SEW-Eurodrive DR Series Addendum To The Operating Instructions
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SEW-Eurodrive DR Series Addendum To The Operating Instructions

Safety encoders and safety brakes, ac motors
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Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Operating
Instructions
Safety Encoders and Safety Brakes
DR.., DRN.., EDR.., EDRN.. AC Motors
Functional Safety
Edition 12/2017
*24766135_1217*
24766135/EN

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  • Page 1 *24766135_1217* Drive Technology \ Drive Automation \ System Integration \ Services Addendum to the Operating Instructions Safety Encoders and Safety Brakes DR.., DRN.., EDR.., EDRN.. AC Motors Functional Safety Edition 12/2017 24766135/EN...
  • Page 2 SEW-EURODRIVE—Driving the world...

  • Page 3: Table Of Contents

    Table of contents Table of contents General information........................  5 How to use this documentation.................. 5 Content of the documentation.................. 5 Other applicable documentation .................. 5 Safety notes ..........................  6 Preliminary information .................... 6 Designated use ....................... 6 Inspection/maintenance .................... 9 Functional safety (FS) ......................  10 Functionally safe motor options .................. 10 FS mark ........................ 11 Retraceability ........................ 12 Underlying standards .................... 12...
  • Page 4 Table of contents Index ............................  57 Glossary ..........................  58 Addendum to the Operating Instructions – DR.., DRN.., EDR.., EDRN.. AC Motors...

  • Page 5: General Information

    General information How to use this documentation General information How to use this documentation The current version of the addendum to the operating instructions is the ori- ginal. This addendum to the operating instructions contains special information on function- ally safe motor options (safety encoder and safety brake) of the DR.., DRN.., EDR.., EDRN..

  • Page 6: Safety Notes

    Safety notes Preliminary information Safety notes Preliminary information The following general safety notes have the purpose to avoid injury and damage to property. They primarily apply to the use of products described in this documentation. If you use additional components also observe the relevant warning and safety notes. Designated use •...
  • Page 7 Safety notes Designated use 2.2.1 Safety encoder • The safety encoders described in this documentation are intended for use with DR.., DRN.., EDR.., EDRN.. motors. It is not permitted to mount them to other mo- tors. • When using a safety encoder in combination with a BE.. brake, the brake may only be used as a holding brake.
  • Page 8 Safety notes Designated use 2.2.2 Safety brake • The safety brakes described in this documentation are intended for use with DR.., DRN.. motors. It is not permitted to mount them to other motors. • Operation of the BE.. safety brake in potentially explosive areas is not permitted. •...

  • Page 9: Inspection/Maintenance

    Safety notes Inspection/maintenance Inspection/maintenance Work on a drive with functionally safe motor options – indicated by the FS logo on the motor nameplate – can be performed by the operator. Any work on the safety encoder and/or the safety brake are carried out at your own risk.

  • Page 10: Functional Safety (Fs)

    Functional safety (FS) Functionally safe motor options Functional safety (FS) Functionally safe motor options Drives from SEW‑EURODRIVE are optionally available with functionally safe motor options. These options are intended for implementation of safety functions in safety- relevant applications. SEW‑EURODRIVE assumes responsibility for the delivered drive in terms of compli- ance of the functionally safe motor options with the functional safety regulations.

  • Page 11: Fs Mark

    Functional safety (FS) FS mark The safety brakes cannot trigger a safe state at the machine autonomously. The brakes have to be supplemented with a suitable brake control and monitored by brake diagnostics, if necessary. The overall system triggers a suitable error response, e.g. the safe state, on request.

  • Page 12: Retraceability

    Functional safety (FS) Retraceability Retraceability Functionally safe motor options can be retraced by SEW‑EURODRIVE with the motor serial number and thus have a unique assignment to the motor. If the SEW‑EURODRIVE service replaces a safety encoder or a safety brake, the re- traceability is ensured.

  • Page 13: Safety Functions

    Functional safety (FS) Safety functions Safety functions 3.6.1 Safety functions safety encoder ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y add-on encoders The following safety functions according to EN  61800‑5‑2 regarding speed, direction of rotation, idle state and relative position can be implemented in functionally safe sys- tems with the sine/cosine interface of the safety encoders: •...

  • Page 14: Requirements To The Follow-Up Electronics

    Functional safety (FS) Requirements to the follow-up electronics Requirements to the follow-up electronics 3.7.1 Add-on encoders: ES7S, EG7S, AS7W, AG7W, AS7Y, AG7Y The monitoring of the sine/cosine signals for detecting the safe state is performed by the follow-up electronics. The follow-up electronics has to check the sine/cosine sig- nals of the rotary encoder for validity.

  • Page 15: Brake Diagnostics

    Functional safety (FS) Brake diagnostics Brake diagnostics In applications with brakes, the braking torque represents an important criterion for the functionality of the brake. In the event of a reduction in or loss of braking torque, the correct functionality of the application is no longer ensured. As a result, the safety of the machine and/or even the safety of persons may be decreased.

  • Page 16: Motor Combinations

    Functional safety (FS) Motor combinations Motor combinations 3.9.1 Safety encoders The safety encoders described below are intended for use with DR.., DRN.., EDR.., EDRN.. motors. It is not permitted to mount them to other motors. Safety encoders at the DR.., DRN.. AC motor Motors Part number coders...
  • Page 17 Functional safety (FS) Motor combinations 3.9.2 Safety brake Motor combinations with BE.. brake Depending on the demands placed on the brake, different brake mounting sizes are available for mounting to the respective motor. The following table shows the possible motor and brake combinations: DR..
  • Page 18 Functional safety (FS) Motor combinations Braking torque graduations Depending on the demands placed on the brake, different braking torque graduations are available depending on the brake sizes. The following table shows the available graduations: Brake (M BE05 BE11 BE20 Bmax (5 Nm) (10 Nm) (20 Nm)

  • Page 19: Validation

    Functional safety (FS) Validation 3.10 Validation The system manufacturer has to perform an overall evaluation for determining the safety of a machine. The effectiveness of each risk minimization must be checked. It must also be checked if the required safety integrity (SIL and/or PL) is reached for each implemented safety function.

  • Page 20: Motor Structure

    Motor structure Nameplates Motor structure Nameplates 4.1.1 Motor The following figure shows an example motor nameplate with FS logo: R87 DRS90L4BE5/TF 41027997618 0001 Inverter duty VPWM 3ph.IEC60034 1400/22 220-242Δ/380-420Y r/min TEFC 2.2 S1 81.1 IE1 8.6/4.95 P.F. eff % 2.2 S1 7.2/4.15 84.0 IE1 P.F.
  • Page 21 Motor structure Nameplates 4.1.3 Safety brake The following figure shows an example self-adhesive label of a safety brake with FS logo: BE20 MN: 12345678901234 Use only with SEW-Rectifier ID: 0001.123456789012.160112 9007203740398475 Identification number of the brake: • 0001.: Plant • 123456789012.: Serial number of the brake •...

  • Page 22: Mechanical Installation

    Mechanical installation Manual brake release Mechanical installation INFORMATION Note that greases and oils must not be allowed on the mechanical connections of the safety components during assembly or operation. Manual brake release If the manual brake release was ordered, the manual brake release is installed and set at the factory.

  • Page 23: Electrical Installation

    Electrical installation Connecting the EI7C FS encoder Electrical installation INFORMATION SEW‑EURODRIVE recommends using prefabricated cables from SEW‑EURODRIVE to connect the safety encoders. Connecting the EI7C FS encoder There is an 8-pin M12 plug connector on the terminal box for connection. M12 AVRE male, A-coded Pin 1:...

  • Page 24: Ei7C Fs Visual Feedback

    Electrical installation EI7C FS visual feedback EI7C FS visual feedback The LED display, which is visible when the fan guard is removed, provides visual feed- back about the signal track state. A red LED and a green LED are used as a status display for the EI7C FS safety en- coder.

  • Page 25: Temperature Sensor /Tf

    Electrical installation Temperature sensor /TF 6.2.5 LED codes for the operating statuses Normal operation Displayed status Green LED Red LED (status) (error) No voltage or defective Internal diagnostics error No error No errors at the moment. Error code Most recent error is displayed. An error has occurred.

  • Page 26: Brake Control

    Electrical installation Brake control Brake control The brake is released electrically. The brake applies after the voltage is switched off. The braking or stopping takes place mechanically. These voltage disconnection types are distinguished: • Functional control Control of the brake outside functional safety. •...

  • Page 27: Inspection/Maintenance

    Inspection/maintenance Safety encoder Inspection/maintenance Safety encoder Certain demands on the mechanical coupling of the encoder system to the motor must be met so that the encoder can be used for safety-relevant tasks. With the EI7C FS built-in encoder, no work may be performed on the encoder. Order the SEW‑EURODRIVE service to perform any necessary work on the encoder.

  • Page 28: Removing/Installing The Encoder

    Inspection/maintenance Removing/installing the encoder Removing/installing the encoder INFORMATION When installing an encoder, observe the tightening torques specified in this docu- mentation to avoid a faulty mechanical connection between the drive component and the rotary encoder according to EN 61800-5-2. 7.2.1 Required tools You need the following tools to assemble and disassemble the encoders.
  • Page 29 Inspection/maintenance Removing/installing the encoder 7.2.2 Removing/installing the encoder from DR..71 – 132, DRN80 – 132S The following figure illustrates the disassembly procedure using the ES7./AS7. en- coder as an example: [362] [619] [B] [G] [220] [35] [34] [361] 2583101195 [34] Tapping screw Retaining screws for the torque bracket [35] Fan guard Central retaining screw...
  • Page 30 Inspection/maintenance Removing/installing the encoder Re-assembly ® 1. Apply a contact corrosion prevention compound, e.g. NOCO fluid to the encoder pin. 2. Install the tooth lock washer [G] and tighten the central retaining screw [B] with a tightening torque of 2.75 Nm ± 5%. •...
  • Page 31 Inspection/maintenance Removing/installing the encoder 7.2.3 Removing/installing the encoder from DR..150 – 280, DRN132M – 280 The following figure illustrates the disassembly procedure using the EG7./AG7. en- coder as an example: SW17 [706] [657] [707] [35] [220] [232] [619] [715] [361] [33] [34] 2583097355 [33] Washer [657] Canopy...
  • Page 32 Inspection/maintenance Removing/installing the encoder Disassembling EG7./AG7. 1. Depending on the housing design, perform one of the following steps: • Loosen the screws [707] and remove the canopy [657]. Use SW13 spacer bolts [706] to counterhold. Remove forced cooling fan, if installed. •...

  • Page 33: Measuring Wobbling

    Inspection/maintenance Measuring wobbling Measuring wobbling Fault exclusion of the mechanical motor-encoder connection according to EN 61800-5-2 requires that the encoder is seated properly. Wobbling must be meas- ured each time an encoder is installed to ensure it is seated properly. Measure wobbling as described in the following chapters. 7.3.1 Encoders for DR..71 –...
  • Page 34 Inspection/maintenance Measuring wobbling 7.3.2 Encoders for DR..160 – 280, DRN132M – 280 1. Place the sensor on the upper edge of the encoder as shown in the figure below: > 5 mm 9007203226345867 2. The measurement must be carried out within the marked zone (maximum width = 5 mm).

  • Page 35: Inspection And Maintenance Intervals

    Inspection/maintenance Inspection and maintenance intervals Inspection and maintenance intervals Inspect and service the safety brake according to the projected inspection and main- tenance intervals or every 0.5 to 2 years depending on the load conditions. If a diagnostic unit /DUE is used, the wear output of the evaluation unit indicates whether brake maintenance is required.

  • Page 36: Safety Brake

    Inspection/maintenance Safety brake Safety brake NOTICE Improperly carried out work or changes to the technical properties on functionally safe motor options. Loss of the safety function. ü Improperly carried out work on functionally safe motor options or changes to the technical properties can result in loss of the motor options' safety functions.
  • Page 37 Inspection/maintenance Safety brake Type of work Work permitted? Comments Retrofit manual brake Contact SEW‑EURODRIVE. release /HR. Replace manual brake re- – lease /HR. Retrofit diagnostic Replacement of safety brake neces- unit /DUE. sary. Replace diagnostic unit / – DUE. Retrofit brake monitoring / Replacement of safety brake neces- DUB.

  • Page 38: Preliminary Work For Motor And Brake Maintenance

    Inspection/maintenance Preliminary work for motor and brake maintenance Preliminary work for motor and brake maintenance 7.6.1 General information Proceed as described in the respective documentation to remove and install the en- coder/safety encoder and/or forced cooling fan. Before you complete the maintenance work, restore all protection devices at the drive. INFORMATION Observe the following points for inspection and maintenance: •...
  • Page 39 Inspection/maintenance Preliminary work for motor and brake maintenance 7.6.3 Order information for operating supplies and auxiliary material for maintenance The following sections lists the various operating supplies and auxiliary materials that are required for correct maintenance. Manufacturer Operating sup- Part num- Quan- Place Motors...

  • Page 40: Inspection Steps For Dr..71 - 225, Drn80 - 225 Brakemotors

    Inspection/maintenance Inspection steps for DR..71 – 225, DRN80 – 225 brakemotors Inspection steps for DR..71 – 225, DRN80 – 225 brakemotors WARNING Risk of crushing if the hoist falls or in the event of uncontrolled device behavior. Severe or fatal injuries. • Secure or lower the hoist drives. •...
  • Page 41 Inspection/maintenance Inspection steps for DR..71 – 225, DRN80 – 225 brakemotors 120° 18014398689460619 4. Remove abrasion from the brake. 5. Install the sealing strip [66] and clamping strap [157], if necessary. 6. Install the fan guard with encoder mount or fan guard [35] and the forced cooling fan [170].

  • Page 42: Work Steps For Brake Replacement

    Inspection/maintenance Work steps for brake replacement Work steps for brake replacement WARNING Risk of crushing if the hoist falls or in the event of uncontrolled device behavior. Severe or fatal injuries. • Secure or lower the hoist drives. • Secure and/or fence in the driven machine. •...
  • Page 43 Inspection/maintenance Work steps for brake replacement 7.8.1 DR..71 – 80, DRN80 1. Remove the terminal box cover and loosen the brake cable from the brake control/ terminals. If necessary, attach trailing wire to brake cables. 2. Loosen cap screws [13] and remove brake endshield with brake [550] from stator [1].
  • Page 44 Inspection/maintenance Work steps for brake replacement 7.8.2 DR..90 – 132, DRN90 – 132S 1. Remove the terminal box cover and loosen the brake cable from the brake control/ terminals. 2. Loosen screws [900] and remove brake [550] from brake endshield. 3.
  • Page 45 Inspection/maintenance Work steps for brake replacement 7.8.3 DR..160 – 225, DRN132M – 225 1. Loosen safety screws of the brake plug connector [698] and remove plug con- nector. 2. Loosen screws [900] and remove brake [550] from brake endshield. 3. Replace retaining ring [62], driver [70] and key [71], if necessary. 4.

  • Page 46: Diagnostic Unit /Due For Function And Wear Monitoring

    Inspection/maintenance Diagnostic unit /DUE for function and wear monitoring Diagnostic unit /DUE for function and wear monitoring The evaluation unit has a 5-pin DIP switch that is labeled with the numbers 1 to 5. Use it to set the measuring range and the maximum permitted wear limit (maximum work- ing air gap).
  • Page 47 Inspection/maintenance Diagnostic unit /DUE for function and wear monitoring 7.9.1 DIP switch setting values for option /DUE The following tables show the setting values of the DIP switches the option /DUE when a BE.. safety brake is present. Wear limit BE1 –...

  • Page 48: Technical Data

    Technical data Safety encoder Technical data Safety encoder 8.1.1 Characteristic safety values INFORMATION In addition to the documentation, you can also obtain the characteristic safety values of components by SEW-EURODRIVE in the SEW-EURODRIVE library for the SIS- TEMA software tool. The documentation as well as the library are available for down- load at http://www.sew-eurodrive.de/.
  • Page 49 Technical data Safety encoder Characteristic safety values AS7W, AG7W, AS7Y, AG7Y Characteristic safety values according to EN 62061/IEC 61508 EN ISO 13849‑1 Safety class/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 6.4 × 10 1/h = 6.4 FIT (T ≤...
  • Page 50 Technical data Safety encoder 8.1.2 Encoders ES7S, EG7S, AS7Y, AG7Y, AS7W, AG7W Designation Value Operating temperature of encoder -30 °C to +85 °C Ambient temperature of motor -30 °C to +60 °C Storage temperature -15 °C to +70 °C Maximum speed 6000 1/min Vibration resistance (EN 60068-2-6) ≤100 m/s ≈...
  • Page 51 Technical data Safety encoder AS7Y, AG7Y Name Value Operating voltage DC +7 to +30 V Current consumption without load 100 mA Resolution of the incremental section Sin/cos interface 2048 periods/revolution Accuracy of the incremental section 0.0194 ° (70 angular seconds) Resolution of the absolute section SSI interface, gray-coded 12 bit = 4096 revolutions (single-turn) 12 bit = 4096 revolutions (multi-turn)
  • Page 52 Technical data Safety encoder EI7C FS Supply min. Typ. max. Unit Operating voltage 19.2 Max. current consumption (with no = 24 V, I = 0) load) 1) The voltage supply must come from SELV/PELV circuits in accordance with DIN EN 61131-2 Name Value Max.

  • Page 53: Safety Brake

    Technical data Safety brake Safety brake 8.2.1 Braking work until maintenance Braking work BE.. brake Braking work BE.. safety brake until inspection (W until inspection (W Insp Insp in 10  J in 10  J FS code – FS04, FS07 FS02 FS11 Brake BE05...
  • Page 54 Technical data Safety brake 8.2.3 Safety characteristics INFORMATION In addition to the documentation, you can also obtain the characteristic safety values of components by SEW-EURODRIVE in the SEW-EURODRIVE library for the SIS- TEMA software tool. The documentation as well as the library are available for down- load at http://www.sew-eurodrive.de.
  • Page 55 Technical data Safety brake 8.2.4 Brake controls Combinations of brake controls The tables below show the standard and optional combinations of safety brake and brake rectifiers. Installation in control cabinet Type des- Voltage range BE05 BE11 BE20 BE30 ignation BE32 BST 0.6S AC 460 BST 0.7S...
  • Page 56 Technical data Safety brake Installation in the motor wiring space Type des- Voltage range BE05 BE11 BE20 BE30 ignation BE32 BG 1.4 AC 230 – 575 • • – – – – BG 1.5 AC 150 – 500 • • –...
  • Page 57 Index Index Icons Mechanical installation Manual brake release /HR...... 22 (Dis)assembly work ........ 27, 36 Motor maintenance, preliminary work .... 39 /TF ...............  25 Motor/brake assignment ........ 17 Brake Perform concentricity test ........ 33 Braking torque graduations ...... 18 Perform wobble measurement ...... 33 Maintenance intervals ........
  • Page 58 Glossary Glossary Number of cycles until 10% of the components Safe Brake Control safety function endanger through failure (for pneumatic and elec- tromechanical components) Cat. Category Safe Brake Hold safety function Common cause failure Safe brake system Diagnostic coverage Safe Direction safety function Average diagnostic coverage Safety integrity level SISTEMA...
  • Page 64 SEW-EURODRIVE—Driving the world SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Str. 42 76646 BRUCHSAL GERMANY Tel. +49 7251 75-0 Fax +49 7251 75-1970 sew@sew-eurodrive.com www.sew-eurodrive.com...

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