3057 / A3058 Alarm message Pulse 2 plausibility error at expansion input DIO X.05. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3059 / A3060 Alarm message Faulty 24 V signal at DIO X.05. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present 144 Operating Instructions MOVISAFE UCS.B

145 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3061 / A3062 Alarm message Pulse 1 plausibility error at expansion input DIO X.06. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3063 / A3064 Alarm message Pulse 2 plausibility error at expansion input DIO X.06. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3065 / A3066 Alarm message Pulse 1 plausibility error at expansion input DIO X.07. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3067 / A3068 Alarm message Pulse 1 plausibility error at expansion input DIO X.07. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3069 / A3070 Alarm message Pulse 2 plausibility error at expansion input DIO X.07. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3071/ A3072 Alarm message Faulty 24 V signal at DIO X.07. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3073 / A3074 Alarm message Pulse 1 plausibility error at expansion input DIO X.08. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Operating Instructions MOVISAFE UCS.B 145

146 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3075 / A3076 Alarm message Pulse 2 plausibility error at expansion input DIO X.08. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3077/ A3078 Alarm message Faulty 24 V signal at DIO X.08. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3079 / A3080 Alarm message Pulse 1 plausibility error at expansion input DIO X.09. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3081 / A3082 Alarm message Pulse 2 plausibility error at expansion input DIO X.09. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3083/ A3084 Alarm message Faulty 24 V signal at DIO X.09. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3085 / A3086 Alarm message Pulse 1 plausibility error at expansion input DIO X.10. The configured pulse 1 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring Alarm code A 3087 / A3088 Alarm message Pulse 2 plausibility error at expansion input DIO X.10. The configured pulse 2 voltage is not present at this input. Remedy Check configuration of the binary input according to configuration and wiring diagram Check wiring 146 Operating Instructions MOVISAFE UCS.B

147 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3089/ A3090 Alarm message Faulty 24 V signal at DIO X.10. The 24 V voltage is not permanently present at this input. Remedy Check voltage at this binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3101 / A3102 Alarm message Pulse 1 plausibility error at digital input DI X.01. There is no pulse 1 voltage at binary input DI X.01 Remedy Check configuration of the binary input DI X.01 according to configuration and wiring diagram Check wiring Alarm code A 3103 / A3104 Alarm message Pulse 1 plausibility error at digital input DI X.02. There is no pulse 1 voltage at binary input DI X.02 Remedy Check configuration of the binary input DI X.02 according to configuration and wiring diagram Check wiring Alarm code A 3105 / A3106 Alarm message Pulse 1 plausibility error at digital input DI X.03 There is no pulse 1 voltage at binary input DI X.03 Remedy Check configuration of the binary input DI X.03 according to configuration and wiring diagram Check wiring Alarm code A 3107 / A3108 Alarm message Pulse 1 plausibility error at digital input DI X.04 There is no pulse 1 voltage at binary input DI X.04 Remedy Check configuration of the binary input DI X.04 according to configuration and wiring diagram Check wiring Alarm code A 3109 / A3110 Alarm message Pulse 1 plausibility error at digital input DI X.05 There is no pulse 1 voltage at binary input DI X.05 Remedy Check configuration of the binary input DI X.05 according to configuration and wiring diagram Check wiring Alarm code A 3111 / A3112 Alarm message Pulse 1 plausibility error at input DI X.06 There is no pulse 1 voltage at binary input DI X.06 Remedy Configure binary input DI06 in accordance with the project planning and wiring diagram Check wiring Operating Instructions MOVISAFE UCS.B 147

148 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3113 / A3114 Alarm message Pulse 1 plausibility error at digital input DI X.07 There is no pulse 1 voltage at binary input DI X.07 Remedy Check configuration of the binary input DI X.07 according to configuration and wiring diagram Check wiring Alarm code A 3115 / A3116 Alarm message Pulse 1 plausibility error at binary input DI X.08 There is no pulse 1 voltage at binary input DI X.08 Remedy Check configuration of the binary input DI X.08 according to configuration and wiring diagram Check wiring Alarm code A 3117 / A3118 Alarm message Pulse 2 plausibility error at input DI X.01 There is no pulse 2 voltage at binary input DI X.01 Remedy Check configuration of the binary input DI X.01 according to configuration and wiring diagram Check wiring Alarm code A 3119 / A3120 Alarm message Pulse 2 plausibility error at binary input DI X.02. There is no pulse 2 voltage at binary input DI X.02 Remedy Check configuration of the binary input DI X.02 according to configuration and wiring diagram Check wiring Alarm code A 3121 / A3122 Alarm message Pulse 2 plausibility error at binary input DI X.03 There is no pulse 2 voltage at binary input DI X.03 Remedy Check configuration of the binary input DI X.03 according to configuration and wiring diagram Check wiring Alarm code A 3123 / A3124 Alarm message Pulse 2 plausibility error at binary input DI X.04 There is no pulse 2 voltage at binary input DI X.04 Remedy Check configuration of the binary input DI X.04 according to configuration and wiring diagram Check wiring Alarm code A 3125 / A3126 Alarm message Pulse 2 plausibility error at binary input DI X.05 There is no pulse 2 voltage at binary input DI X.05 Remedy Check configuration of the binary input DI X.05 according to configuration and wiring diagram Check wiring 148 Operating Instructions MOVISAFE UCS.B

149 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3127 / A3128 Alarm message Pulse 2 plausibility error at binary input DI X.06 There is no pulse 2 voltage at binary input DI X.06 Remedy Check configuration of the binary input DI X.06 according to configuration and wiring diagram Check wiring Alarm code A 3129 / A3130 Alarm message Pulse 2 plausibility error at binary input DI X.07 There is no pulse 2 voltage at binary input DI X.07 Remedy Check configuration of the binary input DI X.07 according to configuration and wiring diagram Check wiring Alarm code A 3131 / A3132 Alarm message Pulse 2 plausibility error at binary input DI X.08 There is no pulse 2 voltage at binary input DI X.08 Remedy Check configuration of the binary input DI X.08 according to configuration and wiring diagram Check wiring Alarm code A 3133 / A3134 Alarm message Pulse 1 plausibility error at binary input DI X.09 There is no pulse 1 voltage at binary input DI X.09 Remedy Check configuration of the binary input DI X.09 according to configuration and wiring diagram Check wiring Alarm code A 3135 / A3136 Alarm message Pulse 1 plausibility error at binary input DI X.10 There is no pulse 1 voltage at binary input DI X.10 Remedy Check configuration of the binary input DI X.10 according to configuration and wiring diagram Check wiring Alarm code A 3137 / A3138 Alarm message Pulse 1 plausibility error at binary input DI X.11 There is no pulse 1 voltage at binary input DI X.11 Remedy Check configuration of the binary input DI X.11 according to configuration and wiring diagram Check wiring Alarm code A 3139 / A3140 Alarm message Pulse 1 plausibility error at binary input DI X.12 There is no pulse 1 voltage at binary input DI X.12 Remedy Check configuration of the binary input DI X.12 according to configuration and wiring diagram Check wiring Operating Instructions MOVISAFE UCS.B 149

150 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3141 / A3142 Alarm message Pulse 1 plausibility error at binary input DI X.13 There is no pulse 1 voltage at binary input DI X.13 Remedy Check configuration of the binary input DI X.13 according to configuration and wiring diagram Check wiring Alarm code A 3143 / A3144 Alarm message Pulse 1 plausibility error at binary input DI X.14 There is no pulse 1 voltage at binary input DI X.14 Remedy Check configuration of the binary input DI X.14 according to configuration and wiring diagram Check wiring Alarm code A 3147 / A3148 Alarm message Pulse 2 plausibility error at binary input DI X.09 There is no pulse 2 voltage at binary input DI X.09 Remedy Check configuration of the binary input DI X.09 according to configuration and wiring diagram Check wiring Alarm code A 3149 / A3150 Alarm message Pulse 2 plausibility error at binary input DI X.10 There is no pulse 2 voltage at binary input DI X.10 Remedy Check configuration of the binary input DI X.10 according to configuration and wiring diagram Check wiring Alarm code A 3151 / A3152 Alarm message Pulse 2 plausibility error at binary input DI X.11 There is no pulse 2 voltage at binary input DI X.11 Remedy Check configuration of the binary input DI X.11 according to configuration and wiring diagram Check wiring Alarm code A 3153 / A3154 Alarm message Pulse 2 plausibility error at binary input DI X.12 There is no pulse 2 voltage at binary input DI X.12 Remedy Check configuration of the binary input DI X.12 according to configuration and wiring diagram Check wiring Alarm code A 3155 / A3156 Alarm message Pulse 2plausibility error at binary input DI X.13 There is no pulse 2 voltage at binary input DI X.13 Remedy Check configuration of the binary input DI X.12 according to configuration and wiring diagram Check wiring 150 Operating Instructions MOVISAFE UCS.B

151 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3157 / A3158 Alarm message Pulse 2 plausibility error at binary input DI X.14 There is no pulse 2 voltage at binary input DI X.14 Remedy Check configuration of the binary input DI X.14 according to configuration and wiring diagram Check wiring Alarm code A 3159/ A3160 Alarm message Faulty 24 V signal at binary input DI X.01. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3161/ A3162 Alarm message Faulty 24 V signal at binary input DI X.02. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3163 / A3164 Alarm message Faulty 24 V signal at binary input DI X.03. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3165 / A3166 Alarm message Faulty 24 V signal at binary input DI X.04. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3167 / A3168 Alarm message Faulty 24 V signal at binary input DI X.05. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3169 / A3170 Alarm message Faulty 24 V signal at binary input DI X.06. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Operating Instructions MOVISAFE UCS.B 151

152 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3171 / A3172 Alarm message Faulty 24 V signal at binary input DI X.07. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3173 / A3174 Alarm message Faulty 24 V signal at binary input DI X.08. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3175 / A3176 Alarm message Faulty 24 V signal at binary input DI X.09. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3177 / A3178 Alarm message Faulty 24 V signal at binary input DI X.10. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3179 / A3180 Alarm message Faulty 24 V signal at binary input DI X.11. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3181 / A3182 Alarm message Faulty 24 V signal at binary input DI X.12. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code A 3183 / A3184 Alarm message Faulty 24 V signal at binary input DI X.13. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present 152 Operating Instructions MOVISAFE UCS.B

153 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3185 / A3186 Alarm message Faulty 24 V signal at binary input DI X.14. The 24 V voltage is not permanently present at the binary input. Remedy Check voltage at binary input Check wiring Check whether pulse 1 or pulse 2 is present Alarm code Alarm message Remedy A 3191 / A3192 Short circuit error at digital inputs. Short circuit between the digital inputs within one module. Contact the manufacturer. Alarm code Alarm message Remedy A 3197 / A3198 Faulty OSSD input check. Faulty OSS test Check 24 V input voltage of all OSSD inputs. Alarm code A 3209 / A3210 Alarm message Faulty encoder supply voltage X7. Encoder supply voltage does not correspond with configured threshold Faulty component in the module. Remedy Check the configuration Check the encoder supply voltage Switch unit off and on again Alarm code A 3213 / A3214 Alarm message Faulty encoder supply voltage X8. Encoder supply voltage does not correspond with configured threshold Faulty component in the module. Remedy Check the configuration Check the encoder supply voltage Switch unit off and on again Alarm code A 3229 / A3230 Alarm message Faulty plausibility test of encoder supply voltage. Encoder voltage value Remedy Check the encoder supply voltage Check the encoder supply voltage cabling Alarm code A 3301 / A3302 Alarm message Plausibility error in the velocity detection of axis 1 The difference between the two speed sensors is higher than the configured speed cut-off threshold. Remedy Check the theory of the track using the data set for the encoder configuration Check the velocity sensor Use the SCOPE function to set speed signals so that they are congruent Operating Instructions MOVISAFE UCS.B 153

154 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3303 / A3304 Alarm message Plausibility error in the position detection of axis 1 The difference between the two position sensors is higher than the configured value. Remedy Check the theory of the track with the data configured for the encoder setting Check position signal Are all signals connected correctly to the 9-pin encoder connector? Check the encoder connector for correct wiring. Is the jumper between pin 1 and pin 2 on the 9-pin encoder connector closed (SSI absolute encoder)? Use the SCOPE function to set positions signals so that they are congruent Alarm code A 3307 / A3308 Alarm message Plausibility error faulty position range of axis 1 The current position is outside the configured range. Remedy Check the theory of the track with the data configured for the encoder setting Check position signal, correct offset if necessary Use the SCOPE function to read off the position and set in ratio to the configured values Alarm code A 3309 / A3310 Alarm message Plausibility error faulty speed of axis 1. The current speed exceeds the configured maximum speed. Remedy The drive moves outside the permitted and configured speed range Check configuration (set max. velocity) Analyze the speed development using the SCOPE function Alarm code A 3311 / A3312 Alarm message Faulty configuration of acceleration of axis 1. The current acceleration is outside the configured acceleration range. Remedy The drive has exceeded the permitted acceleration range Check the configuration (maximum acceleration) Analyze the course of the acceleration using the SCOPE function Alarm code A 3313 / A3314 Alarm message SSI sensor error Encoder step SSI value within one cycle is too large. Remedy Check encoder cabling Check encoder configuration Alarm code A 3318 Alarm message Faulty incremental encoder of axis 1 Track A does not correspond with track B. Remedy Check encoder cabling Check encoder configuration Alarm code A 3321 / A3322 Alarm message Plausibility error in the velocity detection of axis 2 The difference between the two speed sensors is higher than the configured speed cut-off threshold. 154 Operating Instructions MOVISAFE UCS.B

155 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3321 / A3322 Remedy Check the theory of the track using the data set for the encoder configuration Check the velocity sensor Use the SCOPE function to set speed signals so that they are congruent Alarm code A 3323 / A3324 Alarm message Plausibility error in the position detection of axis 2 The difference between the two position sensors is higher than the configured value. Remedy Check the theory of the track with the data configured for the encoder setting Check position signal Are all signals connected correctly to the 9-pin encoder connector? Check the encoder connector for correct wiring. Is the jumper between pin 1 and pin 2 on the 9-pin encoder connector closed (SSI absolute encoder)? Use the SCOPE function to set positions signals so that they are congruent Alarm code A 3327 / A3328 Alarm message Plausibility error faulty position range of axis 2 The current position is outside the configured range. Remedy Check the theory of the track with the data configured for the encoder setting Check position signal, correct offset if necessary Use the SCOPE function to read off the position and set in ratio to the configured values Alarm code A 3329 / A3330 Alarm message Plausibility error faulty speed of axis 2. The current speed exceeds the configured maximum speed. Remedy The drive moves outside the permitted and configured speed range Check configuration (set max. velocity) Analyze the speed development using the SCOPE function Alarm code A 3331 / A3332 Alarm message Faulty configuration of acceleration of axis 2. The current acceleration is outside the configured acceleration range. Remedy The drive has exceeded the permitted acceleration range Check the configuration (maximum acceleration) Analyze the course of the acceleration using the SCOPE function Alarm code A 3333 / A3334 Alarm message Plausibility error sin/cos encoder Incorrect encoder type connected. Remedy Check the configuration Check encoder assignment Alarm code A 3337 / A3338 Alarm message Faulty incremental encoder of axis 2 Track A does not correspond with track B. Remedy Check encoder cabling Check encoder configuration Operating Instructions MOVISAFE UCS.B 155

156 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code Alarm message Remedy A 3407 / A3408 Difference level RS485 driver 1 (error INC_B or SSI_CLK) faulty. No encoder connection, incorrect encoder type. Check the encoder connection. Alarm code Alarm message Remedy A 3409 / A3410 Difference level RS485 driver 2 (error INC_A or SSI_DATA) faulty. No encoder connection, incorrect encoder type. Check encoder connection Alarm code A 3411 / A3412 Alarm message Error sin/cos plausibility (X7). Faulty plausibility monitoring of the individual tracks. Remedy Check encoder connection Sine to cosine track must be linear Alarm code A 3413 / A3414 Alarm message Error sin/cos plausibility (X8). Faulty plausibility monitoring of the individual tracks. Remedy Check encoder connection Sine to cosine track must be linear Alarm code Alarm message Remedy A 3457 / A3458 Faulty reference voltage of extension board. Hardware error on extension board. Expansion card check. Alarm code A 3473 / A3474 Alarm message Faulty TTL/HTL signal. Faulty encoder signal. Remedy Encoder connection check Encoder signal check Alarm code A 3505 / A3506 Alarm message Read head error WCS encoder system axis 1. WCS read head has detected an error. Remedy Read error types of WCS encoder system. Alarm code A 3507 / A3508 Alarm message Read head error WCS encoder system axis 2. WCS read head has detected an error. Remedy Read error types of WCS encoder system. 156 Operating Instructions MOVISAFE UCS.B

157 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3551 / A3552 Alarm message SSI_ECE STATUS 1. axis SSI ext encoder Faulty evaluation of 1st status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3553 / A3554 Alarm message SSI_ECE STATUS 1. axis SSI ext encoder Faulty evaluation of 2nd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3555 / A3556 Alarm message SSI_ECE STATUS 1. axis SSI ext encoder Faulty evaluation of 3rd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3557 / A3558 Alarm message SSI_ECE STATUS 1. axis SSI ext encoder Faulty evaluation of 4th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3559 / A3560 Alarm message SSI_ECE STATUS 1. axis SSI ext encoder Faulty evaluation of 5th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3561 / A3562 Alarm message SSI_ECE STATUS 2. axis SSI ext encoder Faulty evaluation of 1st status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3563 / A3564 Alarm message SSI_ECE STATUS 2. axis SSI ext encoder Faulty evaluation of 2nd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Operating Instructions MOVISAFE UCS.B 157

158 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code A 3565 / A3566 Alarm message SSI_ECE STATUS 2. axis SSI ext encoder Faulty evaluation of 3rd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3567 / A3568 Alarm message SSI_ECE STATUS 2. axis SSI ext encoder Faulty evaluation of 4th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3569 / A3570 Alarm message SSI_ECE STATUS 2. axis SSI ext encoder Faulty evaluation of 5th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3571 / A3572 Alarm message SSI STATUS 1. axis SSI encoder Faulty evaluation of 1st status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3573 / A3574 Alarm message SSI STATUS 1. axis SSI encoder Faulty evaluation of 2nd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3575 / A3576 Alarm message SSI STATUS 1. axis SSI encoder Faulty evaluation of 3rd status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code A 3577 / A3578 Alarm message SSI STATUS 1. axis SSI encoder Faulty evaluation of 4th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder 158 Operating Instructions MOVISAFE UCS.B

159 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 3579 / A3580 Alarm message SSI STATUS 1. axis SSI encoder Faulty evaluation of 5th status bit. Remedy Encoder connection check Encoder signal check Replacement of SSI encoder Alarm code Alarm message Remedy A 3801 / A3802 Faulty switching of output DIO X.01. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3803 / A3804 Faulty switching of output DIO X.02. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3805 / A3806 Faulty switching of output DIO X.03. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3807 / A3808 Faulty switching of output DIO X.04. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3809 / A3810 Faulty switching of output DIO X.05. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3811 / A3812 Faulty switching of output DIO X.06. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3813 / A3814 Faulty switching of output DIO X.07. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Operating Instructions MOVISAFE UCS.B 159

160 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code Alarm message Remedy A 3815 / A3816 Faulty switching of output DIO X.08. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3817 / A3818 Faulty switching of output DIO X.09. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 3819 / A3820 Faulty switching of output DIO X.10. Short circuit of the output with "24V" or "0V". Switch unit off and on again. Alarm code Alarm message Remedy A 4001 / A4002 CCW and CW monitoring (in SDI1 module) activated simultaneously. Multiple activation. Only one direction of rotation can be activated in the SDI1 module. Alarm code Alarm message Remedy A 4003 / A4004 CCW and CW monitoring (in SDI2 module) activated simultaneously. Multiple activation. Only one direction of rotation can be activated in the SDI2 module. Alarm code Alarm message Remedy A 4601 / A4602 CCW and CW monitoring range of the SLP1 activated simultaneously. Multiple activation. Only one enable may be activated in the programming. Alarm code Alarm message Remedy A 4603 / A4604 CCW and CW monitoring range of the SLP2 activated simultaneously. Multiple activation. Only one enable may be activated in the programming. 160 Operating Instructions MOVISAFE UCS.B

161 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code A 4605 / A4606 Alarm message SLP1 teach in status error. SET and QUIT input have faulty switching sequence. Remedy Check the configuration Check the switching sequence Alarm code A 4607 / A4608 Alarm message SLP2 teach in status error. SET and QUIT input have faulty switching sequence. Remedy Check the configuration Check the switching sequence Alarm code Alarm message Remedy A 4609 / A4610 SLP1 teach in position error. Teach-in position outside measuring range. Check transfer position. Alarm code Alarm message Remedy A 4611 / A4612 SLP2 teach in position error. Teach-in position outside measuring range. Check transfer position. Alarm code A 4613 / A4614 Alarm message SLP1 teach in SOS activation error. Drive moved during teach-in (SOS error). Remedy The drive must be at standstill when using the teach-in function. Check whether SOS has already tripped. Alarm code A 4615 / A4616 Alarm message SLP2 teach in SOS activation error. Drive moved during teach-in (SOS error). Remedy The drive must be at standstill when using the teach-in function. Check whether SOS has already tripped. Alarm code Alarm message Remedy A 4901 / A4902 CCW and CW monitoring (in SLI1 module) activated simultaneously. Multiple activation. Only one enable may be activated in the programming. Alarm code Alarm message Remedy A 4903 / A4904 CCW and CW monitoring (in SLI2 module) activated simultaneously. Multiple activation. Only one enable may be activated in the programming. Operating Instructions MOVISAFE UCS.B 161

162 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code Alarm message Remedy A 5001 / A5002 Test for deactivation of binary inputs DI X failed. Binary inputs are still faulty after deactivation. Check the binary input wiring. Alarm code A 6701 / A6702 Alarm message Timeout error flag input element timer. Input element with time monitoring is faulty. Remedy Check wiring of input element Input element faulty Alarm code A 6703 / A6704 Alarm message Timeout error flag two-hand operation. Two-hand operation with time monitoring is faulty. Remedy Check wiring of input element Input element faulty List of ECS messages INFORMATION When using the ECS function block, additional messages are issued which do not necessarily result in disabling all outputs. Alarm code E3301 / 3302 Alarm message Plausibility error in the speed recording The difference between the two speed sensors is higher than the configured speed cut-off threshold. Remedy Check track again with the data of the encoder configuration. Check speed sensor Use the SCOPE function to set speed signals so that they are congruent Alarm code E3303 / 3304 Alarm message Plausibility error in the position detection of axis 1. The difference between the two position signals is higher than the configured increment cut-off threshold. Remedy Check track with the configured data of the encoder setting Check position signal Are all signals connected correctly to the 9-pin encoder connector? Check the encoder connector for correct wiring. Use the SCOPE function to set positions signals so that they are congruent 162 Operating Instructions MOVISAFE UCS.B

163 Diagnostics Error and alarm messages kva i P f n Hz 10 Alarm code E3307 / 3308 Alarm message Plausibility error faulty position range of axis 1. The current position is outside the configured measurement range. Remedy Check track with the configured data of the encoder setting Check position signal, correct offset if necessary Use the SCOPE function to read off the position and set in ratio to the configured values Alarm code E3309 / 3310 Alarm message Plausibility error faulty speed of axis 1. The current speed exceeds the configured maximum speed. Remedy The drive moves outside the permitted and configured speed range Check the configuration (encoder screen: max. set speed) Analyze the speed development using the SCOPE function Alarm code E3311 / 3312 Alarm message Plausibility error faulty acceleration of axis 1. The current acceleration is outside the configured acceleration range. The drive has exceeded the permitted acceleration range Remedy Check the configuration (encoder screen: max. set speed) Analyze the speed/acceleration development using the SCOPE function Alarm code E3407 / 3408 Alarm message Difference level RS485 driver 1. Error: Faulty "B" or "Cycle" signal. No encoder connection Incorrect encoder type is connected Remedy Check the encoder connection. Check encoder cabling Alarm code E3409 / 3410 Alarm message Difference level RS485 driver 2. Error: Faulty "A" or "DATA" signal. No encoder connection Incorrect encoder type is connected Remedy Check the encoder connection. Check encoder cabling Alarm code E3411 / 3412 Alarm message Plausibility error sin/cos encoder X7. Faulty plausibility monitoring of the individual tracks. Remedy Check the encoder connection. Check encoder cabling Sine to cosine track must be linear Operating Instructions MOVISAFE UCS.B 163

164 10 kva i P f n Hz Diagnostics Error and alarm messages Alarm code E3413 / 3414 Alarm message Plausibility error sin/cos encoder X8. The wiring of the encoder does not correspond to the configured data. Remedy Check encoder type and configuration (SSI/incremental) Check the encoder connection/wiring Check polarity of encoder data Check function of the encoder 164 Operating Instructions MOVISAFE UCS.B

165 Technical Data General technical data kva i P f n Hz Technical Data 11.1 General technical data MOVISAFE All sizes Protection class IP20 (EN 60529) Interference immunity Meets EN and EN Ambient temperature 0 C 50 C Climate class 3k3 (EN ) Operating life h 1) 1) At 50 C ambient temperature MOVISAFE UCS10B UCS11B UCS12B UCS23B UCS25B Size (H D W) mm mm mm mm Weight 0.3 kg 0.31 kg 0.39 kg 0.3 kg 0.11 kg Fastening Mounted to standard rail 11.2 Characteristic safety values of MOVISAFE UCS10B Characteristic safety values Safety class / standard SIL 3 according to IEC Category 4 according to EN Performance level e according to EN ISO System structure 2 channels with diagnostics (1oo2D) Type of operating mode "High demand" according to IEC (high demand rate) Probability of dangerous failure per hour (PFH < /h value) Service life or proof test interval according to EN Safe condition 20 years, after which the component must be replaced with a new one. Value "0" for all safety-oriented F-DO process values (output disabled) Safety function Safe logic processing Safe digital inputs/outputs Safe relay outputs Operating Instructions MOVISAFE UCS.B 165

166 11 kva i P f n Hz Technical Data Characteristic safety values of MOVISAFE UCS11B 11.3 Characteristic safety values of MOVISAFE UCS11B Characteristic safety values Safety class / standard SIL 3 according to IEC Category 4 according to EN Performance level e according to EN ISO System structure 2 channels with diagnostics (1oo2D) Type of operating mode "High demand" according to IEC (high demand rate) Probability of dangerous failure per hour (PFH < /h value) Service life or proof test interval according to EN Safe condition 20 years, after which the component must be replaced with a new one. Value "0" for all safety-oriented F-DO process values (output disabled) Safety function STO, SS1, SS2, SOS, SLA, SAR, SLS, SSR, SLP, SLI, SDI, SCA, SSM according to IEC Safe logic processing Safe digital inputs/outputs Safe relay outputs 11.4 Characteristic safety values of MOVISAFE UCS12B Characteristic safety values Safety class / standard SIL 3 according to IEC Category 4 according to EN Performance level e according to EN ISO System structure 2 channels with diagnostics (1oo2D) Type of operating mode "High demand" according to IEC (high demand rate) Probability of dangerous failure per hour (PFH < /h value) Service life or proof test interval according to EN Safe condition 20 years, after which the component must be replaced with a new one. Value "0" for all safety-oriented F-DO process values (output disabled) Safety function STO, SS1, SS2, SOS, SLA, SAR, SLS, SSR, SLP, SLI, SDI, SCA, SSM according to IEC Safe logic processing Safe digital inputs/outputs Safe relay outputs 166 Operating Instructions MOVISAFE UCS.B

167 Technical Data Characteristic safety values of MOVISAFE UCS23B kva i P f n Hz Characteristic safety values of MOVISAFE UCS23B Characteristic safety values Safety class / standard SIL 3 according to IEC Category 4 according to EN Performance level e according to EN ISO System structure 2 channels with diagnostics (1oo2D) Type of operating mode "High demand" according to IEC (high demand rate) Probability of dangerous failure per hour (PFH < /h value) Service life or proof test interval according to EN Safe condition Safety function 20 years, after which the component must be replaced with a new one. Value "0" for all safety-oriented F-DO process values (output disabled) Safe digital inputs/outputs 11.6 Plug connectors of basic module Connector assignment X6 Type: RJ10 plug connector X6 Signal description Specification Parameter setting and diagnostic interface Point-to-point connection Asynchronous, RS485 Baud rate: 38.4 kbaud Data bit: 8 Parity: No Stop bit: Connector assignment X7/X8 Type: D-sub socket X7/X8 PIN TTL incremental SIN/COS SSI absolute N.C. N.C. N.C. 2 DGND DGND DGND 3 N.C. N.C. N.C. 4 B SIN- Pulse 5 A COS+ DATA+ 6 A COS- DATA 7 N.C. N.C. N.C. 8 B SIN+ Pulse + 9 U s U s U s Operating Instructions MOVISAFE UCS.B 167

168 11 kva i P f n Hz Technical Data Plug connectors of basic module Specification of encoder interfaces TTL incremental encoders Signal level Measuring signal A/B track Max. input clock frequency RS phase difference 200 khz SIN/COS encoder Signal level Measuring signal A/B track Max. input clock frequency AC 1V pp 90 phase difference 200 khz SSI absolute encoder Signal level Data format Data width Clock rate Pulse break between clock pulse trains RS422 Binary code Gray code bit (configurable) 19 bit (for SSI-WCS) Master mode: 150 khz Slave mode: Max. 200 khz min. 30 μs max. 2 ms Connector assignment X11 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DC+24 V DC 24 V voltage supply DC 20.4 V 27.6 V 2 DC+24 V 3 0V24 0 V reference potential - 4 0V Operating Instructions MOVISAFE UCS.B

169 Technical Data Plug connectors of basic module kva i P f n Hz Connector assignment X12 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 U_ENC_1 Encoder supply voltage X7 DC 5 V 24 V 2 Reference potential for encoder supply - GND_ENC_1 voltage X7 3 DO 0.00 Signal and auxiliary output 1 DC 24 V, 0.1 A 4 DO 0.01 Signal and auxiliary output 2 DC 24 V, 0.1 A Connector assignment X13 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 U_ENC_2 Encoder supply voltage X8 DC 5 V 24 V 2 Reference potential for encoder supply - GND_ENC_2 voltage X8 3 N.C N.C. Operating Instructions MOVISAFE UCS.B 169

170 11 kva i P f n Hz Technical Data Plug connectors of basic module Connector assignment X21 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI 0.13 Input 13 DC 24 V, suitable for OSSD 2 DI 0.14 Input 14 DC 24 V, suitable for OSSD 3 P1 Pulse output 1 for safe inputs DC 24 V, pulsed 4 P2 Pulse output 2 for safe inputs Max A Clock frequency: 125 Hz Connector assignment X22 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI 0.01 Input 1 DC 24 V, suitable for OSSD 2 DI 0.02 Input 2 DC 24 V, suitable for OSSD 3 DI 0.03 Input 3 DC 24 V, suitable for OSSD 4 DI 0.04 Input 4 DC 24 V, suitable for OSSD 170 Operating Instructions MOVISAFE UCS.B

171 Technical Data Plug connectors of basic module kva i P f n Hz Connector assignment X31 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DO 0.2_P HISIDE output 2 DC 24 V, 0.5 A 2 DO 0.2_M LOSIDE output 2 DGND 3 DO 0.3_P HISIDE output 3 DC 24 V, 0.25 A 4 DO 0.3_M LOSIDE output 3 DGND Connector assignment X32 HTL counting input Signal level pulse frequency DC 24 V / 0 V Max. 10 khz (switching logic debounced) Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI 0.05 Input 5/HTL counting input A DC 24 V 2 DI 0.06 Input 6/HTL counting input A DC 24 V 3 DI 0.07 Input 7/HTL counting input B DC 24 V 4 DI 0.08 Input 8/HTL counting input B DC 24 V Operating Instructions MOVISAFE UCS.B 171

172 11 kva i P f n Hz Technical Data Plug connectors of basic module Connector assignment X41 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 K 0.11 Relay 1, contact 1 DC 24 V, 2 A or 2 K 0.12 Relay 1, contact 2 AC 230 V, 2 A 3 K 0.21 Relay 2, contact 1 DC 24 V, 2 A or 4 K 0.22 Relay 2, contact 2 AC 230 V, 2 A Connector assignment X42 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI 0.09 Input 9 DC 24 V, suitable for OSSD 2 DI 0.10 Input 10 DC 24 V, suitable for OSSD 3 DI 0.11 Input 11 DC 24 V, suitable for OSSD 4 DI 0.12 Input 12 DC 24 V, suitable for OSSD 172 Operating Instructions MOVISAFE UCS.B

173 Technical Data Plug connectors of expansion module kva i P f n Hz Plug connectors of expansion module Connector assignment X15 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DC+24 V DC 24 V voltage supply DC 20.4 V 27.6 V 2 DC+24 V 3 0V24-0 V reference potential 4 0V Connector assignment X16 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 N. C N. C. 3 DO X.0 Signal and auxiliary output 1 DC 24 V, 0.1 A 4 DO X.1 Signal and auxiliary output 2 DC 24 V, 0.1 A Operating Instructions MOVISAFE UCS.B 173

174 11 kva i P f n Hz Technical Data Plug connectors of expansion module Connector assignment X25 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DIO X.01 2 DIO X.02 Binary input/ output 1 Binary input/ output 2 DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A 3 P1 Pulse output 1 for safe inputs DC 24 V, pulsed 4 P2 Pulse output 2 for safe inputs Clock frequency: 125 Hz Connector assignment X26 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI X.01 Input 1 DC 24 V, suitable for OSSD 2 DI X.02 Input 2 DC 24 V, suitable for OSSD 3 DI X.03 Input 3 DC 24 V, suitable for OSSD 4 DI X.04 Input 4 DC 24 V, suitable for OSSD 174 Operating Instructions MOVISAFE UCS.B

175 Technical Data Plug connectors of expansion module kva i P f n Hz Connector assignment X35 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DIO X.03 2 DIO X.04 3 DIO X.05 4 DIO X.06 Binary input/ output 3 Binary input/ output 4 Binary input/ output 5 Binary input/ output 6 DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A Connector assignment X36 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI X.05 Input 5 DC 24 V 2 DI X.06 Input 6 DC 24 V 3 DI X.07 Input 7 DC 24 V 4 DI X.08 Input 8 DC 24 V Operating Instructions MOVISAFE UCS.B 175

176 11 kva i P f n Hz Technical Data Plug connectors of expansion module Connector assignment X45 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DIO X.07 2 DIO X.08 3 DIO X.09 4 DIO X.10 Binary input/ output 7 Binary input/ output 8 Binary input/ output 9 Binary input/ output 10 DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A DC 24 V DC 24 V, 0.25 A Connector assignment X46 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment Signal description Specification 1 DI X.09 Input 9 DC 24 V, suitable for OSSD 2 DI X.10 Input 10 DC 24 V, suitable for OSSD 3 DI X.11 Input 11 DC 24 V, suitable for OSSD 4 DI X.12 Input 12 DC 24 V, suitable for OSSD 176 Operating Instructions MOVISAFE UCS.B

177 Technical Data Plug connectors of diagnostic module kva i P f n Hz Plug connectors of diagnostic module Connector assignment X49 Plug connector type Max. core cross section Coding Phoenix terminal, 4-pole 1.5 mm 2 (AWG16) Terminal Assignment 1 CAN High 2 CAN Low 3 DGND 4 N.C Technical data of SEW encoders TTL incremental encoder Type designation Supply voltage Output signal EH1R ES1R DC 9 26 V ES2R EV1R: According to RS422 (1024 increments/revolution) ES7R EG7R DC V SIN/COS encoder Type designation Supply voltage Output signal ES1S ES2S DC 9 26 V EH1S EV1S AC 1 V pp SIN/COS (1024 increments/revolution) ES7S DC V EG7S EH7S Operating Instructions MOVISAFE UCS.B 177

178 11 kva i P f n Hz Technical Data Technical data of SEW encoders Combination encoders Hiperface and sin/cos Type designation Supply voltage Output signal AK0H ES1H AS1H ES3H AS3H ES4H AS4H EV1H AV1H Positive connection Hiperface encoders: AV6H AF1H EF1H DC 12 V AC 1 V pp SIN/COS (128 increments/revolution) AC 1 V pp SIN/COS (1024 increments/revolution) Combination encoders RS485 and sin/cos Type designation Supply voltage Output signal ES7W EG7W AS7W AG7W DC V AC 1 V pp SIN/COS (2048 increments/revolution) Combination encoders SSI and sin/cos Type designation Supply voltage Output signal AV1Y AC 1 V pp SIN/COS (512 increments/revolution) SSI Gray code ( increments) DC V AS7Y AC 1 V pp SIN/COS AG7Y (2048 increments/revolution) SSI Gray code ( increments) 178 Operating Instructions MOVISAFE UCS.B

179 Technical Data Dimension drawing kva i P f n Hz Dimension drawing UCS25B UCS10B UCS11B UCS23B UCS12B Operating Instructions MOVISAFE UCS.B 179

180 12 Appendix Description of input elements 12 Appendix 12.1 Description of input elements General information The individual switches of the following input elements can be freely assigned to the digital inputs of the basic or I/O modules Operating mode selection switch Switch type Comment Classification according to EN ISO Classification according to EN positions Operating mode selection 3 positions switch, monitored PL e SIL 3 INFORMATION When changing the position of the operating mode selection switch, use the Safe PLC program that is to be created to ensure that the outputs of MOVISAFE are deactivated (EN ) Light curtain Switch type Comment Classification according to EN ISO NC contacts Light curtain for increased demands 2 NC contacts for time monitoring Light curtain, monitored 1 NO + 1 NC contacts Light curtain for increased demands 1 NO + 1 NC contacts, timemonitored Light curtain, monitored PL e SIL 3 Classification according to EN Emergency stop Switch type Comment Classification according to EN ISO NC contact Emergency stop, basic PL d 1) SIL 2 2 NC contacts Emergency stop for increased demands 2 NC contacts for time monitoring Emergency stop, monitored PL e SIL 3 1) Observe fault exclusion and limiting conditions according to EN ISO Classification according to EN Operating Instructions MOVISAFE UCS.B

181 Appendix Description of input elements Start/reset Switch type Comment Classification according to EN ISO ) The alarm/reset input is edge-controlled and can always be operated with a DC 24 V voltage. Classification according to EN Sensor Switch type Comment Classification according to EN ISO NC contact Basic sensor 1 NO contact Basic sensor 2 NC contacts Sensor for increased demands 2 NC contacts for time monitoring 1 NO + 1 NC contacts, timemonitored Monitored sensor Monitored sensor PL d SIL 2 PL e SIL 3 1 NO contact Alarm reset, basic 1) NO contact Logic reset, basic PL d SIL 2 1 NO contact Start monitoring, basic (special function) - - Classification according to EN Door monitoring Switch type Comment Classification according to EN ISO NC contacts Door monitoring for increased demands 2 NC contacts for time monitoring Door monitoring, monitored 1 NO + 1 NC contacts Door monitoring for increased demands 1 NO + 1 NC contacts, timemonitored Door monitoring, monitored 2 NO + 2 NC contacts Door monitoring for increased demands 2 NO + 2 NC contacts, timemonitored Door monitoring, monitored 3 NC contacts Door monitoring for increased demands 3 NC contacts, time-monitored Door monitoring, monitored PL e SIL 3 Classification according to EN Operating Instructions MOVISAFE UCS.B 181

182 12 Appendix Diagnostic values Confirmation button Switch type Comment Classification according to EN ISO NC contact Confirmation button, basic 1 NO contact Confirmation button, basic 2 NC contacts Confirmation button, increased demands Confirmation button, monitored PL d SIL 2 PL e SIL 3 Classification according to EN Two-hand button Switch type Comment Classification according to EN ISO changers Two-hand button, increased demands according to EN 574 type III C 2 NO contacts Two-hand button, monitored in accordance with EN 574 type III A PL e 2 NC contacts for time monitoring Classification according to EN SIL 3 SIL 1 INFORMATION Users cannot change the fixed pulse assignment specified for these input elements Diagnostic values The diagnostic values specify the diagnostic coverage (DC value) that can be assumed for calculating the performance level Binary inputs INFORMATION Refer to the manufacturer's specifications (MTTF d, FIT numbers, etc.) for the safety-relevant evaluation of the sensor subsystem. The DC values listed in the table should be applied conservatively to ensure compliance with the boundary conditions ("Comment" column). Fault exclusions are permitted according to the relevant standards. The specified boundary conditions must be permanently ensured. If several sensor systems are required for an individual safety function to work properly, their partial value must be combined correctly according to the selected method. Measure Cyclical test pulse by changing the input signals dynamically. DC value Comment 90 Only effective if pulse assignment is active. Use Cross fault monitoring for single-channel sensors. 182 Operating Instructions MOVISAFE UCS.B

183 Appendix Diagnostic values 12 Measure Cross comparison on input signals with dynamic test if short circuits cannot be detected (with multiple inputs/outputs). Cross comparison of input signals and intermediate results in the logic (L) and temporal monitoring of the logical program run as well as detection of static failures and short circuits (with multiple inputs/ outputs). Plausibility check, for example using the NO and NC contacts of positively-driven relays. DC value Comment 90 Cyclical change of input signals required, for example by regular acknowledgement. 99 Cyclical change of input signals required, for example by regular acknowledgement. 99 Only effective in conjunction with active monitoring function for input element (EMU function). Use Monitoring of dual-channel sensors. Monitoring of dual-channel sensors. Monitoring of dual-channel, complementary sensors Binary outputs INFORMATION For a safety assessment of the output subsystem when using external elements in the switch-off circuit, e.g. for switching amplification, the manufacturer's specification (MTTF d, FIT values, B 10d value, etc.) must be used. The DC values listed in the table should be applied conservatively to ensure compliance with the boundary conditions ("Comment" column). Fault exclusions are permitted according to the relevant standards. The specified boundary conditions must be permanently ensured. When using elements to amplify signals in safety circuits, the the function of these elements must be monitored using suitable feedback contacts, etc. (see wiring examples). Suitable feedback contacts are contacts that are connected with the contacts in the cut-off circuit in a forced-switching manner. Measure Cross comparison of output signals and intermediate results in the logic (L) and temporal monitoring of the logical program run as well as detection of static failures and short circuits (with multiple inputs/outputs). DC value Comment 99 When using elements to amplify switching (external relays or contactors), the measure is only effective together with the feedback function of switch contacts (EMU function). Use Monitoring of outputs with direct function as safety circuit, or monitoring of safety circuits with elements to amplify switching in conjunction with feedback function of their outputs. Operating Instructions MOVISAFE UCS.B 183

184 12 Appendix Diagnostic values Encoder interface Diagnostics for sensors for position and/or speed detection. Measure DC value Comment Use Cross comparison of input signals and intermediate results in the logic (L) and temporal monitoring of the logical program run as well as detection of static failures and short circuits (with multiple inputs/ outputs). Cross comparison of input signals without dynamic test. Monitoring of some sensor characteristics (response time, range of analog signals, such as electrical resistance, capacitance) INFORMATION 99 Use only for: Two-channel sensor systems (2 separate sensors) Dual-channel subsystem of sensors (incremental encoders) Diagnostics for the single- and dualchannel subsystem of specifically suited sensor systems (SIN/ COS encoders, Resolvers) Dynamic operation/ no standstill monitoring % The DC value depends on the following factors: frequency of the dynamic state, which is standstill or movement, and the quality of the monitoring measure (60 90 % for incremental encoders, 95 99% for SIN/COS encoders) 60 Diagnostics of specific sensor characteristics. Only for use with velocity and position sensors (see chapter "Connecting position and velocity sensors") Monitoring of dual-channel sensor systems or the relevant subsystem of sensors for dynamic operation. Do not use for standstill monitoring! Monitoring of dual-channel sensor systems or subsystem of sensors for nondynamic operation. To be used in particular for standstill monitoring! Monitoring of the singlechannel subsystem of singlechannel sensors. Refer to the manufacturer's specifications (MTTF d, FIT numbers, etc.) for the safety-relevant evaluation of the sensor subsystem. If the manufacturer requires specific diagnostic measures to ensure the specified safety-relevant values, these measures must be checked according to the previous table with respect to the specific encoder. If you are in doubt, please contact the manufacturer. The DC values listed in the table should be applied conservatively to ensure compliance with the boundary conditions ("Comment" column). An estimate of the frequency of the dynamic state might be necessary to determine the DC value for safety functions with standstill monitoring. A DC value of 90 % can be assumed as guide value. Fault exclusions are permitted according to the relevant standards. The specified boundary conditions must be permanently ensured. If several sensor systems are required for an individual safety function to work properly, their partial value must be combined correctly according to the selected method. This also applies to a combination of digital and analog sensors (such as safely reduced speed with open safety door = door contact + encoder for speed detection). A sufficiently low tolerance with respect to the cut-off thresholds of the individual safety functions must be ensured by selecting a suitable resolution of the sensor system. 184 Operating Instructions MOVISAFE UCS.B

185 Appendix Response times of MOVISAFE Response times of MOVISAFE The following table lists the response times of MOVISAFE. The calculation of response times is based on the cycle time of the system. The cycle time (T_cycle) for MOVISAFE is 8 ms during operation. The specified response times correspond to the maximum run time for the specific application within MOVISAFE. Depending on the application, additional application-specific response times for the sensors and actuators used have to be added to get the total run time. INFORMATION If the "overspeed distance monitoring" filter is used, the response time will increase depending on the set distance. Function Activation of a monitoring function via ENABLE with subsequent switch-off via digital output. Activation of a monitoring function via ENABLE with subsequent switch-off via relay output. Response of an already activated monitoring function including PLC processing for position and velocity processing via digital output. Response of an already activated monitoring function including PLC processing for position and velocity processing via relay output. Response time ms 24 1) 47 1) Explanation 1) When activated, the response time increases according to the filter value Activating a safety function with the ENABLE signal. 16 1) For a monitoring function that has been activated via ENABLE, MOVISAFE needs one cycle to calculate the current speed value. In the next cycle, after the monitoring function has been calculated, the information is further 39 1) processed and output by the PLC. That is, once the programmed logic has been performed, this can lead, e.g. to the switching of an output. Activating digital output via digital input. 16 Activating an input and switching the output. Activating relay output via digital input. 26 Activating an input and switching the output. Deactivating digital output via digital input 16 Deactivating an input and in this way deactivating the output. Deactivating relay output via digital input. 47 Deactivating an input and in this way deactivating the output. Mean value filter 0 64 Group run time of average value generator according to setting in MOVISAFE Config UCS (sensor interface). This run time only affects monitoring functions in conjunction with position/velocity/acceleration, not the logic processing. Operating Instructions MOVISAFE UCS.B 185

186 12 Appendix Response times of MOVISAFE Calculating the response time of MOVISAFE with overspeed distance monitoring If the "overspeed distance monitoring" function is used for speed monitoring, the total response time of MOVISAFE UCS.B will increase. Two cases are distinguished. 1. Faulty acceleration beyond the monitored velocity. v v Max v t t R = 2 s a F + 2 t UCS v Max v 0 t R s F a t UCS = Maximum permitted velocity = Monitored velocity (SLS/SCA) = Response time of MOVISAFE UCS.B = Permitted distance for overspeed distance monitoring = Acceleration of the drive = Cycle time of MOVISAFE UCS.B 186 Operating Instructions MOVISAFE UCS.B

187 Appendix Response times of MOVISAFE Constant travel above the monitored velocity. v v Max v t t R = v s Max F v t UCS v Max v 0 t R s F a t UCS = Maximum permitted velocity = Monitored velocity (SLS/SCA) = Response time of MOVISAFE UCS.B = Permitted distance for overspeed distance monitoring = Acceleration of the drive = Cycle time of MOVISAFE UCS.B Fast channel Fast channel is a feature of MOVISAFE that allows for faster responses than when processing the safety programs in a normal cycle (= 8 ms). The sampling time of the fast channel is 2 ms. A binary output can be switched off in group as a response. The following response time can be specified: 6 ms (worst case condition) INFORMATION When using the fast channel, note that a switch-off for a specified velocity threshold within the time listed above is only possible if the resolution of the sensor information is sufficient. The smallest resolvable switching threshold of the fast channel requires at least 2 edge changes at the selected sensor system within 2 ms. Operating Instructions MOVISAFE UCS.B 187

188 12 Appendix IL code list of MOVISAFE UCS.B 12.4 IL code list of MOVISAFE UCS.B Operator Operand Description LD All input and output operands Sets current result equal to operand. LD NOT All input and output operands Sets current result equal to operand and inverts operand. ST Only output operands Saves current result to operand address. AND All input and output operands Boolean AND. AND NOT All input and output operands Negated Boolean AND. OR All input and output operands Boolean OR. OR NOT All input and output operands Negated Boolean OR. XOR All input and output operands Boolean exclusive OR. NOT All input and output operands Inverted value of the accumulator. SET FLAG PLC_FLAG in output image Sets flag. RESET FLAG PLC_FLAG in output image Reset flag. SET All input and output operands Sets operands to "1". RESET All input and output operands Sets operands to "0". MACRO_INFO Macro element description Operand field: 2 bytes for identification macro. MACRO_CRC CRC of the previous macro field Operand field: 1. Operand: CRC_LO (8 bits) 2. Operand: CRC_HI (8 bits) INFO Info field Operand field: 1. Operand: Reserved 2. Operand: Reserved 188 Operating Instructions MOVISAFE UCS.B

189 Appendix Abbreviations used Abbreviations used Abbreviation Meaning IL Instruction list BG German association for statutory accident insurance and prevention BGIA German central institute for labor protection CLK Clock DC Safety functions: Diagnostic coverage Voltage ratings: DC voltage DI Digital input (binary input) DIN German institute for standardization DO Digital output (binary output) EMU Emergency Monitoring Unit EMC Electromagnetic compatibility EN European standard HTL High transistor logic (on DC 24 V basis) IP20 Degree of protection for housing ISO International Organization for Standardization OLC Operational limit control OSSD Output signal switching device P1, P2 Pulse output 1, 2 PELV Protective extra low voltage PES Programmable electronic system PDM Position deviation mode PLC Programmable logic controller PSC Position speed control SDI Safe direction SEL Safe emergency limit SELV Safety extra low voltage SLI Safe limited increment SLS Safe limited speed SOS Safe operating stop SSX Safe stop, can be parameterized as SS1 or SS2 SSI Synchronous serial interface TTL Transistor-transistor logic Operating Instructions MOVISAFE UCS.B 189

190 12 Appendix Declaration of conformity for MOVISAFE 12.6 Declaration of conformity for MOVISAFE EC Declaration of Conformity SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42, D Bruchsal declares under sole responsibility that the safety components of the series MOVISAFE UCS10B MOVISAFE UCS11B MOVISAFE UCS12B MOVISAFE UCS23B are in conformity with Machinery Directive 2006/42/EC 1) applied harmonized standards EN :2008 5) EN :2007 EN 50178:1997 EN 13850:2006 EN 62061: 2006 EN 574:1996 1) These products are intended for installation in machines. Startup is prohibited until it has been established that the machinery into which these products are to be incorporated complies with the provisions of the aforementioned Machinery Directive. 5) All safety-relevant requirements of the product-specific documentation (operating instructions, manual, etc.) must be met over the entire product life cycle. 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 Operating Instructions MOVISAFE UCS.B

191 Address List Address List Germany Headquarters Production Sales Service Competence Center Bruchsal Central North East South West SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42 D Bruchsal P.O. Box Postfach 3023 D Bruchsal SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 1 D Graben-Neudorf SEW-EURODRIVE GmbH & Co KG Alte Ricklinger Straße D Garbsen (near Hannover) SEW-EURODRIVE GmbH & Co KG Dänkritzer Weg 1 D Meerane (near Zwickau) SEW-EURODRIVE GmbH & Co KG Domagkstraße 5 D Kirchheim (near München) SEW-EURODRIVE GmbH & Co KG Siemensstraße 1 D Langenfeld (near Düsseldorf) Electronics SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42 D Bruchsal Drive Service Hotline / 24 Hour Service Additional addresses for service in Germany provided on request! Tel Fax sew@sew-eurodrive.de Tel Fax sc-mitte@sew-eurodrive.de Tel Fax sc-nord@sew-eurodrive.de Tel Fax sc-ost@sew-eurodrive.de Tel Fax sc-sued@sew-eurodrive.de Tel Fax sc-west@sew-eurodrive.de Tel Fax sc-elektronik@sew-eurodrive.de SEWHELP France Production Sales Service Haguenau SEW-USOCOME route de Soufflenheim B. P F Haguenau Cedex Production Forbach SEW-USOCOME Zone industrielle Technopôle Forbach Sud B. P F Forbach Cedex Assembly Sales Service Bordeaux Lyon Nantes Paris SEW-USOCOME Parc d'activités de Magellan 62 avenue de Magellan - B. P. 182 F Pessac Cedex SEW-USOCOME Parc d'affaires Roosevelt Rue Jacques Tati F Vaulx en Velin SEW-USOCOME Parc d activités de la forêt 4 rue des Fontenelles F Le Bignon SEW-USOCOME Zone industrielle 2 rue Denis Papin F Verneuil I'Etang Additional addresses for service in France provided on request! Tel Fax sew@usocome.com Tel Tel Fax Tel Fax Tel Fax Tel Fax Operating Instructions MOVISAFE UCS.B 191

192 13 Address List Algeria Sales Alger REDUCOM Sarl 16, rue des Frères Zaghnoune Bellevue El Harrach Alger Tel Fax Argentina Assembly Sales Service Buenos Aires SEW EURODRIVE ARGENTINA S.A. Centro Industrial Garin, Lote 35 Ruta Panamericana Km 37, Garin Tel Fax Australia Assembly Sales Service Melbourne SEW-EURODRIVE PTY. LTD. 27 Beverage Drive Tullamarine, Victoria 3043 Tel Fax enquires@sew-eurodrive.com.au Sydney SEW-EURODRIVE PTY. LTD. 9, Sleigh Place, Wetherill Park New South Wales, 2164 Tel Fax enquires@sew-eurodrive.com.au Austria Assembly Sales Service Wien SEW-EURODRIVE Ges.m.b.H. Richard-Strauss-Strasse 24 A-1230 Wien Tel Fax sew@sew-eurodrive.at Belarus Sales Minsk SEW-EURODRIVE BY RybalkoStr. 26 BY Minsk Tel.+375 (17) Fax +375 (17) sales@sew.by Belgium Assembly Sales Service Brussels SEW Caron-Vector Avenue Eiffel 5 BE-1300 Wavre Tel Fax info@sew-eurodrive.be Service Competence Center Industrial Gears SEW Caron-Vector Rue de Parc Industriel, 31 BE-6900 Marche-en-Famenne Tel Fax service-wallonie@sew-eurodrive.be Antwerp SEW Caron-Vector Glasstraat, 19 BE-2170 Merksem Tel Fax service-antwerpen@sew-eurodrive.be Brazil Production Sales Service Sao Paulo SEW-EURODRIVE Brasil Ltda. Avenida Amâncio Gaiolli, Rodovia Presidente Dutra Km 208 Guarulhos SP SAT - SEW ATENDE Tel Fax sew@sew.com.br Bulgaria Sales Sofia BEVER-DRIVE GmbH Bogdanovetz Str.1 BG-1606 Sofia Tel Fax bever@mail.bg 192 Operating Instructions MOVISAFE UCS.B

193 Address List 13 Cameroon Sales Douala Electro-Services Rue Drouot Akwa B.P Douala Tel Fax Canada Assembly Sales Service Toronto Vancouver SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, ON L6T 3W1 SEW-EURODRIVE CO. OF CANADA LTD. Tilbury Industrial Park 7188 Honeyman Street Delta, BC V4G 1G1 Montreal SEW-EURODRIVE CO. OF CANADA LTD Rue Leger Lasalle, PQ H8N 2V9 Additional addresses for service in Canada provided on request! Tel Fax Tel Fax Tel Fax Chile Assembly Sales Service Santiago de Chile SEW-EURODRIVE CHILE LTDA. Las Encinas 1295 Parque Industrial Valle Grande LAMPA RCH-Santiago de Chile P.O. Box Casilla 23 Correo Quilicura - Santiago - Chile Tel Fax ventas@sew-eurodrive.cl China Production Assembly Sales Service Assembly Sales Service Tianjin Suzhou Guangzhou Shenyang Wuhan Xi'An SEW-EURODRIVE (Tianjin) Co., Ltd. No. 46, 7th Avenue, TEDA Tianjin SEW-EURODRIVE (Suzhou) Co., Ltd. 333, Suhong Middle Road Suzhou Industrial Park Jiangsu Province, SEW-EURODRIVE (Guangzhou) Co., Ltd. No. 9, JunDa Road East Section of GETDD Guangzhou SEW-EURODRIVE (Shenyang) Co., Ltd. 10A-2, 6th Road Shenyang Economic Technological Development Area Shenyang, SEW-EURODRIVE (Wuhan) Co., Ltd. 10A-2, 6th Road No. 59, the 4th Quanli Road, WEDA Wuhan SEW-EURODRIVE (Xi'An) Co., Ltd. No. 12 Jinye 2nd Road Xi'An High-Technology Industrial Development Zone Xi'An Additional addresses for service in China provided on request! Tel Fax info@sew-eurodrive.cn Tel Fax suzhou@sew-eurodrive.cn Tel Fax guangzhou@sew-eurodrive.cn Tel Fax shenyang@sew-eurodrive.cn Tel Fax wuhan@sew-eurodrive.cn Tel Fax xian@sew-eurodrive.cn Operating Instructions MOVISAFE UCS.B 193

194 13 Address List Colombia Assembly Sales Service Bogotá SEW-EURODRIVE COLOMBIA LTDA. Calle 22 No Bodega 6, Manzana B Santafé de Bogotá Tel Fax sewcol@sew-eurodrive.com.co Croatia Sales Service Zagreb KOMPEKS d. o. o. Zeleni dol 10 HR Zagreb Tel Fax kompeks@inet.hr Czech Republic Sales Prague SEW-EURODRIVE CZ S.R.O. Business Centrum Praha Lužná 591 CZ Praha 6 - Vokovice Tel Fax sew@sew-eurodrive.cz Denmark Assembly Sales Service Copenhagen SEW-EURODRIVEA/S Geminivej DK-2670 Greve Tel Fax sew@sew-eurodrive.dk Egypt Sales Service Cairo Copam Egypt for Engineering & Agencies 33 EI Hegaz ST, Heliopolis, Cairo Tel Fax copam@datum.com.eg Estonia Sales Tallin ALAS-KUUL AS Reti tee 4 EE Peetri küla, Rae vald, Harjumaa Tel Fax veiko.soots@alas-kuul.ee Finland Assembly Sales Service Lahti SEW-EURODRIVE OY Vesimäentie 4 FIN Hollola 2 Tel Fax sew@sew.fi Production Assembly Karkkila SEW Industrial Gears Oy Valurinkatu 6, PL 8 FI Karkkila, Karkkila Tel Fax sew@sew.fi Gabon Sales Libreville ESG Electro Services Gabun Feu Rouge Lalala 1889 Libreville Gabun Tel Fax esg_services@yahoo.fr Great Britain Assembly Sales Service Normanton SEW-EURODRIVE Ltd. Beckbridge Industrial Estate P.O. Box No.1 Normanton, West-Yorkshire WF6 1QR Tel Fax info@sew-eurodrive.co.uk 194 Operating Instructions MOVISAFE UCS.B

195 Address List 13 Greece Sales Service Athens Christ. Boznos & Son S.A. 12, K. Mavromichali Street P.O. Box GR Piraeus Tel Fax info@boznos.gr Hong Kong Assembly Sales Service Hong Kong SEW-EURODRIVE LTD. Unit No , 8th Floor Hong Leong Industrial Complex No. 4, Wang Kwong Road Kowloon, Hong Kong Tel Fax contact@sew-eurodrive.hk Hungary Sales Service Budapest SEW-EURODRIVE Kft. H-1037 Budapest Kunigunda u. 18 Tel Fax office@sew-eurodrive.hu India Registered Office Assembly Sales Service Vadodara SEW-EURODRIVE India Private Limited Plot No. 4, GIDC POR Ramangamdi Vadodara Gujarat Tel , Fax , sales@seweurodriveindia.com subodh.ladwa@seweurodriveindia.com Assembly Sales Service Chennai SEW-EURODRIVE India Private Limited Plot No. K3/1, Sipcot Industrial Park Phase II Mambakkam Village Sriperumbudur Kancheepuram Dist, Tamil Nadu Tel Fax c.v.shivkumar@seweurodriveindia.com Ireland Sales Service Dublin Alperton Engineering Ltd. 48 Moyle Road Dublin Industrial Estate Glasnevin, Dublin 11 Tel Fax info@alperton.ie Israel Sales Tel-Aviv Liraz Handasa Ltd. Ahofer Str 34B / Holon Tel Fax office@liraz-handasa.co.il Italy Assembly Sales Service Solaro SEW-EURODRIVE di R. Blickle & Co.s.a.s. Via Bernini,14 I Solaro (Milano) Tel Fax sewit@sew-eurodrive.it Ivory Coast Sales Abidjan SICA Société industrielle & commerciale pour l'afrique 165, Boulevard de Marseille 26 BP 1115 Abidjan 26 Tel Fax sicamot@aviso.ci Operating Instructions MOVISAFE UCS.B 195

196 13 Address List Japan Assembly Sales Service Iwata SEW-EURODRIVE JAPAN CO., LTD 250-1, Shimoman-no, Iwata Shizuoka Tel Fax Kazakhstan Sales Almaty ТОО "СЕВ-ЕВРОДРАЙВ" , Республика Казахстан г.алматы, пр.райымбека, 348 Latvia Sales Riga SIA Alas-Kuul Katlakalna 11C LV-1073 Riga Lebanon Sales Beirut Gabriel Acar & Fils sarl B. P Bourj Hammoud, Beirut Jordan Kuwait Saudi Arabia Syria Beirut Middle East Drives S.A.L. (offshore) Sin El Fil. B. P Beirut Lithuania Sales Alytus UAB Irseva Statybininku 106C LT Alytus Тел. +7 (727) Факс +7 (727) Tel Fax info@alas-kuul.com Tel Fax ssacar@info.com.lb Tel Fax info@medrives.com Tel Fax info@irseva.lt Luxembourg Assembly Sales Service Brüssel CARON-VECTOR S.A. Avenue Eiffel 5 B-1300 Wavre Tel Fax info@caron-vector.be Malaysia Assembly Sales Service Johore SEW-EURODRIVE SDN BHD No. 95, Jalan Seroja 39, Taman Johor Jaya Johor Bahru, Johor West Malaysia Tel Fax sales@sew-eurodrive.com.my Mexico Assembly Sales Service Quéretaro SEW-EURODRIVE MEXICO SA DE CV SEM M93 Tequisquiapan No. 102 Parque Industrial Quéretaro C.P Quéretaro, México Tel Fax scmexico@seweurodrive.com.mx Morocco Sales Casablanca Afit Route D El Jadida KM 14 RP8 Province de Nouaceur Commune Rurale de Bouskoura MA Casablanca Tel Fax fatima.haquiq@premium.net Operating Instructions MOVISAFE UCS.B

197 Address List 13 Netherlands Assembly Sales Service Rotterdam VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS Rotterdam Postbus NL-3004 AB Rotterdam Tel Fax New Zealand Assembly Sales Service Auckland SEW-EURODRIVE NEW ZEALAND LTD. P.O. Box Greenmount drive East Tamaki Auckland Tel Fax sales@sew-eurodrive.co.nz Christchurch SEW-EURODRIVE NEW ZEALAND LTD. 10 Settlers Crescent, Ferrymead Christchurch Tel Fax sales@sew-eurodrive.co.nz Norway Assembly Sales Service Moss SEW-EURODRIVE A/S Solgaard skog 71 N-1599 Moss Tel Fax sew@sew-eurodrive.no Pakistan Sales Karachi Industrial Power Drives Al-Fatah Chamber A/3, 1st Floor Central Commercial Area, Sultan Ahmed Shah Road, Block 7/8, Karachi Tel Fax seweurodrive@cyber.net.pk Peru Assembly Sales Service Lima SEW DEL PERU MOTORES REDUCTORES S.A.C. Los Calderos, Urbanizacion Industrial Vulcano, ATE, Lima Tel Fax sewperu@sew-eurodrive.com.pe Poland Assembly Sales Service Lodz SEW-EURODRIVE Polska Sp.z.o.o. ul. Techniczna 5 PL Łódź Tel Fax sew@sew-eurodrive.pl 24 Hour Service Tel ( SEW SEW) serwis@sew-eurodrive.pl Portugal Assembly Sales Service Coimbra SEW-EURODRIVE, LDA. Apartado 15 P Mealhada Tel Fax infosew@sew-eurodrive.pt Romania Sales Service Bucharest Sialco Trading SRL str. Madrid nr Bucuresti Tel Fax sialco@sialco.ro Russia Assembly Sales Service St. Petersburg ZAO SEW-EURODRIVE P.O. Box St. Petersburg Russia Tel Fax sew@sew-eurodrive.ru Operating Instructions MOVISAFE UCS.B 197

198 13 Address List Senegal Sales Dakar SENEMECA Mécanique Générale Km 8, Route de Rufisque B.P. 3251, Dakar Serbia Sales Beograd DIPAR d.o.o. Ustanicka 128a PC Košum, IV floor SCG Beograd Tel Fax Tel / Fax office@dipar.rs Singapore Assembly Sales Service Singapore SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore Tel Fax sewsingapore@sew-eurodrive.com Slovakia Sales Bratislava SEW-Eurodrive SK s.r.o. Rybničná 40 SK Bratislava Žilina Banská Bystrica Košice SEW-Eurodrive SK s.r.o. Industry Park - PChZ ulica M.R.Štefánika 71 SK Žilina SEW-Eurodrive SK s.r.o. Rudlovská cesta 85 SK Banská Bystrica SEW-Eurodrive SK s.r.o. Slovenská ulica 26 SK Košice Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk Slovenia Sales Service Celje Pakman - Pogonska Tehnika d.o.o. UI. XIV. divizije 14 SLO Celje Tel Fax pakman@siol.net South Africa Assembly Sales Service Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED Eurodrive House Cnr. Adcock Ingram and Aerodrome Roads Aeroton Ext. 2 Johannesburg 2013 P.O.Box Bertsham 2013 Tel Fax info@sew.co.za Cape Town SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow Park Cnr. Racecourse & Omuramba Road Montague Gardens Cape Town P.O.Box Chempet 7442 Cape Town Tel Fax Telex cfoster@sew.co.za 198 Operating Instructions MOVISAFE UCS.B

199 Address List 13 South Africa Durban SEW-EURODRIVE (PROPRIETARY) LIMITED 2 Monaco Place Pinetown Durban P.O. Box 10433, Ashwood 3605 Tel Fax cdejager@sew.co.za Nelspruit SEW-EURODRIVE (PTY) LTD. 7 Christie Crescent Vintonia P.O.Box 1942 Nelspruit 1200 Tel Fax robermeyer@sew.co.za South Korea Assembly Sales Service Ansan-City SEW-EURODRIVE KOREA CO., LTD. B 601-4, Banweol Industrial Estate , Shingil-Dong Ansan Tel Fax master.korea@sew-eurodrive.com Busan SEW-EURODRIVE KOREA Co., Ltd. No , Songjeong - dong Gangseo-ku Busan Tel Fax master@sew-korea.co.kr Spain Assembly Sales Service Bilbao SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302 E Zamudio (Vizcaya) Tel Fax sew.spain@sew-eurodrive.es Sweden Assembly Sales Service Jönköping SEW-EURODRIVE AB Gnejsvägen 6-8 S Jönköping Box 3100 S Jönköping Tel Fax jonkoping@sew.se Switzerland Assembly Sales Service Basel Alfred lmhof A.G. Jurastrasse 10 CH-4142 Münchenstein bei Basel Tel Fax info@imhof-sew.ch Thailand Assembly Sales Service Chonburi SEW-EURODRIVE (Thailand) Ltd. 700/456, Moo.7, Donhuaroh Muang Chonburi Tel Fax sewthailand@sew-eurodrive.com Tunisia Sales Tunis T. M.S. Technic Marketing Service Zone Industrielle Mghira 2 Lot No Fouchana Tel Fax tms@tms.com.tn Turkey Assembly Sales Service Istanbul SEW-EURODRIVE Hareket Sistemleri San. ve Tic. Ltd. Sti. Bagdat Cad. Koruma Cikmazi No. 3 TR Maltepe ISTANBUL Tel / Fax sew@sew-eurodrive.com.tr Operating Instructions MOVISAFE UCS.B 199

200 13 Address List Ukraine Sales Service Dnepropetrovsk SEW-EURODRIVE Str. Rabochaja 23-B, Office Dnepropetrovsk Tel Fax USA Production Assembly Sales Service Corporate Offices Assembly Sales Service Southeast Region Northeast Region Midwest Region Southwest Region SEW-EURODRIVE INC Old Spartanburg Highway P.O. Box 518 Lyman, S.C SEW-EURODRIVE INC. Pureland Ind. Complex 2107 High Hill Road, P.O. Box 481 Bridgeport, New Jersey SEW-EURODRIVE INC West Main Street Troy, Ohio SEW-EURODRIVE INC Platinum Way Dallas, Texas Western Region SEW-EURODRIVE INC San Antonio St. Hayward, CA Additional addresses for service in the USA provided on request! Tel Fax Sales Fax Manufacturing Fax Assembly Fax Confidential/HR Tel Fax Tel Fax Tel Fax Tel Fax Venezuela Assembly Sales Service Valencia SEW-EURODRIVE Venezuela S.A. Av. Norte Sur No. 3, Galpon Zona Industrial Municipal Norte Valencia, Estado Carabobo Tel Fax Vietnam Sales Ho Chi Minh City Nam Trung Co., Ltd Tran Minh Quyen Street, District 10, HCMC Tel Fax namtrungco@hcm.vnn.vn 200 Operating Instructions MOVISAFE UCS.B

201 Index Index A Abbreviations used Alarm messages Appendix Abbreviations used Declaration of conformity for MOVISAFE Description of input elements Diagnostic values IL code list of MOVISAFE UCS.B Response times of MOVISAFE B Backplane bus connectors...41 Binary input connection Dual-channel sensor, monitored...61 Dual-channel sensor, not monitored...60 Single-channel sensor, monitored...59 Single-channel sensor, not monitored...58 Use of the pulse outputs P1 and P Binary inputs, connection...53 C Characteristic safety values of MOVISAFE UCS10B Characteristic safety values of MOVISAFE UCS11B Characteristic safety values of MOVISAFE UCS12B Characteristic safety values of MOVISAFE UCS23B Combination of various encoder types...85 Communication and establishing a connection RS485 interface X Configuration of the measuring sections Conversion example Conversion factors Measuring error during speed measurement Configuration report Creation Entries Structure Confirmation button Connecting a motor encoder...89 Connecting an absolute encoder...93 Connecting position and velocity sensors Combination of various encoder types...85 Connection Basic modules UCS10B/11B/12B...45 Diagnostic module UCS25B...50 Expansion module UCS23B...48 HTL proximity sensor...87 Connection of binary outputs at the basic module Connection of auxiliary output...73 Dual-channel switching binary output monitored...69 Dual-channel switching binary output not monitored...68 Dual-channel switching relay output monitored...72 Single-pole switching binary output monitored...67 Single-pole switching binary output not monitored...66 Single-pole switching relay output monitored...71 Single-pole switching relay output not monitored...70 Using the safe outputs to control the safe stop..74 Connection of outputs at the basic module...65 Connection of outputs at the expansion module...76 Connection of auxiliary output...82 Dual-channel switching binary output monitored...81 Dual-channel switching binary output not monitored...80 Single-channel switching binary output monitored...79 Single-channel switching binary output not monitored...78 Connection of position and velocity sensors...83 Prefabricated cables...88 Copyright...9 D DAE50B...92 DAE51B...92 DAE52B...90 DAE53B...90 DAE54B...94 DAE55B...98 DAE56B DAE57B...99 DAE58B DAE59B DAE60B Operating Instructions MOVISAFE UCS.B 201

202 Index DAE61B...96 Declaration of conformity for MOVISAFE Definitions...12 Designated use...11 Determining/checking the response times Diagnostic module UCS23B with CAN interface Structure of CAN telegram Structure of CAN telegram Diagnostic values Binary inputs Binary outputs Encoder interface Diagnostics Alarm messages Diagnostic module UCS23B with CAN interface ECS messages Error and alarm messages Meaning of the status LED Meaning of the 7-segment display Dimension drawing Support rail...39 UCS.B Disassembly MOVISAFE UCS.B, step-by-step...44 Door monitoring E ECS messages Electrical connection Safety notes...12 Electrical installation...45 Binary input connection...53 Connection and terminal description for diagnostic module UCS25B...50 Connection and terminal description for expansion module UCS23B...48 Connection and terminal description of basic module UCS10B/11B/12B...45 Connection of position and velocity sensors...83 External DC 24 V supply...51 Measures for electromagnetic compatibility...51 Wiring of the binary outputs...62 Electromagnetic compatibility, measures...51 Emergency stop Error and alarm messages Display options List of error messages Error messages Exclusion of liability...9 External DC 24 V supply...51 External encoder voltage supply...52 G General information...8 Copyright...9 Other applicable documentation...9 General notes Exclusion of liability...9 Right to claim under warranty...9 General technical data I IL code list of MOVISAFE UCS.B Input elements Confirmation button Description Door monitoring Emergency stop Light curtain Operating mode selection switch Sensor Start/reset Two-hand button Installation Electrical...45 Mechanical...38 MOVISAFE UCS.B, step-by-step...43 Installation clearance...39 Installation notes...11 Installation notes UCS.B...38 Integrated safety technology...13 General structure and safety technology architecture...13 Safety functions...15 L LED display...104, 105 LED IN , 105 LED OUT K1, K LED P1, P Status LED...104, 105 Light curtain Operating Instructions MOVISAFE UCS.B

203 Index M Maintenance Disposal Modification/changes to the unit Replacement of the basic module Replacing an SSI absolute encoder Replacing the diagnostic module Replacing the expansion module Servicing Meaning of the signal words...8 Mechanical installation...38 Backplane bus connectors...41 Dimension drawing for support rail...39 Expansion options...40 General installation notes...38 Installation clearance...39 Installation notes...38 Step-by-step disassembly of MOVISAFE UCS.B...44 Step-by-step installation of MOVISAFE UCS.B...43 MOVISAFE UCS10B, unit design...33 MOVISAFE UCS11B, unit design...34 MOVISAFE UCS12B, unit design...35 MOVISAFE UCS23B, unit design...36 MOVISAFE UCS25B, unit design...37 MOVISAFE UCS.B Step-by-step disassembly...44 Step-by-step installation...43 N Nameplate of MOVISAFE UCS.B...32 O Operating instructions, use...8 Operating mode selection switch Operating states LED displays...104, 105 Switch-on sequences Operation Safety notes...12 Other applicable documentation...9 P Part number Basic modules UCS10B/11B/12B...45 Diagnostic module UCS25B...50 Expansion module UCS23B...48 Plug connectors of basic module Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X7/X Plug connectors of diagnostic module Connector assignment X Plug connectors of expansion module Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Connector assignment X Prefabricated cables...88 Connecting a motor encoder...89 Connecting an absolute encoder...93 Connection of an external encoder...91 Connection of TTL incremental encoder simulation DAE50B...92 DAE51B...92 DAE52B...90 DAE53B...90 DAE54B...94 DAE55B...98 DAE56B DAE57B...99 DAE58B DAE59B DAE60B DAE61B...96 Direct connection of an encoder...99 Overview...88 R Replacement of the basic module Replacing an SSI absolute encoder When position processing is active When position processing is inactive Operating Instructions MOVISAFE UCS.B 203

204 Index Replacing the diagnostic module Replacing the expansion module Response times of MOVISAFE Calculating the response time with overspeed distance monitoring Fast channel Right to claim under warranty...9 S Safe Brake Control (SBC)...29 Safe Cam (SCA)...28 Safe Direction (SDI)...24, 25 Safe Operating Stop (SOS)...20 Safe Stop 1 (SS1b)...16 Safe Stop 1 (SS1c)...17 Safe Stop 2 (SS2b)...18 Safe Stop 2 (SS2c)...19 Safe Torque Off (STO)...15 Safely Limited Acceleration (SLA)...21, 22 Safely Limited Increment (SLI)...26 Safely Limited Position (SLP)...27 Safely Limited Speed (SLS)...23 Safety function Safely Limited Acceleration (SLA)...21 Safety functions...15 Limitations...30 Safe Brake Control (SBC)...29 Safe Cam (SCA)...28 Safe Direction (SDI)...24, 25 Safe Operating Stop (SOS)...20 Safe Stop 1 (SS1b)...16 Safe Stop 1 (SS1c)...17 Safe Stop 2 (SS2b)...18 Safe Stop 2 (SS2c)...19 Safe Torque Off (STO)...15 Safely Limited Acceleration (SLA)...22 Safely Limited Increment (SLI)...26 Safely Limited Position (SLP)...27 Safely Limited Speed (SLS)...23 Safety notes...10 Definitions...12 Designated use...11 Electrical connection...12 General...10 Installation...11 Operation...12 Structure...8 Structure of section safety notes...8 Structure of the embedded safety notes...8 Target group...10 Transportation, storage...11 Scope of delivery of MOVISAFE UCS.B...31 Servicing Signal word, meaning...8 Startup Communication and establishing a connection Configuration of measuring sections General information Operating states Requirements Startup steps Storage notes...11 Structure of safety section notes...8 Switch-on sequences T Target groups...10 Technical data Characteristic safety values of MOVISAFE UCS10B Characteristic safety values of MOVISAFE UCS11B Characteristic safety values of MOVISAFE UCS12B Characteristic safety values of MOVISAFE UCS23B Dimension drawing General technical data Plug connectors of basic module Plug connectors of diagnostic module Plug connectors of expansion module SEW encoders Operating Instructions MOVISAFE UCS.B

205 Index Technical data of SEW encoders Combination encoders Hiperface and sin/cos) Combination encoders RS485 and sin/cos Combination encoders SSI and sin/cos SIN/COS encoder TTL incremental encoder Terminal description Basic modules UCS10B/11B/12B...46 Diagnostic module UCS25B...50 Expansion module UCS23B...49 Transportation notes...11 Two-hand button U Unit design of MOVISAFE UCS.B...31 Basic module UCS10B...33 Basic module UCS11B...34 Basic module UCS12B...35 Diagnostic module UCS25B...37 I/O expansion module UCS23B...36 Nameplate...32 Scope of delivery...31 Unit properties of MOVISAFE UCS.B...31 Unit replacement MOVISAFE Replacement of the basic module Replacing the diagnostic module Replacing the expansion module Use of the operating instructions...8 V Validation Configuration report Determining/checking the response times Function test Procedure Validation of the performance level Validation of the performance level W Wiring of the binary outputs segment display, meaning Operating Instructions MOVISAFE UCS.B 205

206 SEW-EURODRIVE Driving the world SEW-EURODRIVE Driving the world SEW-EURODRIVE GmbH & Co KG P.O. Box 3023 D Bruchsal/Germany Phone Fax