Manual. MOVIDRIVE MDX61B Safety Module Option DCS21B/31B. Edition 03/ / EN

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ s MOVIDRIVE MDX61B Safety Module Option DCS21B/31B Edition 03/ / EN Manual

2 SEW-EURODRIVE Driving the world

3 1 General Notes Structure of the safety notes Rights to claim under limited warranty Exclusion of liability Other applicable documentation Safety Notes General Target group Designated use Transportation, storage Installation Electrical connection Operation Definitions Other applicable documentation TÜV certificate Unit Design Unit designations and features Nameplate Unit design of DCS21B Unit design of DCS31B Installation General installation notes Installation of the DCS21B/31B option card Connection and terminal description of option DCS21B/31B Measures for electromagnetic compatibility (EMC) External DC 24 V voltage supply Connection of binary inputs DI1 to DI Using the clock outputs P1 and P Single-channel sensor, untested Dual-channel sensor, untested Single-channel sensor, tested Dual-channel sensor, tested Connection of binary outputs Use of the binary outputs DO2_P and DO2_M Single-pole switching P binary output without test Single-pole switching M binary output without test Dual-channel switching binary output DO0 with external monitoring Dual-channel switching binary output DO0 with external monitoring Connection of position and velocity sensors Combination of different encoder types Configuration of measuring sections Prefabricated cables Encoder wiring diagrams Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 3

4 5 Startup General startup instructions Parameter descriptions Switch-on sequences Connection to PROFINET with PROFIsafe Setting the PROFIsafe address in the slave Validation report Validation Procedure Maintenance Maintenance Changes to the unit Disposal MOVIDRIVE B unit replacement Replacing the inverter Replacing the DCS..B option Diagnostics Meaning of the status LED Error and alarm classes Error messages Alarm messages Technical Data Plug connectors Appendix Safety characteristics of DCS21B/31B Response times of the DCS21B option Response times of the DCS31B option Description of the input elements List of encoders recommended by SEW-EURODRIVE Additional features: Encoder Suitable absolute encoders for master and slave mode Index Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

5 General Notes Structure of the safety notes 1 Handbuch 1 General Notes 1.1 Structure of the safety notes The safety notes in this manual are designed as follows: Symbol SIGNAL WORD Nature and source of hazard. Possible consequence(s) if disregarded. Measure(s) to avoid the hazard. Symbol Signal word Meaning Consequences if disregarded Example: HAZARD Imminent hazard Severe or fatal injuries General hazard WARNING! Possible hazardous situation Severe or fatal injuries CAUTION! Possible hazardous situation Minor injuries Specific hazard, e.g. electric shock STOP! Possible damage to property Damage to the drive system or its environment NOTE Useful information or tip. Simplifies handling of the drive system. 1.2 Rights to claim under limited 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 manual. Therefore, read the manual before you start operating the unit! Make sure that the manual is available to persons responsible for the plant and its operation, as well as to person who work independently on the unit. You must also ensure that the documentation is legible. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 5

6 General Notes 1 Exclusion of liability 1.3 Exclusion of liability You must comply with the information contained in this manual to ensure safe operation of the DCS21B/31B option and to achieve the specified product characteristics and performance requirements. SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of this manual. In such cases, any liability for defects is excluded. 1.4 Other applicable documentation Installation and startup only by trained personnel observing the relevant accident prevention regulations and the following documents: "MOVIDRIVE MDX60B / 61B operating instructions "MOVIDRIVE MDX61B Fieldbus Interface DFS22B PROFINET IO with PROFIsafe" manual Read through this manual carefully before you commence installation and startup of the DCS21B/31B option. As a prerequisite to fault-free operation and fulfillment of warranty claims, you must adhere to the information in the documentation. 6 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

7 Safety Notes General 2 2 Safety Notes The following basic safety notes are intended to prevent injury to persons and damage to property. The operator must make sure that the basic safety notes are read and observed. Make sure that persons responsible for the plant and its operation, as well as persons who work independently on the unit, have read through the operating instructions carefully and understood them. If you are unclear about any of the information in this documentation, or if you require further information, please contact SEW- EURODRIVE. 2.1 General Never install damaged products or take them into operation. Submit a complaint to the shipping company immediately in the event of damage. During operation, drive inverters can have live, bare and movable or rotating parts as well as hot surfaces, depending on their enclosure. Removing covers without authorization, improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to property. Consult the documentation for additional information. 2.2 Target group Only qualified personnel are authorized to install, startup or service the units or correct unit faults (observe IEC or CENELEC HD 384 or DIN VDE 0100 and IEC or DIN VDE 0110 as well as national accident prevention guidelines). Qualified personnel in the context of these basic safety notes are: All persons familiar with installation, assembly, startup, programming, parameter setting and operation of the product who possess the necessary qualifications. In addition to that, they must be familiar with the relevant safety regulations and laws, especially with the requirements of category 4 according to EN and all other standards, directives and laws specified in this documentation. These persons must be explicitly authorized by the company to startup, program, parameterize, label and ground units, systems and circuits in accordance with the safety technology standards. All activity in the other areas of transportation, storage, operation, and disposal must be carried out by persons who are appropriately trained. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 7

8 Safety Notes 2 Designated use 2.3 Designated use Option DCS21B in combination with option DFS22B and option DCS31B are designed for installation in MOVIDRIVE MDX61B inverters size 1 to 6. In case of installation in machines, startup of option DCS21B/31B (i.e. start of designated operation) is prohibited until it is determined that the machine meets the requirements stipulated in the EC Directive 98/37/EC (machine guideline); observe EN Startup (i.e. start of designated operation) is only permitted with adherence to the EMC guideline (89/336/EEC). The EMC test specifications EN , EN , EN , EN and EN form the basis for this. Technical data and information on the connection requirements are provided on the nameplate and in the documentation; these must be observed under all circumstances. 2.4 Transportation, storage You must observe the notes on transportation, storage and proper handling. Observe the climatic conditions as stated in the chapter "Technical Data." 2.5 Installation The units must be installed and cooled according to the regulations and specifications in the relevant documentation. Protect the DCS21B/31B option from improper strain. Especially during transportation and handling, do not allow the components to be deformed or insulation spaces altered. Avoid contact with electronic components and contacts. Option DCS21B/31B contains components that can easily be damaged by electrostatic energy and improper handling. Prevent mechanical damage or destruction of electric components (may pose health risk). The following applications are prohibited unless the unit is explicitly designed for such use: Use in potentially explosive areas Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc. Use in non-stationary applications. 2.6 Electrical connection Observe the applicable national accident prevention guidelines when working on live DCS21B/31B options (e.g. BGV A3). Perform electrical installation according to the pertinent regulations (e.g. cable cross sections, fusing, protective conductor connection). Additional information is contained in the 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). 8 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

9 Safety Notes Operation Operation Systems into which MOVIDRIVE MDX61B with option DCS21B/31B is installed must be equipped with additional monitoring and protection devices, if necessary, according to the applicable safety regulations; e.g. 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 mains and no longer carries any voltage. Mechanical blocking or internal safety functions of the unit can cause a motor standstill. Eliminating the cause of the problem or performing a reset can result in the drive re-starting automatically. If, for safety reasons, this is not permitted for the driven machine, disconnect the unit from the mains before correcting the fault. 2.8 Definitions The designation MOVISAFE is used as a generic term for all derivatives of the MOVISAFE 100B product series. If the manual refers to a certain derivative, the full designation is used. The term "safe" used in this manual refers to the classification as a safe function according to EN PROFIsafe is a technology standard for a safe fieldbus system. The "MOVISAFE ASSIST" system software is a configuration tool for MOVISAFE. The "MOVISAFE CONFIG" parameter setting software is a programing and configuration tool for MOVISAFE. 2.9 Other applicable documentation Description Reference Configuration of the MOVISAFE DCS31B (without fieldbus) using the "MOVISAFE CONFIG" parameter setting software. Configuration of MOVISAFE DCS21B for fieldbus applications with the "MOVISAFE ASSIST" program. Validation report of the implemented parameterization MOVISAFE CONFIG online help ( MOVISAFE Software ROM, Edition 02/2007, part number ) MOVISAFE ASSIST online help ( MOVISAFE Software ROM, Edition 02/2007, part number ) Safety check. This can be generated by the MOVISAFE CONFIG/ASSIST parameter setting software and serves as acceptance protocol. Acceptance TÜV certificate for DCS21B/31B ( MOVISAFE Software ROM, Edition 02/2007, part number ) Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 9

10 Safety Notes 2 TÜV certificate 2.10 TÜV certificate 60048AXX 10 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

11 Unit Design Unit designations and features 3 3 Unit Design 3.1 Unit designations and features DCS21B Velocity monitoring: Speed monitoring Standstill monitoring Direction monitoring Emergency stop monitoring Position monitoring: Position range monitoring Travel range monitoring Target position monitoring 8 digital inputs 2 cycle outputs 6 digital auxiliary outputs Encoder interface SSI / incremental / sin/cos Diagnostics and configuration interface Fieldbus interface CAN NOTE Option DCS21B can only be used in combination with option DFS22B. DCS31B Velocity monitoring: Speed monitoring Standstill monitoring Direction monitoring Emergency stop monitoring Position monitoring: Position range monitoring Travel range monitoring Target position monitoring 8 digital inputs 2 cycle outputs 6 digital auxiliary outputs Encoder interface SSI / incremental / sin/cos Diagnostics and configuration interface Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 11

12 Unit Design 3 Nameplate 3.2 Nameplate Nameplate of DCS21B/31B MOVIDRIVE MDX61B with installed DCS21B/31B option is supplied with two nameplates. The first nameplate (e.g DCS31B following figure) is attached to the contact spring strip of the DCS21B/31B option. It lists the part number and the serial number of the DCS21B/31B option AXX MOVIDRIVE nameplate The second nameplate (e.g. DCS31B following figure) is attached to the MOVI- DRIVE MDX61B. It contains the following information: Unit designation Part number Serial number Input data Version status Reference to the response times in the manual Permitted standards 59492AXX NOTE If option DCS21B/31B is delivered separately, you must attach the supplied nameplate to the MOVIDRIVE MDX61B. 12 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

13 Unit Design Unit design of DCS21B Unit design of DCS21B DCS21B [1] [2] [3] [4] [5] [6] [10] [7] X86 [8] [9] 62115AXX [1] Status LED: Alarm/error Status LED: Watchdog Status LED: System B Status LED: System A [2] X80: DC 24 V voltage supply connection [3] X81: Connection for binary inputs DI1... DI8 and clock signals P1, P2 [4] X82: Connection of binary outputs DO0 / DO1 [5] X83: Connection of binary output DO2 [6] X84: Connection of incremental, sin/cos or absolute encoder (SSI) [7] X85: Connection of incremental, sin/cos or absolute encoder (SSI) [8] X86: Connection of CAN interface [9] X87: Connection of service interface [10] Prefabricated cable DAE34B (part number: ) for CAN bus connection between DCS21B X86 and X31 of the DFS22B option. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 13

14 Unit Design 3 Unit design of DCS31B 3.4 Unit design of DCS31B DCS31B [1] [2] [3] [4] [5] [6] [7] [8] 59385AXX [1] Status LED: Alarm/error Status LED: Watchdog Status LED: System B Status LED: System A [2] X80: DC 24 V voltage supply connection [3] X81: Connection for binary inputs DI1... DI8 and clock signals P1, P2 [4] X82: Connection of binary outputs DO0 / DO1 [5] X83: Connection of binary output DO2 [6] X84: Connection of incremental, sin/cos or absolute encoder (SSI) [7] X85: Connection of incremental, sin/cos or absolute encoder (SSI) [8] X87: Connection of service interface 14 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

15 Installation General installation notes 4 4 Installation 4.1 General installation notes NOTES Signal cables for addressing the binary inputs and contact monitoring must be routed separately. It is essential to route power cables and signal cables separately as well. The cables connected to outputs X82 and X83 may not exceed 30 m. 4.2 Installation of the DCS21B/31B option card NOTES Option DCS21B/31B can only be installed in MOVIDRIVE MDX61B size 1 to 6, but not in size 0. Option DCS21B can only be used in combination with the DFS22B fieldbus interface option. Option DCS21B must be installed in the expansion slot and option DFS22B in the fieldbus slot ( following figure). MOVIDRIVE MDX61B BG1-6 DCS21B DFS22B DCS21B/31B X AXX Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 15

16 Installation 4 Installation of the DCS21B/31B option card Before you begin Read the following notes before installing or removing an option card: STOP! Electrostatic charge. Damage to electronic components. Disconnect the inverter from the power. Switch off the DC 24 V and the supply voltage. Take appropriate measures to protect the option card from electrostatic charge (use discharge strap, conductive shoes, etc.) before touching it. Before installing the option card, remove the keypad ( MOVIDRIVE MDX60B/61B operating instructions, chapter "Removing/ installing the keypad") and the front cover ( MOVIDRIVE MDX60B/61B operating instructions, chapter "Removing/installing the front cover"). After installing the option card, install the front cover ( MOVIDRIVE MDX60B/61B operating instructions, chapter "Removing/ installing the front cover") and the keypad ( MOVIDRIVE MDX60B/61B operating instructions, chapter "Removing/installing the keypad"). Keep the option card in its original packaging until immediately before you are ready to install it. Hold the option card by its edges only. Do not touch any components. 16 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

17 Installation Installation of the DCS21B/31B option card 4 Basic procedure for installing/removing an option card (MDX61B, sizes 1-6) AXX 1. Remove the retaining screws holding the card retaining bracket. Pull the card retaining bracket out evenly from the slot (do not twist). 2. Remove the retaining screws of the black cover plate on the card retaining bracket. Remove the black cover plate. 3. Position the option card onto the retaining bracket so that the retaining screws fit into the corresponding bores on the card retaining bracket. 4. Insert the retaining bracket with installed option card into the slot, pressing slightly so it is seated properly. Secure the card retaining bracket with the retaining screws. 5. To remove the option card, follow the instructions in reverse order. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 17

18 Installation 4 Connection and terminal description of option DCS21B/31B 4.3 Connection and terminal description of option DCS21B/31B Part numbers DCS21B safety module option: Completely prefabricated cable DAE34B (CAN bus connection between DCS21B X86 and DFS22B X31): DCS31B safety module option: NOTES Option DCS21B/31B can only be installed in connection with MOVIDRIVE MDX61B sizes 1 to 6. Option DCS21B can only be used in combination with the DFS22B fieldbus interface. Option DCS21B/31B must be inserted in the expansion slot. Option DCS21B/31B must be supplied with DC 24 V. The total current consumption is DC 2 A. DCS21B DCS31B X87 X86 X83 X82 X81 X80 X83 X82 X81 X80 F WD B A X X X X87 A/F WD B A X AXX 18 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

19 Installation Connection and terminal description of option DCS21B/31B 4 Terminal description Description LED alarm/error LED watchdog LED system B LED system A LED/ Terminal LED A/F LED WD LED B LED A X80: Power supply connection X80:1 X80:2 X81: Connection binary inputs X81:1 P1 X81:2 DI1 X81:3 DI2 X81:4 DI3 X81:5 DI4 X81:6 P2 X81:7 DI5 X81:8 DI6 X81:9 DI7 X81:10 DI8 X82: Connection of binary outputs DO0, DO1 X82:1 DO0_P X82:2 DO0_M X82:3 DO1_P X82:4 DO1_M X83: Connection of binary output DO2 X83:1 DO2_P X83:2 DO2_M X84: Connection of incremental, sin/cos or absolute encoder (encoder 1) X85: Connection of incremental, sin/cos or absolute encoder (encoder 2) X84:1 X84:2 X84:3 X84:4 X84:5 X84:6 X84:7 X84:8 X84:9 X85:1 X85:2 X85:3 X85:4 X85:5 X85:6 X85:7 X85:8 X85:9 X86: CAN bus connection (only for DCS21B) X86:1 X86:2 X86:3 Function The LEDs show the current status of option DCS21B/31B. ( chapter "Local diagnostics") DC 24 V Reference potential 0V24 Clock signal 1 for safe inputs; DC 24 V clocked Binary input 1 Binary input 2 Binary input 3 Binary input 4 Clock signal 2 for safe inputs; DC 24 V clocked Binary input 5 Binary input 6, reserved for reset (only for DCS31B) Binary input 7 Binary input 8 HISIDE output 0 LOSIDE output 0 HISIDE output 1 LOSIDE output 1 HISIDE output 2 LOSIDE output 2 Assignment depends on connected encoder ( chapter "Technical Data") Assignment depends on connected encoder ( chapter "Technical Data") CAN High CAN Low DGND X87: Connection of service interface X87 interface Baud rate: 38.4 kbaud For point-to-point connection only Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 19

20 Installation 4 Measures for electromagnetic compatibility (EMC) 4.4 Measures for electromagnetic compatibility (EMC) Option DCS21B/31B is intended for industrial use (based on the EMC test specifications EN ). A prerequisite is that electromagnetic compatibility of the overall system is ensured by means of pertinent measures. The following measures ensure designated operation of DCS21B/31B: Make sure that the power supply cables of option DCS21B/31B and "switching cables" of MOVIDRIVE MDX61B are routed separately. Route signal cables and power cables of the inverter in separate cable ducts. The minimum distance between the cable ducts should be 10 mm. Use only 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 metallic or metallized connectors are permitted. Ensure EMC-compliant installation of the inverter near the DCS31B. Pay special attention to cable routing and shield installation for the motor cable and the braking resistor connection. All contactors near the DCS21B/31B must be equipped with suitable suppressors. Equipotential bonding For EMC-compliant equipotential bonding, the DCS21B/31B option must be connected as follows after it has been installed in MOVIDRIVE B. If MOVIDRIVE MDX61B is already equipped with a tapped hole (figure I, pos. [1]), connect the tapped hole with X80:2 of the DCS21B/31B option and with X10:10 of MOVIDRIVE MDX61B. Use a M4 x 8 or M4 x 10 grounding screw (not included in the scope of delivery) for the tapped hole (tightening torque Nm). If MOVIDRIVE MDX61B has no tapped hole (see figure II), connect X80:2 with the retaining screw of the card retaining bracket (figure II, pos. [1]) and X10:10 with PE (figure II, pos [2]) by the shortest possible route. I MOVIDRIVE MDX61B BG1-6 DCS21B X80 : 2 II MOVIDRIVE MDX61B BG1-6 [1] DCS21B X80 : 2 DCS21B/31B DCS21B/31B [1] X86 X86 X10 : 10 X10 : 10 [2] 63213AXX 20 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

21 Installation External DC 24 V voltage supply External DC 24 V voltage supply Option DCS21B/31B requires a DC 24 V voltage supply (SELV or PELV, EN 50178). Take the following limiting conditions into account for configuration and installation of the designated power supply unit: It is essential to 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 the DCS21B/31B option not only supplies internal electronic components, but also the external velocity and position sensors. These have no separate short circuit protection. The current consumption of the encoders used should not exceed DC 300 ma. When using encoders with higher operating currents, the encoder voltage supply must be provided separately. Safe electrical isolation against the voltage supply system (e.g. AC 230 V) must be ensured at any rate. 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. Protect option DCS31B externally with a 2 A fuse. Observe local regulations when dimensioning the connection cables. Option DCS21B/31B is immune to interference voltages up to DC 32 V. 4.6 Connection of binary inputs DI1 to DI8 Option DCS21B/31B is equipped with 8 binary inputs (DI1... DI8). They are suitable for connecting single- or dual-channel sensors with or without clocking. NOTE You must configure the binary input DI6 of the DCS31B option as reset input to be able to acknowledge occurring error messages. The connected signals must have a "High" level of DC 24 V (DC +15 V... DC +30 V) and a "Low" level of DC 0 V (DC 3 V... DC +5 V). The inputs are equipped with input filters. An integrated diagnostic function cyclically tests whether the binary inputs and input filters are functioning correctly. If an error is detected, the DCS31B option switches to alarm status and indicates this ( chapter "Local diagnostics"). Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 21

22 Installation 4 Connection of binary inputs DI1 to DI Using the clock outputs P1 and P2 In addition to the binary inputs DI1 to DI8, option DCS21B/31B offers two clock outputs P1 and P2. The P1 and P2 clock outputs are switching DC 24 V outputs that are intended exclusively for monitoring the binary inputs (DI1... DI8). The clock outputs may not be used for other functions within the application. The switching frequency is 240 Hz (stand-alone) for each clock output. Take into account for project planning that the overall current at the outputs may not exceed 300 ma. NOTE When not using the clock, the binary inputs can be used with single-channel, self-monitoring sensors in line with EN up to category 2. With dual-channel sensors and a function test within 24 hours, category 4 can be achieved without clocking. Without a function test within 24 hours, category 3 can be achieved. Note that external measure, especially suitable cable routing, must be employed to prevent a short circuit in the external wiring between different inputs and against the supply voltage of the DCS21B/31B. Each binary input of option DCS31B can be configured individually for the following signal sources: Binary input is assigned to pulse P1 Binary input is assigned to pulse P2 Binary input is assigned to DC 24 V continuous voltage NOTE For the circuit examples below, it is assumed that the components comply with the desired category according to EN and have a safety approval for their respective application. 22 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

23 Installation Connection of binary inputs DI1 to DI Single-channel sensor, untested P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 DC 24 V DC 0 V Figure 1: Single-channel sensor, untested 59258AXX NOTE The single-channel sensor is connected to option DCS21B/31B without clocking. Option DCS31B cannot detect a cross fault or an interrupted signal. Note that this configuration is not permitted for safe applications without additional external measures! Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 23

24 Installation 4 Connection of binary inputs DI1 to DI Dual-channel sensor, untested Before using dual-channel sensors (homogeneous or diversified), check whether they have been approved for the intended purpose. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 DC 24 V DC 0 V Figure 2: Dual-channel sensor (homogeneous), untested 59259AXX Using dual-channel homogeneous sensors without clocking can lead to problems. Short circuits cannot be detected in the supply line of the dual-channel sensor, e.g. in the cable. Safe operation can only be achieved by routing the cables separately and making sure the terminals cannot short circuit. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 DC 24 V DC 0 V Figure 3: Dual-channel sensor (diversified), untested 59260AXX The DCS21B/31B option can operate safely with dual-channel diversified sensors without clocking. NOTE Category 3 in accordance with EN can be achieved with both circuits. 24 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

25 Installation Connection of binary inputs DI1 to DI Single-channel sensor, tested Check whether the sensor is approved for use in fail-safe applications. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI8 P1 P2 DC 24 V DC 0 V X81 Figure 4: Single-channel sensor with clocking 59261AXX When using a single-channel sensor with clocking, the sensor must be connected to the clock output P1 or P2. The clock cycle must then be assigned on the DCS21B/31B option. The following errors are detected if you use a single-channel sensor with clocking: Short circuit against the DC 24 V supply voltage Short circuit against 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 P2 and DI1 is also not detected. With a suitable component and careful wiring of the sensor, category 3 to EN can be achieved. NOTE Category 3 is achieved when there is no possibility of a short circuit between DI1 and P2 or between the sensor connections. Faults can be excluded in accordance with EN ISO , table D8. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 25

26 Installation 4 Connection of binary inputs DI1 to DI Dual-channel sensor, tested All cross fault connections and connections to DC 24 V and DC 0 V can be detected when two independent clock signals are used on a homogeneous sensor. Only use NC contacts for safety applications. X81 P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI P1 P2 DC 24 V DC 0 V Figure 5: Dual-channel sensor (homogeneous) with clocking NOTE 59262AXX Note that when connecting a diversified sensor ( following figure), only the NO contact is tested regularly. As with the homogeneous sensor, all types of faults are detected in the supply line. P1 1 DI1 2 DI2 3 DI3 4 DI4 5 P2 6 DI5 7 DI6 8 DI7 9 DI8 10 X81 P1 P2 DC 24 V DC 0 V Figure 6: Dual-channel sensor (diversified) with clocking NOTE 59263AXX Category 4 to EN can be achieved in both cases when using permitted, positive opening switching elements. 26 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

27 Installation Connection of binary outputs Connection of binary outputs Option DCS21B/31B offers a total of 6 binary outputs. They can be connected individually or in groups: Binary output Category (EN 954-1) Comment DO0_P and DO0_M 4 Complete shutdown channel of category 4 DO0_P 2 DO0_M Only functional DO1_P and DO1_M 4 Complete shutdown channel of category 4 DO1_P 2 DO1_M Only functional DO2_P and DO2_M 4 Complete shutdown channel of category 4 DO2_P 2 DO2_M Only functional The binary outputs are subjected to a plausibility test in all operating states. When switched on, the binary outputs are tested for correct functioning with a cyclical test pulse. The binary output is switched to its inverse value for the duration of the test (< 100 µs), i.e. a P binary output is switched briefly to DC 0V potential, and an M binary output is switched briefly to DC 24 V potential. The binary output test function is performed for group and individual control. Binary output Output voltage Output current DO0_P DO0_M 0.1 A DO1_P DO1_M DO2_P DO2_M DC 24 V 1.5 A NOTES The total current load of the DCS21B/31B option may not exceed 2 A. The output power of the binary outputs DO0/DO1 depends on the output power of the binary output DO2 and the clock outputs P1 and P2. Cross and short circuits in the external wiring of the binary outputs are not detected. For safe outputs, cross faults and short circuit have to be prevented according to EN ISO table D.4. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 27

28 Installation 4 Connection of binary outputs Use of the binary outputs DO2_P and DO2_M The binary outputs DO2_P and DO2_M can be used for control of the safe stop function (X17) of MOVIDRIVE B. X83 1 DO2_P 2 DO2_M MOVIDRIVE MDX61B X17 4 SVI24 3 SOV24 2 VO24 1 DGND 59293AXX Single-pole switching P 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 test, welding of one or more external contacts will not be detected by the DCS21B/31B option. The following sample circuit is not suitable for safety applications. DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 X82 DO2_P DO2_M 1 2 X83 DC 24 V DC 0 V Figure 7: Single-pole switching P binary output Not suitable for safety applications! 59268AXX 28 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

29 Installation Connection of binary outputs Single-pole switching M binary output without test Similar to the previous wiring example, the following sample circuit shows a single-pole M binary output without test. The following sample circuit is not suitable for safety applications. DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 DO2_P DO2_M 1 2 X82 X83 DC 24 V DC 0 V Figure 8: Single-pole switching M binary output Not suitable for safety applications! 59267AXX NOTE Single-pole connections with monitoring of the external safety contact are permitted for use in safety applications up to category 2. Up to category 2, the status of the signal contact can be displayed and evaluated via binary outputs DO1/DO2 or via the fieldbus interface. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 29

30 Installation 4 Connection of binary outputs Dual-channel switching binary output DO0 with external monitoring The dual-channel wiring can also be implemented with a test. The prerequisite for this solution is a switching element with tested forced contacts and test contact (NC contact). The monitoring contact is fed via clock output P1 and read via any input. The EMU1 (Emergency Monitoring Unit 1) must be configured correctly for this solution to function properly. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 X82 DO0_P 1 DO0_M 2 DO1_P 3 DO1_M 4 X83 DO2_P DO2_M 1 2 Figure 9: Dual-channel switching binary output with external contact monitoring 63083AXX NOTE Dual-pole connection of a relay with monitoring of the external safety contact is permitted for use in safety applications up to category 2. Up to category 2, the status of the signal contact can be displayed and evaluated via an additional auxiliary output, e.g. DO0_M. 30 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

31 Installation Connection of binary outputs Dual-channel switching binary output DO0 with external monitoring For safety applications in category 3 and 4, two complementary binary outputs are connected as a group to control two external power contactors. P1 DI1 DI2 DI3 DI4 P2 DI5 DI6 DI7 DI X81 X82 DO0_P 1 DO0_M X83 DO2_P DO2_M 1 2 Figure 10: Dual-channel switching binary output DO0 with external monitoring 63084AXX NOTE Take into account the maximum output current of the binary outputs and the maximum current consumption of the contactors. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 31

32 Installation 4 Connection of position and velocity sensors 4.8 Connection of position and velocity sensors Before you start STOP! Do not plug in or remove encoder connections during operation. Doing so can cause irreparable damage to the electrical components on the encoder. Disconnect the connected encoders and the DCS21B/31B option before plugging in or removing the encoder connections. The DCS21B/31B option has two encoder interfaces for connecting standard incremental, sin/cos and absolute encoders. NOTE SEW-EURODRIVE recommends using the encoders listed in the appendix. Incremental, sin/cos or absolute encoders (binary or Gray Code) can be connected and operated via the same encoder interface. The internal encoder simulation can be used via backplane bus as well. The sin/cos encoders operate in the same way as incremental encoders. Please read the following notes carefully: The DCS21/31B option usually provides the connected sensors with the voltage supply. This voltage is monitored by a diagnostic process. If the sensors are powered by an external voltage supply, you must include the possibility of a voltage supply failure in the error discussion for the overall system. Particularly with shared external voltage supplies, you must document that this fault will be detected when the minimum operating voltage of the encoder system is not maintained. Make sure that EMC measures, such as shielding, have been applied. The two encoders must not impact on each other. This refers to both the electrical and mechanical part. If both encoders are connected to the monitoring system through shared mechanical parts, the connection must be positive and may not include any parts that are subject to wear (chains, toothed belts, etc.). However, if parts subject to wear are used, you must install additional monitoring systems to check the mechanical connection of the sensors (e.g. monitoring of a toothed belt). If position processing is activated, you must use at least one absolute encoder. If you only use one absolute encoder, connect it to X85 (encoder 2). Encoder 1 functions as a process sensor and encoder 2 as a reference sensor. If you are using encoders with different resolutions, configure the encoder with the higher resolution as 'Encoder 1' (X84) and the encoder with the lower resolution as 'Encoder 2' (X85). An internal number format is used in the input fields 'Position', 'Velocity' and 'Acceleration' when the monitoring functions are configured. This can cause the values to be rounded. 32 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

33 Installation Connection of position and velocity sensors 4 The following applies to the use of absolute encoders: Absolute encoders can be read in in the data format SSI binary or SSI Gray Code. This setting is made in the encoder dialog box in the configuration software. The data length is 24 bit Combination of different encoder types Encoder types can be combined depending on the specific application. Note the following limitations: If monitoring functions are used with position processing, at least one sensor must be assigned as an absolute encoder. When combining an absolute encoder with an incremental encoder, connect the incremental encoder to X84 and the absolute encoder to X85. NOTE If the encoder combination of incremental encoder and sin/cos encoder or the internal encoder value of the inverter is configured as "encoder 1" and the absolute encoder as "encoder 2" with position processing, the "higher" encoder serves as process sensor at encoder input 2. This is only possible as of firmware 02. If the internal encoder value of the inverter is to be used, the internal encoder has to be configured in the MOVISAFE CONFIG/ASSIST program as 'encoder 1'. If you change the encoder configuration at a later date, the existing parameters for the monitoring functions may no longer be compatible with the new encoder configuration. In this case, check the parameter settings and value ranges of all the monitoring functions in use. SEW-EURODRIVE recommends using the encoders listed in the appendix. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 33

34 Installation 4 Connection of position and velocity sensors Configuration of measuring sections The most important input parameters for the monitoring functions of the DCS21B/31B option are: Position Velocity Acceleration These input parameters are generated from the connected encoder systems via dual channels. Two independent encoder systems are required to achieve category 4 in accordance with EN One encoder system can be sufficient for certain applications to achieve category 3 in accordance with EN (e.g. only velocity monitoring). Travel types A and B must be configured accordingly for internal signal processing. This can be done using the encoder dialog box in the programming interface. Note the following parameters when configuring the measuring section: Measuring section type You can choose 'linear' or 'rotary' as the measuring section type. Measuring section units For a linear measuring section, you can choose 'mm/sec' or 'm/sec' as the unit for velocity. For rotary measuring sections, you can choose 'mgrad/sec', 'rps' or 'rpm' as the unit for velocity. The selected resolution should correspond to the physics of the measuring section to prevent rounding problems in the configuration. Measuring length The measuring length determines the permitted position range for position processing. If you do not define a measuring length, only monitoring functions with velocity processing properties will be permitted during configuration. Monitoring functions with position processing properties will be deactivated in the dialog box. Once you have activated the measuring length window, i.e. allowed position processing, note that the current position of the drive must be within the measuring length window. The measuring length has a range of and is normalized with the unit specified for the measuring section. Encoder type The following encoders are possible: Absolute encoder: SSI data interface with constant data length of 24 bit Data format binary or Gray Code Encoder with signal level to RS422 If the measuring channel is operated in slave mode, i.e. as a listener, the maximum external clock rate is 150 khz. The pulse break between the clock pulse trains must be greater than 30 µs and less than 6 ms. Incremental encoder: Encoder with signal level to RS422 Measuring signal A/B track with 90 degree phase difference Maximum frequency of the input pulses 200 khz 34 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

35 Installation Connection of position and velocity sensors 4 Sin/cos encoder: Encoder with AC 1 V ss Measuring signal A/B track with 90 degree phase difference Maximum frequency of the input pulses 200 khz Internal encoder simulation via backplane bus: The signals of the motor encoder can be used as encoder 1. The number of pulses of the encoder simulation via backplane bus is 4096 pulses per revolution after starting up the encoders in MOVIDRIVE. NOTE If the internal encoder simulation via backplane bus is used for reference travel of MOVIDRIVE B, the DCS21B/31B option issues the error message 'Plausibility position detection' (F109, subcode 036/037). The error can be acknowledged by a reset. Safety-related switch-off thresholds The basic check is to perform plausibility tests between the two measuring channels A and B of the DCS31B option to compare the current position and velocity values with the configurable thresholds. The 'incremental' switch-off threshold is the deviation in position permitted between the two recording channels A and B in the unit of the velocity. The 'velocity' switch-off threshold is the deviation in velocity permitted between the two recording channels A and B. Diagnostic functions are provided in the SCOPE dialog box of the configuration tool to determine the optimum parameter values. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 35

36 Installation 4 Connection of position and velocity sensors Conversion example The ramp times of the MOVIDRIVE B inverter are based on a setpoint step change of?n = /min. The acceleration value a is calculated using the following formula: a = v t a = Ramp time [ /min] [ min] 60 Example: In MOVITOOLS, P137 Emergency ramp is set to 2 seconds. [ ] [ ] /min 2 a = = [ 1/min ] 2 min 60 Conversion to 1/s 2 : 59723AEN 59725AXX [ 1/min ] 2 a = [ 1/min ] = = 25 [ 1/ s ] 60 [ s] 60 [ s] 59726AXX The values that are entered in the MOVISAFE CONFIG/ASSIST program are based on the measuring section. This means that the motor revolutions still have to be converted to the measuring section. Rotary system: Calculation of the velocity: v = i gear unit v i Motor add. gear 11464AXX 59728AEN v motor i gear unit i add. gear = motor velocity [1/min] = gear unit ratio = gear ratio of the additional gear 36 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

37 Installation Connection of position and velocity sensors 4 Calculation of the acceleration a = i gear unit a i Motor add. gear 59729AEN a motor i gear unit i add. gear = motor acceleration = gear unit ratio = gear ratio of the additional gear Linear system: Calculation of the velocity: 11465AXX v = i gear unit v i Motor add. gear D π drive wheel 59731AEN v v motor i gear unit i add. gear D drive wheel = velocity [m/min] = motor velocity [1/min] = gear unit ratio = gear ratio of the additional gear = drive wheel diameter [m] Calculation of the acceleration: a = i gear unit a x i Motor add. gear xd drive wheel x π 59729AEN a = acceleration [m/min 2 ] a motor = motor acceleration [1/min 2 ] i gear unit = gear unit ratio i add. gear = gear ratio of the additional gear D drive wheel = drive wheel diameter [m] Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 37

38 Installation 4 Connection of position and velocity sensors In many cases, the data in millimeters or minutes can exceed the inputs value range. In this case, you must scale the values from millimeters to meters (for linear systems) or from minutes to seconds (for rotary systems). Velocity: v [ mm/ s] v [ m/ s] = 1000 v [ U/min] v [ U/ s] = AXX Acceleration: 2 2 a[ mm/ s ] a[ m/ s ] = au [ /min ] au [ /min ] au [ / s] = = AXX 38 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

39 Installation Connection of position and velocity sensors Prefabricated cables For connection of an encoder to both a MOVIDRIVE B and the DCS21B/31B option, you can order prefabricated cables from SEW-EURODRIVE. Prefabricated cables allow you to split the encoder signals and to connect the encoder to the options DCS21B/31B and DEH11B/21B. DAE31B The prefabricated cable DAE31B is suitable for the following encoders: Incremental encoder Sin/cos encoder Hiperface encoder (only the sin/cos tracks are evaluated) [B] DAE31B [A] [C] Part number DAE31B: / Length of DAE31B: 300 mm ±30 mm 62133AXX Terminal Connection of encoder [A] 15-pin D-sub socket X15, DEH11B/21B [B] 15-pin D-sub connector X84/85, DCS21B/31B [C] 9-pin D-sub connector 1 COS + (signal track A) COS + (signal track A) COS + (signal track A) 2 SIN + (signal track B) SIN + (signal track B) SIN + (signal track B) 3 - (signal track C) - (signal track C) - (signal track C) 4 DATA + DATA TF/TH/KTY TF/TH/KTY COS (signal track A) SIN (signal track B) 8 DGND DGND - 9 COS (signal track A) COS (signal track A) - 10 SIN (signal track B) SIN (signal track B) (signal track C) - (signal track C) - 12 DATA DATA TF / TH / KTY + TF / TH / KTY U S U S - Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 39

40 Installation 4 Connection of position and velocity sensors DAE32B The prefabricated cable DAE32B is suitable for SSI absolute encoders in slave mode: [B] DAE32B [A] [C] 62779AXX Part number DAE32B: / Length of DAE32B: 300 mm ±30 mm Terminal SSI encoder [A] 9-pin D-sub socket X62, DEH21B [B] 9-pin D-sub connector 1 DATA + DATA + DATA Clock + 3 Clock + Clock DGND DGND DGND 6 DATA DATA DATA Clock 8 Clock Clock - 9 DC 24 V DC 24 V DC 24 V X84/85 DCS21B/31B [C] 9-pin D-sub connector 40 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

41 Installation Connection of position and velocity sensors 4 DAE33B The prefabricated cable DAE33B is suitable for connecting sin/cos encoders: [A] [B] 63085AXX Part number DAE33B: / Length of DAE33B: 300 mm ±30 mm Terminal Encoder [A] 15-pin D-sub socket X84/85 DCS21B/31B [B] 9-pin D-sub connector 1 1 Signal track A 2 2 Signal track B 3 n. c. Signal track C 4 n. c. Data+ 5 n. c. Reserved 6 n. c. TF 7 n. c. Reserved 8 5 DGND 9 6 Signal track A 10 7 Signal track B 11 n. c. Signal track C 12 n. c. Data 13 n. c. Reserved 14 n. c. TF V ss Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 41

42 Installation 4 Connection of position and velocity sensors DAE34B The prefabricated cable DAE34B is used for a CAN bus connection between DCS21B X86 and X31 of option DFS22B. [B] [A] DAE34B 63086AXX Part number DAE34B: / Length of DAE34B: 150 mm ±30 mm Terminal X31 DFS22B [A] 3-pin terminal X86 DCS21B [B] 3-pin terminal 1 CAN High CAN High 2 CAN Low CAN Low 3 GND GND 42 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

43 Installation Connection of position and velocity sensors Encoder wiring diagrams Connecting an absolute encoder in master mode max. 100 m DCS21B/31B X84/X85 Takt + Takt - DATA + DATA DC 0 V DC 24 V AXX In this type of wiring, clock signals of option DCS21B/31B are sent to the absolute encoder, and data is transferred from the encoder to option DCS21B/31B. Connecting an absolute encoder in slave mode max. 100 m DEH21B X62 DATA + DATA - Takt + Takt - DC 0 V DC 24 V DCS21B/31B X84/X AXX In this type of wiring, the clock signals and data are read along. In this example, option DCS21B/31B does not supply a voltage to the encoder. Please observe the following limitations: Maximum clock rate: 150 khz Rest period between two clock pulse trains: minimum 30 µs and maximum 6 ms Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 43

44 Installation 4 Connection of position and velocity sensors Connecting an incremental encoder max. 100 m DCS21B/31B X84/X85 B B A A DC 0 V DC 24 V AXX Connecting a sin/cos encoder max. 100 m DCS21B/31B X84/X85 COS + COS - SIN + SIN - DC 0 V DC 24 V AXX 44 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

45 Installation Connection of position and velocity sensors 4 Single encoder concept For applications in category 3 it is possible to use only one encoder. In this case, the signal outputs of the encoder are split between X15 of the DEH11B/DEH21B option and X85 of the DCS21B/31B option ( following figure). The internal encoder simulation via backplane bus can be used as encoder 1. Hiperface COS + 3 RD COS - 4 BU SIN + 5 YE SIN - 6 GN 3 11 DATA - 7 VT 6 DATA + 8 BK 4 5 TF/TH/KTY + 9 BN TF/TH/KTY - 10 WH DC 0 V 11 GYPK DC 24 V 12 RDBU PK GY max. 100 m DEH11B/21B X15: DCS21B/31B X84/X AXX NOTES Mechanical faults such as shaft breakage and slip are not detected and have to be ruled out by appropriate measures in the system design. The design of the mechanical system and of the encoder must be subjected to a failure mode and effect analysis based on the system. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 45

46 I Startup 5 General startup instructions 0 5 Startup 5.1 General startup instructions Prerequisites The following prerequisites must be fulfilled to ensure successful startup The system must be configured correctly The MOVISAFE CONFIG/ASSIST configuration software must be installed. The software is available on the MOVISAFE Software ROM, edition 02/2007, part no MOVITOOLS version 4.50 or higher Firmware version of the MOVIDRIVE MDX61B: or higher For detailed project planning information and a description of the parameters, refer to the online help files in the MOVISAFE CONFIG/ASSIST parameter setting software and in the MOVITOOLS operating software. Prerequisites for using the MOVISAFE CONFIG/ASSIST parameter setting software: Only for MOVISAFE CONFIG: Activation with a USB license dongle (part number ) Operating system: Microsoft Windows 2000, XP or Vista Required hard disk space: approx. 100 MB RAM: min. 256 MB, recommended: 512 MB or more Required hardware components: Interface adapter UWS21A (RS232 RS485) or interface adapter USB11A (USB RS485). For more information on hardware components, refer to the MOVIDRIVE MDX60B/61B catalog. Startup steps Make sure that the installation of the DCS21B/31B option 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. Integrate additional safety features depending on the application to prevent possible injuries and damages to machines. Switch on the line voltage and the DC 24 V supply voltage, if applicable. Startup the drive with MOVIDRIVE MDX61B as described in the "MOVIDRIVE MDX60B/61B" operating instructions. Parameterize and program the DCS21B/31B option according to your application. There is no need to activate the factory settings. If you have activated the factory settings, the terminal assignment and the parameter of the MOVIDRIVE MDX61B are reset to the basic setting. Use parameters P555/P556 to reset the fault and alarm response of the DCS option to "NO RESPONSE" or to "DISPLAY FAULT" ( chapter 5.2 "Parameter descriptions"). The set fault response will also be triggered in the CONTROLLER INHIBIT inverter status. Perform a validation ( chapter 6 "Validation"). Create a validation report ( chapter 5.4 "Validation report"). 46 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

47 Startup Parameter descriptions I Parameter descriptions The parameter group P55x DCS safety module includes display and setting values that are specific to the DCS21B/31B option. The factory setting is indicated by underline. P550 Status DCS safety module Display value that cannot be changed. The parameter P550 show the current status of option DCS21B/31B. RUN: Normal operation. STOP: Operation of option DCS21B/31B was stopped via the programming interface. ALARM: Option DCS21B/31B has issued an alarm. ERROR: Option DCS21B/31B has issued an error. You have the following options to read the corresponding error or alarm message from the error memory of option DCS21B/31B: Via the service interface X87 With the DBG60B keypad With the MOVISAFE CONFIG/ASSIST parameter setting software, if P555/P556 is set to "NO RESPONSE". P551 Binary inputs DCS DI1... DI8 Display value that cannot be changed. Parameter P551 shows the current status of the binary inputs of option DCS21B/31B in the order DI1... DI8. P552 Binary outputs DCS DO0_P... DO2_M Display value that cannot be changed. Parameter P552 shows the current status of the binary outputs of option DCS21B/31B in the following order: DO0_P DO0_M DO1_P DO1_M DO2_P DO2_M P553 Serial number DCS Display value that cannot be changed. The parameter P553 show the serial number of option DCS21B/31B. The displayed serial number must be identical with the series number on the nameplate of option DCS21B/31B, which is attached to the MOVIDRIVE MDX61B. You have to enter the serial number in the validation report ( chapter "Validation"). P554 CRC DCS Display value that cannot be changed. The parameter CRC DCS shows the CRC (cyclic redundancy check) of the program stored on the DCS21B/31B option. You have to enter the CRC in the validation report ( chapter "Validation"). Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 47

48 I Startup 5 Parameter descriptions 0 P555 Error response DCS / P556 Alarm response DCS Factory setting: IMM. STOP / FAULT If option DCS21B/31B reports an error (P555) or an alarm (P556), the inverter performs the set response (No response / Display error). SEW-EURODRIVE recommends to set P555 and P556 to "Display error", since option DCS21B/31B or a higher-level safety controller are responsible for safety-oriented disconnection. P557 Actual position source DCS Setting range: Motor encoder (X15) / Ext. encoder (X14) / absolute encoder If the option "Inverter encoder" is set as encoder 1 in the MOVISAFE CONFIG/ASSIST parameter setting software, the setting in P557 determines which encoder signal is evaluated by the DCS21B/31B option. P952 Clock rate Setting range: % Defines the clock rate at which absolute encoder information is transmitted from the encoder to the inverter. Clock rate = 100% corresponds to the nominal frequency of the encoder. If an absolute encoder is used with MOVIDRIVE B with option DCS..B in slave mode, P952 must be set according to chapter "Suitable absolute encoders for master and slave mode". Option DCS..B can process a maximum clock rate of 150 khz in slave mode. 48 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

49 Startup Switch-on sequences I Switch-on sequences After each restart of option DCS21B/31B, the following operating states are run through and displayed at the front status LEDs in case of fault-free operation. DCS21B/31B A/F WD B A Status LED LED A/F: Alarm/error LED WD: Watchdog LED B: System B LED A: System A 62780AXX Operating state LED display Mode Description 1 LEDs "A" and "B" flash in sync (change every 1.2 s) LED "WD" off LED "A/F" off STARTUP Synchronization between both processor systems and check of the configuration/firmware data. 2 SENDCONFIG Distribution of the configuration/firmware data and another check of this data. Then range check of the configuration data. 3 LEDs "A" and "B" flash in sync (change every 0.8 s) LED "WD" off LED "A/F" off 4 LEDs "A" and "B" flash in sync (change every 0.4 s) LED "WD" off LED "A/F" off STARTUP BUS RUN If applicable. Watchdog is active, i.e. all outputs can be switched. NOTE For operating states 1, 2 and 3, the outputs are automatically switched off by the firmware. In "RUN" mode (operating state "4"), the outputs are controlled by the implemented PLC program. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 49

50 I Startup 5 Connection to PROFINET with PROFIsafe Connection to PROFINET with PROFIsafe NOTE For detailed information, refer to the "MOVIDRIVE MDX61B Fieldbus Interface DFS22B PROFINET IO with PROFIsafe" manual Setting the PROFIsafe address in the slave The PROFIsafe address (parameter F_Dest_Add) can be read of during operation of the DCS21B using the MOVISAFE -ASSIST parameter setting software. The read-off value is displayed in MOVISAFE ASSIST in the window "PROFIsafe parameter" in the field "Online" (see following figure). [1] 63283AEN Click on the button [1] to transfer the value read-off online to the project (field "configured"). After successful configuration, both values are identical. 50 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

51 Startup Validation report I Validation report For ensuring the implemented safety functions, the user must check and document the parameters and links after successful startup and parameterization. This is supported by the MOVISAFE CONFIG/ASSIST parameter setting software. You can call up the validation report directly from the programming interface under the menu item [File] / [Configuration report]. The first page of the validation report can be used for general information about the system (plant, customer, supplier, setter, etc.). On the second page of the validation report, you can enter more detailed information about the system/machine. These entries are for information purposes only. However, they should be synchronized with the inspection authority/the inspector in terms of content and scope. The last page of the validation report contains the itemization for the safety check. Here, you must enter the following information: Serial number (identical with the serial number on the nameplate) Correspondence between the read-off serial number and the serial number on the nameplate of option DCS21B/31B Identity of the subassembly Here, the inspector of the safety subassembly confirms that the CRC displayed in the programming interface is identical to the one in the DCS21B/31B option. This CRC signature comprises a five-digit number that is displayed in the connection dialog box of the configuration tool in the diagnostic system information section. In this case, the DCS21B/31B option must have an active connection. Once all header data has been entered, you can generate the validation report by pressing the 'Save' button. The configuration tool creates a text file (.TXT) with the file name of the parameter/parameter data record. The text file includes the following information: The 3 pages of the header data edited above Encoder configuration Parameters of the monitoring functions Monitoring functions not required are also listed. They must also be checked! NOTES The correct program and parameter data must be loaded to create the validation report. All listed parameters and program instructions must be validated at the system/machine and confirmed manually written in the validation report The inspector must validate all configured data again in a printout of the validation report. All limit values set for the monitoring functions must be checked. The printed AWL code must be validated. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 51

52 Validation 6 Procedure 6 Validation 6.1 Procedure The concept for the DCS21B/31B option is based on the following prerequisites: Parameter and PLC data stored in the DCS21B/31B cannot change automatically. Online tests and corresponding signatures ensure this by implementing basic measures on the subassembly. However, the configured parameters cannot be evaluated by the subassembly. This affects the parameters of the sensors, thresholds and limit values. The user must confirm that the data of the test protocol matches the parameters in the subassembly. 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 by inspecting the code. The MOVISAFE CONFIG/ASSIST parameter setting software generates a suitable output form and stores it in a text file (.txt). The program enters the following information in the text file: Manufacturer: SEW-EURODRIVE GmbH & Co Type: DCS21B or DCS31B Version of the hardware and activated functions You must enter the following data in the text file: Serial number (identical with the serial number on the nameplate) Correspondence between the read-off serial number and the serial number on the nameplate of the unit The text file can then be printed out. Any other entries must be made manually: Date the configuration data record was created CRC signature from the data record 52 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

53 Maintenance Maintenance 7 7 Maintenance 7.1 Maintenance The DCS21B/31B option is fitted with a battery for saving data. The battery can only be replaced (every 10 years) by SEW-EURODRIVE. 7.2 Changes to the unit Hardware modifications Any changes to the DCS21B/31B option can only be performed by SEW- EURODRIVE. Firmware modifications Only SEW-EURODRIVE is authorized to make changes to the firmware. Repair Only SEW-EURODRIVE is authorized to repair the DCS21B/31B option. Warranty NOTE 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). 7.3 Disposal Please observe current national regulations. Dispose of the following materials separately in accordance with the country-specific regulations in force, as: Electronics scrap Plastics Sheet metal Copper Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 53

54 Maintenance 7 MOVIDRIVE B unit replacement 7.4 MOVIDRIVE B unit replacement Replacing the inverter When replacing the inverter, you must insert the DCS..B option of the original unit into the new inverter. All parameters and PLC data are retained. If you insert the memory card of the replaced MOVIDRIVE B in the new MOVIDRIVE B, the new unit is recognized without any additional measures Replacing the DCS..B option When replacing the DCS.B option, the data of the replaced DCS..B must be loaded into the new option. The CRC (cyclic redundancy check) must be identical before and after the replacement (check with P554 CRC DCS, see chapter "Parameter descriptions"). Proceed as follows to replace the DCS..B option: 1. First you have to read off and write down the CRC of option DCS..B. To do so, you can either start the MOVISAFE ASSIST parameter setting software and select the menu item [Communication], or select P554 CRC DCS in MOVITOOLS. 2. Switch off the line voltage before replacing the DCS..B option. Do not switch off the DC 24 V supply voltage. 3. Start the MOVISAFE ASSIST parameter setting software. 4. In MOVISAFE ASSIST, select the COM interface of your PC (menu item [General]/ [Parameter]) and establish a connection between DCS..B and MOVISAFE ASSIST. 5. Switch to the STOP mode. 6. Load the configuration data of the replaced DCS..B option (menu item [Edit configuration]) into the PC. 7. Switch off the DC 24 V supply voltage. 8. Replace the DCS..B option card. 9. Switch the DC 24 V supply voltage back on. 10.Perform steps 3 to 5 again. 11.Load the configuration data from the PC file and send it to the DCS..B option (menu item [Edit configuration]). 12.Switch to RUN mode. 13.Check the CRC in MOVISAFE ASSIST (menu item [Communication]) or in MOVITOOLS with P554 CRC DCS. 14.If the CRC is identical, perform the startup steps as specified in chapter "General startup instructions". 54 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

55 Diagnostics Meaning of the status LED kva i P f n Hz 8 8 Diagnostics 8.1 Meaning of the status LED DCS21B/31B A/F WD B A Status LED LED A/F: Alarm/error LED WD: Watchdog LED B: System B LED A: System A 62780AXX Status display The status LEDs display the current status of option DCS21B/31B. Operating status 1 LED display Mode Description LEDs "A" and "B" flash in sync (change every 1.2 s) LED "WD" off LED "A/F" off STARTUP Synchronization between both processor systems and check of the configuration/firmware data. 2 SENDCONFIG Distribution of the configuration/firmware data and another check of this data. Then range check of the configuration data. 3 LEDs "A" and "B" flash in sync (change every 0.8 s) LED "WD" off LED "A/F" off 4 LEDs "A" and "B" flash in sync (change every 0.4 s) LED "WD" off LED "A/F" off 5 LEDs "A" and "B" flash in sync (change every 2 s) LED "WD" off LED "A/F" off 6 LEDs "A" and "B" flash in sync (change every 1.6 s) LED "WD" off LED "A/F" flashing 7 LEDs "A" and "B" flash in sync (change every 0.4 s) LED "WD" off LED "A/F" on STARTUP BUS RUN STOP ALARM Error If applicable. Watchdog is active, i.e. all outputs can be switched. In STOP mode, you can load parameter and program data into the DCS21B/31B. ALARM can be reset via PLC function Error can only be reset via ON/OFF of option DCS21B/31B. NOTES For operating states 1, 2 and 3, the outputs are automatically switched off by the firmware. In "RUN" operating mode (display "4"), the outputs are controlled by the implemented PLC program. In operating modes 6 and 7, all outputs are deactivated. When option DCS21B/31B is restarted, the outputs are enabled in the "RUN" operating mode (display "4") and switched according to the logic used. If the reason for the alarm is still present (e.g. faulty encoder signals), an alarm is triggered that deactivates the outputs. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 55

56 n kva 8 f Diagnostics i Error and alarm classes P Hz 8.2 Error and alarm classes The DCS21B/31B option makes a general distinction between fatal errors and alarm messages. Error type Description Impact on the system Fatal error Alarm Fatal error or activation of an internal safety function. Due to reasons of safety, a cyclical program run is no longer possible. Functional error caused by an external process. The monitoring function triggers an ALARM, but the subassembly remains in standby mode. All outputs are deactivated Reset condition Switch the DCS21B/31B option off and on again Acknowledge with a reset NOTE You have the following options to read the corresponding subcode of the error or alarm message of option DCS21B/31B: Using MOVITOOLS MotionStudio via the XT option slot on the MOVIDRIVE B Using the DBG60B keypad (firmware status.13) Using the X87 service interface of the MOVISAFE CONFIG/ASSIST parameter setting software. 56 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

57 Diagnostics Error messages kva i P f n Hz Error messages NOTE Should the unit issue an error message that is not described here, proceed as follows: Under which conditions did the error occur? Safe the current configuration record Document the error code and the suberror code Contact the SEW-EURODRIVE service Fatal error code F1001, error 108, subcode 001 Error message Error during transfer of configuration data to the monitoring unit. Interruption in connection during program download. Troubleshooting Send the configuration files again. Fatal error code F1003, error 108, subcode 002 Error message Configuration data for software version of the subassembly is invalid. Subassembly configured with incorrect software version of the programming interface. Troubleshooting Configure subassembly with permitted version of the programming interface. Then switch subassembly off and on again. Fatal error code F1007, error 108, subcode 003 Error message Unit was programmed with incorrect programming interface. Program or configuration data was loaded into the unit with an incorrect programming interface. Troubleshooting Check the design of the subassembly. Configure again with a valid programming interface. Then switch the unit off and on again. Fatal error code F3203/3204, error 108, subcode 004/005 Error message Defective reference voltage. Supply voltage of the subassembly is defective. Faulty component in the subassembly Troubleshooting Check supply voltage Switch unit off and on again Fatal error code F3205/3206, error 108, subcode 006/007 Error message Defective system voltage. Supply voltage of the subassembly is defective. Faulty component in the subassembly Troubleshooting Check supply voltage Switch unit off and on again Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 57

58 n kva 8 f Diagnostics i Error messages P Hz Fatal error code F3207/3208, error 108, subcode 008/009 Error message Defective test voltage. Supply voltage of the subassembly is defective. Faulty component in the subassembly Troubleshooting Check supply voltage Switch unit off and on again Fatal error code F3210, error 108, subcode 010 Error message Faulty DC 24 V voltage supply. Supply voltage of the subassembly is defective. Faulty component in the subassembly Troubleshooting Check supply voltage Switch unit off and on again Fatal error code F3214, error 108, subcode 011 Error message Ambient temperature of the unit is not in the defined range. Temperature at the place of operation is not in the permitted range. Troubleshooting Check the ambient temperature. Fatal error code F3306, error 108, subcode 012 Error message Plausibility check for position changeover. For the position changeover, ZSC, JSS or DMC is permanently activated. Troubleshooting Check ZSC activation Check JSS activation Check DMC activation (only for monitoring via position) Fatal error code F3603, error 108, subcode 013 Error message Faulty switching of the LOSIDE driver DO2_P/DO2_M. Short circuit of the output. Troubleshooting Check wiring at the output. Fatal error code F3604, error 108, subcode 014 Error message Faulty switching of the HISIDE driver DO2_P/DO2_M. Short circuit of the output. Troubleshooting Check wiring at the output. Fatal error code F3605, error 108, subcode 015 Error message Faulty switching of the LOSIDE driver DO0_M. Short circuit of the output. Troubleshooting Check wiring at the output. 58 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

59 Diagnostics Error messages kva i P f n Hz 8 Fatal error code F3606, error 108, subcode 016 Error message Faulty switching of the HISIDE driver DO0_P. Short circuit of the output. Troubleshooting Check wiring at the output. Fatal error code F3607, error 108, subcode 017 Error message Faulty switching of the LOSIDE driver DO1_M. Short circuit of the output. Troubleshooting Check wiring at the output. Fatal error code F3608, error 108, subcode 018 Error message Faulty switching of the HISIDE driver DO1_P. Short circuit of the output. Troubleshooting Check wiring at the output. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 59

60 n kva 8 f Diagnostics i Alarm messages P Hz 8.4 Alarm messages NOTE An alarm displayed on the MOVIDRIVE B must be reset with two time-delayed reset commands. A single reset command of the MOVIDRIVE B will trigger a subsequent error in option DCS21B/31B. Alarm code A2401, error 109, subcode 001 Alarm message Communication error at the CAN interface of the inverter. The DCS21B/31B option does not receive any valid data from the inverter. Troubleshooting Check hardware connection to the inverter Check version of the inverter Alarm code A3101/3102, error 109, subcode 002/003 Alarm message Plausibility error at binary input at pulse P1. There is no pulse 1 voltage at the DI1 binary input. Troubleshooting Check configuration of the DI1 binary input according to configuration and wiring diagram Check wiring Alarm code A3103/3104, error 109, subcode 004/005 Alarm message Plausibility error at binary input at pulse P2. There is no pulse 1 voltage at the DI2 binary input. Troubleshooting Check configuration of the DI2 binary input according to configuration and wiring diagram Check wiring Alarm code A3105/3106, error 109, subcode 006/007 Alarm message Pulse 1 plausibility error at binary input DI3. There is no pulse 1 voltage at the DI3 binary input. Troubleshooting Check configuration of the DI3 binary input according to configuration and wiring diagram Check wiring Alarm code A3107/3108, error 109, subcode 008/009 Alarm message Pulse 1 plausibility error at binary input DI4. There is no pulse 1 voltage at the DI4 binary input. Troubleshooting Check configuration of the DI4 binary input according to configuration and wiring diagram Check wiring Alarm code A3109/3110, error 109, subcode 010/011 Alarm message Pulse 1 plausibility error at binary input DI5. There is no pulse 1 voltage at the DI05 binary input. Troubleshooting Check configuration of the DI5 binary input according to configuration and wiring diagram Check wiring 60 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

61 Diagnostics Alarm messages kva i P f n Hz 8 Alarm code A3111/3112, error 109, subcode 012/013 Alarm message Pulse 1 plausibility error at binary input DI6. There is no pulse 1 voltage at the DI6 binary input. Troubleshooting Check configuration of the DI6 binary input according to configuration and wiring diagram Check wiring Alarm code A3113/3114, error 109, subcode 014/015 Alarm message Pulse 1 plausibility error at binary input DI7. There is no pulse 1 voltage at the DI7 binary input. Troubleshooting Check configuration of the DI7 binary input according to configuration and wiring diagram Check wiring Alarm code A3115/3116, error 109, subcode 016/017 Alarm message Pulse 1 plausibility error at binary input DI8. There is no pulse 1 voltage at the DI8 binary input. Troubleshooting Check configuration of the DI8 binary input according to configuration and wiring diagram Check wiring Alarm code A3117/3118, error 109, subcode 018/019 Alarm message Pulse 2 plausibility error at input DI1. There is no pulse 2 voltage at the DI1 binary input. Troubleshooting Check configuration of the DI1 binary input according to configuration and wiring diagram Check wiring Alarm code A3119/3120, error 109, subcode 020/021 Alarm message Pulse 2 plausibility error at binary input DI2. There is no pulse 2 voltage at the DI2 binary input. Troubleshooting Check configuration of the DI2 binary input according to configuration and wiring diagram Check wiring Alarm code A3121/3122, error 109, subcode 022/023 Alarm message Pulse 2 plausibility error at binary input DI3. There is no pulse 2 voltage at the DI3 binary input. Troubleshooting Check configuration of the DI3 binary input according to configuration and wiring diagram Check wiring Alarm code A3123/3124, error 109, subcode 024/025 Alarm message Pulse 2 plausibility error at binary input DI4. There is no pulse 2 voltage at the DI4 binary input. Troubleshooting Check configuration of the DI4 binary input according to configuration and wiring diagram Check wiring Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 61

62 n kva 8 f Diagnostics i Alarm messages P Hz Alarm code A3125/3126, error 109, subcode 026/027 Alarm message Pulse 2 plausibility error at binary input DI5. There is no pulse 2 voltage at the DI5 binary input. Troubleshooting Check configuration of the DI5 binary input according to configuration and wiring diagram Check wiring Alarm code A3127/3128, error 109, subcode 028/029 Alarm message Pulse 2 plausibility error at binary input DI6. There is no pulse 2 voltage at the DI6 binary input. Troubleshooting Check configuration of the DI6 binary input according to configuration and wiring diagram Check wiring Alarm code A3129/3130, error 109, subcode 030/031 Alarm message Pulse 2 plausibility error at binary input DI7. There is no pulse 2 voltage at the DI7 binary input. Troubleshooting Check configuration of the DI7 binary input according to configuration and wiring diagram Check wiring Alarm code A3131/3132, error 109, subcode 032/033 Alarm message Pulse 2 plausibility error at binary input DI8. There is no pulse 2 voltage at the DI8 binary input. Troubleshooting Check configuration of the DI8 binary input according to configuration and wiring diagram Check wiring Alarm code A3301/3302, error 109, subcode 034/035 Alarm message Plausibility error in the speed acquisition The difference between the two velocity sensors is higher than the configured speed cut-off threshold. Troubleshooting Check track again with the data set in the configuration of the encoders Check the velocity sensor Use the SCOPE function to set speed signals so that they are congruent Alarm code A3303/3304, error 109, subcode 036/037 Alarm message Plausibility error in the position acquisition The difference between the two position sensors is higher than the configured value. Troubleshooting 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. 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 62 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

63 Diagnostics Alarm messages kva i P f n Hz 8 Alarm code A3307/3308, error 109, subcode 038/039 Alarm message Plausibility error - incorrect position range. The current position is outside the configured range. Troubleshooting 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 A3309/3310, error 109, subcode 040/041 Alarm message Plausibility error - incorrect velocity. The current velocity is exceeds the configured maximum velocity. Troubleshooting The drive moves outside the permitted and configured velocity range Check configuration (set max. velocity) Analyze the velocity development using the SCOPE function Alarm code A3311/3312, error 109, subcode 042/043 Alarm message Configuration error: Acceleration. The current acceleration is outside the configured acceleration range. Troubleshooting Check encoder type and configuration (SSI/incremental) Check the encoder connection/wiring Check polarity of the encoder data Check function of the encoder Alarm code A3401/3402, error 109, subcode 044/045 Alarm message Plausibility error in encoder interface (A3401 = encoder 1 and A3402 = encoder 2). The wiring of the encoder does not correspond to the configured data. Troubleshooting Check encoder type and configuration (SSI/incremental) Check the encoder connection/wiring Check polarity of the encoder data Check function of the encoder Alarm code A3403/3404, error 109, subcode 046/047 Alarm message Faulty voltage supply of the encoder (A3401 = encoder 1 and A3402 = encoder 2). Encoder voltage supply is outside of the defined range (min. DC 20 V / max. DC 29 V). Troubleshooting Overload in the supply voltage of the encoder; internal fuse has triggered Check supply voltage of the DCS21B/31B option Alarm code A3405/3406, error 109, subcode 048/049 Alarm message Error in reference voltage. The reference voltage input of the encoder system is outside the defined range. Troubleshooting Check reference voltage input of the encoder system. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 63

64 n kva 8 f Diagnostics i Alarm messages P Hz Alarm code A3407/3408, error 109, subcode 050/051 Alarm message Difference level of RS485 driver 1 (error INC_B or SSI_CLK) is faulty. No encoder connection, incorrect encoder type. Troubleshooting Check the encoder connection. Alarm code A3409/3410, error 109, subcode 052/053 Alarm message Difference level of RS485 driver 2 (error INC_B or SSI_CLK) is faulty. No encoder connection, incorrect encoder type. Troubleshooting Check the encoder connection. Alarm code A3411/3412, error 109, subcode 054/055 Alarm message Incremental counter deviation. No encoder connection, incorrect encoder type. Troubleshooting Check the encoder connection. Alarm code A3413/3414, error 109, subcode 056/057 Alarm message Plausibility error in encoder interface (A3401 = encoder 1 and A3402 = encoder 2). The wiring of the encoder does not correspond to the configured data. Troubleshooting Check encoder type and configuration (SSI/incremental) Check the encoder connection/wiring Check polarity of the encoder data Check function of the encoder Alarm code A3415/3416, error 109, subcode 058/059 Alarm message Plausibility error - sin/cos encoder connection. Incorrect encoder type connected. Troubleshooting Check the encoder connection Check the encoder connection (jumper between pin 1 and pin2) Alarm code A3417/3418, error 109, subcode 060/061 Alarm message Plausibility error - incremental encoder connection. Incorrect encoder type connected. Troubleshooting Check the encoder connection Check the encoder connection (jumper between pin 1 and pin2) Alarm code A3419/3420, error 109, subcode 062/063 Alarm message Plausibility error - incremental encoder connection. Phase error of the incremental or sin/cos encoder. Troubleshooting Check the encoder connection Replace the defective encoder 64 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

65 Diagnostics Alarm messages kva i P f n Hz 8 Alarm code A3421/3422, error 109, subcode 064/065 Alarm message Plausibility error - SSI encoder connection. Connected encoder type does not correspond to the configuration. Troubleshooting Check the encoder connection Check connected encoder Alarm code A3423/3424, error 109, subcode 066/067 Alarm message Plausibility error - SSI Listener encoder connection. Connected encoder type does not correspond to the configuration. Troubleshooting Check the encoder connection Check connected encoder Alarm code A3609/3610, error 109, subcode 068/069 Alarm message Faulty switching of the LOSIDE driver DO2_M/DO2_P. DC 0 V short circuit at the output. Troubleshooting Check wiring at the output. Alarm code A3611/3612, error 109, subcode 070/071 Alarm message Faulty switching of the LOSIDE driver DO0_M/DO0_P. DC 0 V short circuit at the output. Troubleshooting Check wiring at the output. Alarm code A3613/3614, error 109, subcode 072/073 Alarm message Faulty switching of the LOSIDE driver DO1_M/DO1_P. DC 0 V short circuit at the output. Troubleshooting Check wiring at the output. Alarm code A3615, error 109, subcode 074 Alarm message Undervoltage test WD for LOSIDE driver. DC 0 V short circuit at on of the DC 0 V outputs. Troubleshooting Check wiring at the outputs. Alarm code A3616, error 109, subcode 075 Alarm message Undervoltage test WD for HISIDE driver. DC -24 V short circuit at on of the DC -24 V outputs. Troubleshooting Check wiring at the outputs. Alarm code A4001/4002, error 109, subcode 076/077 Alarm message CCW and CW monitoring (in DMC module) activated simultaneously. Multiple activation. Troubleshooting Only one monitoring direction can be activated in the programming. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 65

66 n kva 8 f Diagnostics i Alarm messages P Hz Alarm code A4601/4602, error 109, subcode 078/079 Alarm message CCW and CW monitoring range of the OLC activated simultaneously. Multiple activation. Troubleshooting Only one direction of rotation can be activated in the DMC module. Alarm code A4901/4902, error 109, subcode 080/081 Alarm message CCW and CW monitoring range of the OLC activated simultaneously. Multiple activation. Troubleshooting Only one direction of rotation can be activated in the DMC module. Alarm code A6701/6702, error 109, subcode 082/083 Alarm message Timeout error MET. Input element with time monitoring is faulty. Troubleshooting Check wiring of input element Input element is faulty Alarm code A6703/6704, error 109, subcode 084/085 Alarm message Timeout error MEZ. Two-hand operation with time monitoring is faulty. Troubleshooting Check wiring of input element Input element is faulty Alarm code A4401/4402, error 109, subcode 086/087 Alarm message EMU1 monitoring error Faulty monitoring of the external disconnection channel Troubleshooting Check hardware connections Pick-up or release time to short Check switching contacts Alarm code A4403/4404, error 109, subcode 088/089 Alarm message EMU2 monitoring error Faulty monitoring of the external disconnection channel Troubleshooting Check hardware connections Pick-up or release time to short Check switching contacts 66 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

67 Technical Data Plug connectors kva i P f n Hz 9 9 Technical Data 9.1 Plug connectors Connector designation: X80 Type: Phoenix terminal, 2-pole Manufacturer: Phoenix Contact Order designation: X80 PIN Signal description Specification 1 DC+24 V DC 24 V voltage supply DC 20 V... DC 29 V 2 0V24 0 V reference potential Connector designation: X81 Type: Phoenix terminal, 10-pole Manufacturer: Phoenix Contact Order designation: X81 PIN Signal description Specification 1 Pulse 1 Clock signal 1 for safe inputs DC 24 V, clocked 2 DI1 Input 1 3 DI2 Input 2 4 DI3 Input 3 DC 20 V to DC 29 V 5 DI4 Input 4 6 Pulse 2 Clock signal 2 for safe inputs DC 24 V, clocked 7 DI5 Input 5 8 DI6 Input 6 9 DI7 Input 7 10 DI8 Input 8 DC 20 V to DC 29 V Connector designation: X82 Type: Phoenix terminal Manufacturer: Phoenix Contact Order designation: X82 PIN Assignment Assignment Assignment Signal description 1 DO0_P HISIDE output 0 2 DO0_M LOSIDE output 0 3 DO1_P HISIDE output 1 4 DO1_M LOSIDE output 1 Specification DC 24 V, 0.1 A Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 67

68 n kva 9 f Technical Data i Plug connectors P Hz Connector designation: X83 Type: Phoenix terminal, 2-pole Manufacturer: Phoenix Contact Order designation: X83 PIN Assignment Signal description 1 DO2_P HISIDE output 2 DO2_M LOSIDE output Specification DC 24 V, 1.5 A Connector designation: X84/X85 Type: D-sub socket Manufacturer: Diverse Figure 11: Connector assignment X84/X AXX Connector assignment X84/X85 (depending on the technology): X84/X85 PIN Incremental Sin/cos SSI absolute Master mode SSI absolute Slave mode 1 A SIN+ DATA+ DATA+ 2 B COS+ N.C. N.C. 3 N.C. N.C. Clock + N.C. 4 N.C. N.C. N.C. Clock + 5 GND GND GND N.C. 6 A SIN DATA DATA 7 B COS N.C. Clock 8 N.C. N.C. Clock N.C V 24 V 24 V N.C. 68 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

69 Appendix Safety characteristics of DCS21B/31B Appendix 10.1 Safety characteristics of DCS21B/31B Safety characteristics Highest possible safety category SIL 3 according to EN Category 4 according to EN Performance level e according to EN ISO System structure 2 channels with diagnostics (1002) Type of operating mode High demand rate according to EN Probability of dangerous failure per hour (PFH <3.00E-09 (1 FIT) value) Proof test interval (EN 61508) 10 years, after which the component must be replaced with a new one Safe status Value "0" for all safety-oriented F-DO process values (output disabled) 10.2 Response times of the DCS21B option The following table lists the response times of the DCS21B options. For the PROFIsafe application, the cycle time (T_cycle) is 28 ms. The specified response times correspond to the maximum run time for the specific application within the DCS21B option. For bus applications, the processing time of the safety controller and, depending on the application, other application-specific response times of the used sensors and actuators must be added to get the total run time. For calculating the run time in the safety controller, refer to the technical data of the manufacturer. Function PROFIsafe bus timeout (Minimum timeout interval) Reading in of a digital NC contact and transfer to the safety controller via PROFIsafe. Reading in of a digital NO contact and transfer to the safety controller via PROFIsafe. Response time [ms] Explanation 125 The minimum timeout interval for the bus is 125 ms. If a general bus error is assumed (e.g. corrupt data, interrupted communication), all outputs of the DCS21B option are deactivated after the specified time has elapsed. The same applies for the connection from the DCS21B to the safety controller. Information: The timeout interval of the bus system can be scaled freely in the safety controller (e.g S7) under "HW Config". For calculating the response time of the DCS21B option, the timeout interval must be used. 84 The DCS21B recognizes the opening of a live contact within one cycle. For the transfer to the safe bus system, two more cycles are required. 112 For a NO contact to be recognized as active ("1"), an active signal level must be present at the input for an entire clock cycle of the DCS21B option. In the worst case, sampling will take two cycles to make relevant information available for internal processing. Two more cycles are required for transfer to the bus; this means the total number of cycles is 4. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 69

70 Appendix 10 Response times of the DCS21B option Function Response of an already activated monitoring function using local disconnection for position and speed processing Response of an already activated monitoring function using local disconnection for acceleration processing Response of an already activated monitoring function including transmission to PROFIsafe for position and speed processing Response of an already activated monitoring function including transmission to PROFIsafe for acceleration processing Activation of an ENABLE input of a monitoring function for transmission via PROFIsafe Activation of an output for transmission via PROFIsafe Response time [ms] Explanation 56 For a monitoring function that has already been activated via PROFIsafe, the DCS21B option needs one cycle to calculate the current speed value. During the next cycle, after calculating the monitoring function, the result is entered in the system image. If local disconnection has been activated (available on the DCS21B option), a programmed output is operated in the same cycle, if required. Information: When using local disconnection and ENABLE via the bus system, the specified time is the relevant response time. 84 For a monitoring function that has already been activated via PROFIsafe, the DCS21B option needs two cycles to calculate the current acceleration value. During the next cycle, after calculating the monitoring function, the result is entered in the system image. If local disconnection has been activated (available in the DCS21B option), a programmed output is operated within the same cycle, if required. Information: When using local disconnection and ENABLE via the bus system, the specified time is the relevant response time. 112 For a monitoring function that has already been activated via PROFIsafe, the DCS21B option needs one cycle to calculate the current speed value. During the next cycle, after calculating the monitoring function, the result is entered in the system image. Two more cycles are required for forwarding the result to the safety controller via PROFIsafe. 140 For a monitoring function that has already been activated via PROFIsafe, the DCS21B option needs two cycles to calculate the current acceleration value. During the next cycle, after calculating the monitoring function, the result is entered in the system image. Two more cycles are required for forwarding the result to the safety controller via PROFIsafe. 56 Two cycles are required for reading off information of the PROFIsafe input telegram and for entry in the process image. 56 Two cycles are required for reading off output information from the PROFIsafe input telegram and for entry in the process image. After the information has been entered in the process image, the input is activated/deactivated within the same cycle. 70 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

71 Appendix Response times of the DCS31B option Response times of the DCS31B option The following table lists the response times of the DCS31B options. The cycle time of the system is the basis for the calculation of response times. The cycle time (T_cycle) of the DCS31B option is 25 ms. The specified response times correspond to the maximum run time for the specific application within the DCS31B option. 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. Function Reading in of a digital NC contact and further processing by the internal safety controller Reading in of a digital NO contact and further processing by the internal safety controller Response of an already activated monitoring function including PLC processing for position and speed processing Response of an already activated monitoring function including PLC processing for acceleration processing Response of a monitoring function activated by an external input including processing of the safety controller when using a NC contact. Response of a monitoring function activated by an external input including processing of the safety controller when using a NO contact. Response time [ms] Explanation 58 The DCS31B option recognizes an NC contact within one cycle. Another cycle is needed for further processing including the switching an output. 75 For a NO contact to be recognized as active ("1"), an active signal level must be present at the input for an entire clock cycle of the DCS31B option. In the worst case, sampling will take two cycles to make relevant information available for internal processing. As another cycle is needed for processing the input signal, this results in a total signal run time of three cycles. Note: Try to avoid using NO contacts in safety circuits! 50 For a monitoring function that has already been activated via ENABLE, the DCS31B option needs one cycle to calculate the current speed value. In the next cycle, after the monitoring function has been calculated, the information is further processed and output by the PLC. That is, once the programmed logic has been performed, this can lead, for example, to the switching of an output. 75 For a monitoring function that has already been activated via ENABLE, the DCS31B option needs two cycles to calculate the current acceleration value. In the next cycle, after the monitoring function has been calculated, the information is further processed and output by the PLC. That is, once the programmed logic has been performed, this can lead, for example, to the switching of an output. 83 The input signal processing lasts one clock cycle. Another cycle is needed for setting the ENABLE input of the required monitoring function. In the next cycle, the monitoring function and behavior of the result is calculated and, if necessary, the output is activated. 100 For processing the digital input signal, two cycles are required in the worst case. Another cycle is needed for setting the ENABLE input of the required monitoring function. In the next cycle, the monitoring function and processing of the result is calculated and, if necessary, the output is activated. Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 71

72 Appendix 10 Description of the input elements 10.4 Description of the input elements General information The individual switches of the following input elements can be assigned to the digital outputs DI1 to DI8 as required. Operating mode selection switch Switch type Comment EN rating 2 settings Operation mode selection switch Category 4 SIL3 3 settings Operating mode selection switch, monitored Category 4 SIL3 EN IEC rating NOTE 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 the DCS21B/31B option are deactivated (EN/60204). Light curtain Switch type Comment EN rating EN IEC rating 2 NC contacts Light curtain for increased demands Category 4 SIL3 2 NC contacts for time Light curtain, monitored Category 4 SIL3 monitoring 1 NO + 1 NC contact Light curtain for increased demands Category 4 SIL3 1 NO + 1 NC contact, timemonitored Light curtain, monitored Category 4 SIL3 Emergency stop Switch type Comment EN rating EN IEC rating 1 NC contacts Emergency stop, simple Category 3 SIL2 2 NC contacts Emergency stop for increased Category 4 SIL3 demands 2 NC contacts for time monitoring Emergency stop, monitored Category 4 SIL3 Start/reset Switch type Comment EN rating EN IEC rating 1 NO contact Alarm reset, simple 1) NO contact Logic reset, simple Category 3 SIL2 1 NO contact Start monitoring, simple (special function) - - 1) The Alarm/reset input is subject to edge control and can always be operated with a DC 24 V voltage. 72 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

73 Appendix Description of the input elements 10 Sensor Switch type Comment EN rating EN IEC rating 1 NC contacts Sensor input, simple Category 3 SIL2 1 NO contact Sensor input, simple Category 3 SIL2 2 NC contacts Sensor input for increased demands Category 4 SIL3 2 NC contacts for time Sensor input, monitored Category 4 SIL3 monitoring 1 NO + 1 NC contact Sensor input for increased demands Category 4 SIL3 1 NO + 1 NC contact, timemonitored Sensor input, monitored Category 4 SIL3 Door monitoring Switch type Comment EN rating EN IEC rating 2 NC contacts Door monitoring for increased Category 4 SIL3 demands 2 NC contacts for time Door monitoring, monitored Category 4 SIL3 monitoring 1 NO + 1 NC contact Door monitoring for increased Category 4 SIL3 demands 1 NO + 1 NC contact, timemonitored Door monitoring, monitored Category 4 SIL3 2 NO + 2 NC contact Door monitoring for increased Category 4 SIL3 demands 2 NO + 2 NC contact, timemonitored Door monitoring, monitored Category 4 SIL3 3 NC contacts Door monitoring for increased Category 4 SIL3 demands 3 NC contacts, time-monitored Door monitoring, monitored Category 4 SIL3 Confirmation button Switch type Comment EN rating EN IEC rating 1 NC contacts Confirmation button, simple Category 3 SIL2 1 NO contact Confirmation button, simple Category 3 SIL2 2 NC contacts Confirmation button for increased Category 4 SIL3 demands 2 NC contacts for time monitoring Confirmation button, monitored Category 4 SIL3 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 73

74 Appendix 10 List of encoders recommended by SEW-EURODRIVE 10.5 List of encoders recommended by SEW-EURODRIVE Incremental encoder Type designation Power supply Output signal EH1R, ES1R, ES2R, EV1R DC 24 V According to RS422 (1024 increments/revolution) Sin/cos encoder Sin/cos encoders and encoders that make such signal tracks available can be used in single encoders solutions up to category 3 according to EN There are no additional safety requirements for the encoder electronics. Type designation Power supply Output signal ES1S, ES2S, EH1S, EV1S ES7S, EG7S, EH7S EI7S DC 24 V AC 1 V ss sin/cos (1024 increments/revolution) AC 1 V ss sin/cos (24 increments/revolution) Hiperface encoder (sin/cos tracks) With Hiperface encoders, only the sin/cos tracks are evaluated by the MOVISAFE. The voltage supply of the Hiperface encoders is provided by the DEH11B/21B option card of MOVIDRIVE B. Type designation Power supply Output signal ES1H, AS1H ES3H, ES4H, AS3H, AS4H EV1H, AV1H Positive connection Hiperface encoder: AF6H AF1H EF1H DC 12 V AC 1 V ss sin/cos (1024 increments/revolution) SSI absolute encoder (combination encoder) Type designation Power supply Output signal AV1Y DC 24 V AC 1 V ss sin/cos (512 increments/revolution) increments SSI-Gray Internal MOVI- DRIVE B encoder simulation Type designation Power supply Output signal MDX61B backplane bus increments/revolution 74 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

75 Appendix Additional features: Encoder Additional features: Encoder Speed sensor Various encoder types are available as standard for installation in DR. series AC motors. The encoders can be combined with other optional additional features, such as brake and forced cooling fan. For questions, please contact your contact partner for drives at SEW-EURODRIVE. Encoder overview Electrical interface 1V SS sin/cos Electrical interface HTL (push-pull) Electrical interface TTL (RS422) RS485 encoder (sin/cos tracks) Electrical interface MSSI + 1 V SS sin/cos Electrical interface MSSI + TTL Designation For motor size Encoder type Mounting type Specification [Periods/revolution] Supply voltage [V] ES7S Shaft centered DC 7-30 EG7S Speed sensor 1024 EH7S 315 Hollow shaft DC EI7S Built-in encoder Shaft centered 24 DC 9-30 Designation For motor size Encoder type Mounting type Specification [Periods/revolution] EI7C 24 EI76 Built-in Shaft centered EI72 encoder 2 EI71 1 Designation For motor size Encoder type Mounting type ES7R EG7R Designation For motor size Encoder type Mounting type ES7W EG7W Absolute encoder (single-turn) AS7W Absolute AG7W encoder (multi-turn) Designation For motor size Encoder type Mounting type AS7Y Absolute AG7Y encoder SSI (multi-turn) Designation For motor size Encoder type Mounting type AH7Y 315 Specification [Periods/revolution] Supply voltage [V] DC 9-30 Supply voltage [V] Speed sensor Shaft centered 1024 DC 7-30 Absolute encoder SSI (multi-turn) Specification [Periods/revolution] Supply voltage [V] Shaft centered 2048 DC 7-30 Specification [Periods/revolution] Supply voltage [V] Shaft centered 2048 DC 7-30 Specification [Periods/revolution] Supply voltage [V] Hollow shaft 2048 DC 9-30 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 75

76 Appendix 10 Suitable absolute encoders for master and slave mode 10.7 Suitable absolute encoders for master and slave mode Connect only those encoders listed in the following table to the DCS21B/31B option. You must check whether other encoders are suitable and released for use by SEW- EURODRIVE. If an absolute encoder is used in slave mode with a MOVIDRIVE B with DCS..B option, you must set P952 Clock rate according to the following table. Option DCS..B can process a maximum clock rate of 150 khz in slave mode. Manufacturer Encoder designation Absolute encoder in slave mode: Setting P952 Clock rate Comments Hübner HMG161-S24 H2048 (AH7Y) Rotary encoder Heidenhain ROQ 424 (AV1Y) 50 % Rotary encoder Elgo LIMAX SSG1-D9M3 Linear distance sensor Balluf BTL5-S112-M...-P-S32 50 % Linear distance sensor TR-Electronic TR CE58 Rotary encoder TR CE65 50 % Rotary encoder TR CE100MSSI Rotary encoder TR ZE65 M 50 % Rotary encoder TR LA41K SSI Linear distance sensor TR LA66K SSI 50 % Linear distance sensor TR LE100 SSI 50 % Laser distance measuring instr. TR LE200 Laser distance measuring instr. Leuze BPS37 50 % Barcode measuring system Leuze-electronic Leuze OMS1 50 % Laser distance measuring instr. Leuze OMS2 Laser distance measuring instr. AMS200 Laser distance measuring instr. Fritz Kübler 9081 Rotary encoder MTS Sensors IVO Sick / Stegmann Pepperl & Fuchs 1) Previously STAHL 2) Previously VISOLUX Temposonics RP Temposonics RH Temposonics RF Temposonics RD3 Linear distance sensor Linear distance sensor Linear distance sensor Linear distance sensor GM % Rotary encoder GXMMW 50 % Rotary encoder Sick ATM60 Rotary encoder Sick DME % Laser distance measuring instr. Sick DME 4000 Laser distance measuring instr. Sick DME % Laser distance measuring instr. Stegmann AG100 MSSI 60 % Rotary encoder Stegmann AG % Rotary encoder POMUX KH53 Linear distance sensor AVM58X-1212 Rotary encoder WCS2A 1) 60 % Barcode distance sensor WCS3A 1) 60 % Barcode distance sensor EDM 2) 50 % Laser distance measuring instr. 76 Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

77 Index Index A Additional encoder features...75 Encoder overview...75 Alarm messages...60 C Confirmation button...73 Connection of binary inputs DI1 to DI8 Dual-channel sensor, tested...26 Dual-channel sensor, untested...24 Single-channel sensor, tested...25 Single-channel sensor, untested...23 Using the clock outputs P1 and P Connection of binary outputs...27 Connection of position and velocity sensors...32 Before you start...32 Combination of different encoder types...33 Configuration of measuring sections...34 Connecting a sin/cos encoder...44 Connecting an absolute encoder in master mode...43 Connecting an absolute encoder in slave mode...43 Connecting an incremental encoder...44 Prefabricated cables...39 Single encoder concept...45 Connection of the binary outputs Dual-channel switching binary output DO0 with external monitoring... 30, 31 Single-pole switching M binary output without test...29 Single-pole switching P binary output without test...28 Connection to PROFINET with PROFIsafe...50 Setting the PROFIsafe address in the slave.50 D DAE31B...39 DAE32B...40 DAE33B...41 DAE34B...42 DCS21B/31B Terminal description...18 Definitions...9 Diagnostics...55 Alarm messages...60 Error and alarm classes...56 Error messages...57 Meaning of the status LED...55 Status display...55 E Encoder list (recommended by SEW-EURODRIVE) Hiperface encoders Incremental encoder Internal MOVIDRIVE B encoder simulation Sin/cos encoder SSI absolute encoder (combination encoder) Encoder overview Encoder wiring diagrams Error and alarm classes Error messages Exclusion of liability... 6 G General notes... 5 I Input elements Confirmation button Description Door monitoring Emergency stop Light curtain Operating mode selection switch Sensor Start/reset Installation Configuration of measuring sections Connection of binary inputs DI1 to DI Connection of binary outputs Connection of position and velocity sensors 32 External DC 24 V voltage supply General installation notes Measures for electromagnetic compatibility.20 Terminal description of option DCS21B/31B 18 Installation notes Combination of different encoder types Installation of the DCS21B/31B option card M Maintenance Changes to the unit Disposal Maintenance during operation Meaning of the status LED Measures for electromagnetic compatibility N Nameplate Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B 77

78 11 Index O Other applicable documentation... 6, 9 P Parameter descriptions...47 Plug connectors...67 Prefabricated cables...39 DAE31B...39 DAE32B...40 DAE33B...41 DAE34B...42 Project planning notes Speed sensor...75 R Response times of the DCS21B option...69 Response times of the DCS31B option...71 Rights to claim under limited warranty...5 S Safety characteristics of DCS21B/31B...69 Safety notes...7 Definitions...9 Designated use...8 Electrical connection...8 General...7 Installation...8 Operation...9 Target group...7 Transportation, storage...8 Setting the PROFIsafe address in the slave...50 Startup...46 Prerequisites...46 Startup steps...46 Switch-on sequences...49 Validation report...51 Status display...55 Structure of the safety notes...5 Suitable absolute encoders for master and slave mode...76 Switch-on sequences...49 T Technical data Plug connectors...67 Terminal description of DCS21B/31B...18 TÜV certificate...10 U Unit design DCS21B...13 DCS31B...14 Unit features DCS21B...11 DCS31B...11 Unit replacement...54 Replacing the DCS..B option...54 Replacing the inverter...54 V Validation Validation report Manual MOVIDRIVE MDX61B Safety Module Option DCS21B/31B

79 Address List Address List Germany Headquarters Production 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 Hotline / 24 Hour 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 Haguenau SEW-USOCOME 48-54, route de Soufflenheim B. P F Haguenau Cedex Production Forbach SEW-EUROCOME Zone Industrielle Technopôle Forbach Sud B. P F Forbach Cedex Assembly Bordeaux Lyon 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 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 /

80 Address List Algeria Alger Réducom 16, rue des Frères Zaghnoun Bellevue El-Harrach Alger Tel Fax Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S.A. Centro Industrial Garin, Lote 35 Ruta Panamericana Km 37, Garin Tel Fax Australia Assembly 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 Townsville SEW-EURODRIVE PTY. LTD. 12 Leyland Street Garbutt, QLD 4814 Tel Fax enquires@sew-eurodrive.com.au Austria Assembly Wien SEW-EURODRIVE Ges.m.b.H. Richard-Strauss-Strasse 24 A-1230 Wien Tel Fax sew@sew-eurodrive.at Belarus Minsk SEW-EURODRIVE BY RybalkoStr. 26 BY Minsk Tel.+375 (17) Fax +375 (17) sales@sew.by Belgium Assembly Brüssel SEW Caron-Vector S.A. Avenue Eiffel 5 B-1300 Wavre Tel Fax info@caron-vector.be Competence Center Industrial Gears SEW Caron-Vector S.A. Rue de Parc Industriel, 31 BE-6900 Marche-en-Famenne Tel Fax service-wallonie@sew-eurodrive.be Brazil Production Sao Paulo SEW-EURODRIVE Brasil Ltda. Avenida Amâncio Gaiolli, 152 Rodovia Presidente Dutra Km 208 Guarulhos SP SAT SEW ATENDE Additional addresses for service in Brazil provided on request! Tel Fax sew@sew.com.br Bulgaria Sofia BEVER-DRIVE GmbH Bogdanovetz Str.1 BG-1606 Sofia Tel Fax bever@fastbg.net 80 04/2008

81 Address List Cameroon Douala Electro-s Rue Drouot Akwa B.P Douala Tel Fax Canada Assembly Toronto Vancouver SEW-EURODRIVE CO. OF CANADA LTD. 210 Walker Drive Bramalea, Ontario L6T3W1 SEW-EURODRIVE CO. OF CANADA LTD Honeyman Street Delta. B.C. V4G 1 E2 Montreal SEW-EURODRIVE CO. OF CANADA LTD Rue Leger LaSalle, Quebec H8N 2V9 Additional addresses for service in Canada provided on request! Tel Fax marketing@sew-eurodrive.ca Tel Fax marketing@sew-eurodrive.ca Tel Fax marketing@sew-eurodrive.ca Chile Assembly 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 Assembly Tianjin Suzhou Guangzhou Shenyang 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, 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 Colombia Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Calle 22 No Bodega 6, Manzana B Santafé de Bogotá Tel Fax sewcol@sew-eurodrive.com.co Croatia Zagreb KOMPEKS d. o. o. PIT Erdödy 4 II HR Zagreb Tel Fax kompeks@inet.hr 04/

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83 Address List Hungary Budapest SEW-EURODRIVE Kft. H-1037 Budapest Kunigunda u. 18 Tel Fax office@sew-eurodrive.hu India Assembly Vadodara SEW-EURODRIVE India Private Limited Plot No. 4, GIDC POR Ramangamdi Vadodara Gujarat Tel Fax sales@seweurodriveindia.com subodh.ladwa@seweurodriveindia.com Ireland Dublin Alperton Engineering Ltd. 48 Moyle Road Dublin Industrial Estate Glasnevin, Dublin 11 Tel Fax info@alperton.ie Israel Tel-Aviv Liraz Handasa Ltd. Ahofer Str 34B / Holon Tel Fax office@liraz-handasa.co.il Italy Assembly Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s. Via Bernini,14 I Solaro (Milano) Tel Fax sewit@sew-eurodrive.it Ivory Coast Abidjan SICA Ste industrielle et commerciale pour l'afrique 165, Bld de Marseille B.P. 2323, Abidjan 08 Tel Fax Japan Assembly Iwata SEW-EURODRIVE JAPAN CO., LTD 250-1, Shimoman-no, Iwata Shizuoka Tel Fax sewjapan@sew-eurodrive.co.jp Korea Assembly Ansan-City SEW-EURODRIVE KOREA CO., LTD. B 601-4, Banweol Industrial Estate , Shingil-Dong Ansan Tel Fax master@sew-korea.co.kr Busan SEW-EURODRIVE KOREA Co., Ltd. No , Songjeong - dong Gangseo-ku Busan Tel Fax master@sew-korea.co.kr Latvia Riga SIA Alas-Kuul Katlakalna 11C LV-1073 Riga Tel Fax info@alas-kuul.com 04/

84 Address List Lebanon Beirut Gabriel Acar & Fils sarl B. P Bourj Hammoud, Beirut Lithuania Alytus UAB Irseva Naujoji 19 LT Alytus Tel Fax gacar@beirut.com Tel Fax info@irseva.lt Luxembourg Assembly Brüssel CARON-VECTOR S.A. Avenue Eiffel 5 B-1300 Wavre Tel Fax info@caron-vector.be Malaysia Assembly 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 Queretaro SEW-EURODRIVE MEXIKO SA DE CV SEM M93 Tequisquiapan No. 102 Parque Industrial Queretaro C.P Queretaro, Mexico Tel Fax scmexico@seweurodrive.com.mx Morocco Casablanca Afit 5, rue Emir Abdelkader MA Casablanca Tel Fax ali.alami@premium.net.ma Netherlands Assembly Rotterdam VECTOR Aandrijftechniek B.V. Industrieweg 175 NL-3044 AS Rotterdam Postbus NL-3004 AB Rotterdam Tel Fax info@vector.nu New Zealand Assembly 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 Moss SEW-EURODRIVE A/S Solgaard skog 71 N-1599 Moss Tel Fax sew@sew-eurodrive.no 84 04/2008

85 Address List Peru Assembly 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 Lodz SEW-EURODRIVE Polska Sp.z.o.o. ul. Techniczna 5 PL Łódź Tel Fax sew@sew-eurodrive.pl 24 Hour Tel ( SEW SEW) serwis@sew-eurodrive.pl Portugal Assembly Coimbra SEW-EURODRIVE, LDA. Apartado 15 P Mealhada Tel Fax infosew@sew-eurodrive.pt Romania Bucureşti Sialco Trading SRL str. Madrid nr Bucuresti Tel Fax sialco@sialco.ro Russia Assembly St. Petersburg ZAO SEW-EURODRIVE P.O. Box St. Petersburg Russia Tel Fax sew@sew-eurodrive.ru Senegal Dakar SENEMECA Mécanique Générale Km 8, Route de Rufisque B.P. 3251, Dakar Serbia Beograd DIPAR d.o.o. Ustanicka 128a PC Košum, IV floor SCG Beograd Tel Fax senemeca@sentoo.sn Tel / Fax office@dipar.co.yu Singapore Assembly Singapore SEW-EURODRIVE PTE. LTD. No 9, Tuas Drive 2 Jurong Industrial Estate Singapore Tel Fax sewsingapore@sew-eurodrive.com Slovakia Bratislava SEW-Eurodrive SK s.r.o. Rybničná 40 SK Bratislava Žilina SEW-Eurodrive SK s.r.o. ul. Vojtecha Spanyola 33 SK Žilina Tel Fax sew@sew-eurodrive.sk Tel Fax sew@sew-eurodrive.sk 04/

86 Address List Slovakia Banská Bystrica SEW-Eurodrive SK s.r.o. Rudlovská cesta 85 SK Banská Bystrica Tel Fax Slovenia Celje Pakman - Pogonska Tehnika d.o.o. UI. XIV. divizije 14 SLO Celje Tel Fax pakman@siol.net South Africa Assembly 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 dross@sew.co.za Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Rainbow Park Cnr. Racecourse & Omuramba Road Montague Gardens Cape Town P.O.Box Chempet 7442 Cape Town Tel Fax Telex dswanepoel@sew.co.za Durban SEW-EURODRIVE (PROPRIETARY) LIMITED 2 Monaceo Place Pinetown Durban P.O. Box 10433, Ashwood 3605 Tel Fax dtait@sew.co.za Spain Assembly Bilbao SEW-EURODRIVE ESPAÑA, S.L. Parque Tecnológico, Edificio, 302 E Zamudio (Vizcaya) Tel Fax sew.spain@sew-eurodrive.es Sweden Assembly Jönköping SEW-EURODRIVE AB Gnejsvägen 6-8 S Jönköping Box 3100 S Jönköping Tel Fax info@sew-eurodrive.se Switzerland Assembly Basel Alfred lmhof A.G. Jurastrasse 10 CH-4142 Münchenstein bei Basel Tel Fax info@imhof-sew.ch Thailand Assembly Chonburi SEW-EURODRIVE (Thailand) Ltd. 700/456, Moo.7, Donhuaroh Muang Chonburi Tel Fax sewthailand@sew-eurodrive.com Tunisia Tunis T. M.S. Technic Marketing 5, Rue El Houdaibiah 1000 Tunis Tel Fax tms@tms.com.tn 86 04/2008

87 Address List Turkey Assembly 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 Ukraine Dnepropetrovsk SEW-EURODRIVE Str. Rabochaja 23-B, Office Dnepropetrovsk Tel Fax sew@sew-eurodrive.ua USA Production Assembly Assembly Greenville San Francisco Philadelphia/PA Dayton SEW-EURODRIVE INC Old Spartanburg Highway P.O. Box 518 Lyman, S.C SEW-EURODRIVE INC San Antonio St. Hayward, California 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 Dallas SEW-EURODRIVE INC Platinum Way Dallas, Texas Additional addresses for service in the USA provided on request! Tel Fax Fax Manuf Fax Ass Telex cslyman@seweurodrive.com Tel Fax cshayward@seweurodrive.com Tel Fax csbridgeport@seweurodrive.com Tel Fax cstroy@seweurodrive.com Tel Fax csdallas@seweurodrive.com Venezuela Assembly Valencia SEW-EURODRIVE Venezuela S.A. Av. Norte Sur No. 3, Galpon Zona Industrial Municipal Norte Valencia, Estado Carabobo Tel Fax ventas@sew-eurodrive.com.ve sewfinanzas@cantv.net 04/

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91 SEW-EURODRIVE Driving the world

92 Drive Technology \ Drive Automation \ System Integration \ s How we re driving the world With people who think fast and develop the future with you. With a worldwide service network that is always close at hand. With drives and controls that automatically improve your productivity. With comprehensive knowledge in virtually every branch of industry today. With uncompromising quality that reduces the cost and complexity of daily operations. SEW-EURODRIVE Driving the world With a global presence that offers responsive and reliable solutions. Anywhere. With innovative technology that solves tomorrow s problems today. With online information and software updates, via the Internet, available around the clock. SEW-EURODRIVE GmbH & Co KG P.O. Box 3023 D Bruchsal / Germany Phone Fax sew@sew-eurodrive.com