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Motrona DS230 Series Safety Manual

Safety monitor for sincos and incremental encoders / sensors
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Safety Manual
Safety monitor for SinCos and incremental encoders / sensors
Product features:
• Monitoring underspeed, overspeed, standstill and direction of rotation
• SIL3 and PLe certification
• Safety functions equivalent to EN61800-5-2 (SS1, SS2, SOS, SLS, SDI, SSM)
• Mounting to 35 mm top hat rail (according to EN 60715)
• USB interface for simple parametrization by the OS 6.0 operator surface
• Optional available display and programming unit BG230 for parametrization and indication
• Inputs for:
• Outputs:
• Signal splitter:
Available devices:
 DS230: All inputs and outputs as well as signal splitter function
 DS236: All inputs and outputs, but without signal splitter function
 DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function
 DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter
motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, info@motrona.com, www.motrona.com
DS230 / DS240 series
2 SinCos encoders
2 RS422 incremental encoders
2 HTL/PNP incremental encoders, proximity switches or control signals
1 Relay Output 5 ... 36 VDC (NO), (safety related)
1 Analog Output 4 ... 20 mA, (safety related)
4 Control HTL Outputs, (safety related)
1 SinCos Splitter Output, (safety related)
1 RS422 Splitter Output, (safety related)

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Summary of Contents for Motrona DS230 Series

  • Page 1  DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function  DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, info@motrona.com, www.motrona.com...
  • Page 2 First edition series Rechtliche Hinweise: All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH. Any reproduction, modification, usage or publication in other electronic and printed media as well as in the internet requires prior written authorization by motrona GmbH.

  • Page 3: Table Of Contents

    Table of Contents 1. Safety Instructions and Responsibility ............5 1.1. General Safety Instructions .................. 5 1.2. Use according to the intended purpose ..............5 1.3. Installation ......................6 1.4. Cleaning, Maintenance and Service Notes ............6 2. Introduction ....................7 3.
  • Page 4 6. Operational Modes ..................31 6.1. Operational Modes of DS23x types ..............31 6.2. Operational Mode of DS24x types ..............32 6.3. Achievable Safety Levels of DS23x ..............33 6.4. Achievable Safety Level of DS24x ..............34 6.5. „Operational Mode“ = 0 (DS23x) ................ 35 6.6.

  • Page 5: Safety Instructions And Responsibility

    1. Safety Instructions and Responsibility 1.1. General Safety Instructions This operation manual is a significant component of the unit and includes important rules and hints about the installation, function and usage. Non-observance can result in damage and/or impairment of the functions to the unit or the machine or even in injury to persons using the equipment! Please read the following instructions carefully before operating the device and observe all safety and warning instructions! Keep the manual for later use.

  • Page 6: Installation

    Please find all respective hints and rules on www.motrona.com/download.html --> [General EMC Rules for Wiring, Screening and Earthing]. 1.4. Cleaning, Maintenance and Service Notes To clean the front of the unit please use only a slightly damp (not wet!), soft cloth.

  • Page 7: Introduction

    2. Introduction This series of speed monitors is suitable for safety-related monitor tasks e. g. over-speed, under- speed, standstill and direction of rotation. This SIL3/PLe certified generation of devices was developed to achieve functional safety by supporting a wide range of sensors and encoders in different combinations.

  • Page 8: Available Models

    3. Available Models D S 2 x x Unit Speed Monitor Application Safety Applications Housing Housing for DIN rail mounting into a control cabinet (according to EN 60715) Inputs 2 Inputs for SinCos encoders 2 Inputs for incremental RS422 encoders 2 Inputs for HTL/PNP incremental encoders or HTL/PNP control signals 1 Input for SinCos encoder with SIL3 / PLe...

  • Page 9: Block Diagrams And Connections

    4. Block Diagrams and Connections 4.1. DS230 Block Diagram 4.2. DS230 Connections Ds230_03a_oi_e.doc / Jun-15 Page 9 / 100...

  • Page 10: Ds236 Block Diagram

    4.3. DS236 Block Diagram 4.4. DS236 Connections Ds230_03a_oi_e.doc / Jun-15 Page 10 / 100...

  • Page 11: Ds240 Block Diagram

    4.5. DS240 Block Diagram 4.6. DS240 Connections Ds230_03a_oi_e.doc / Jun-15 Page 11 / 100...

  • Page 12: Ds246 Block Diagram

    4.7. DS246 Block Diagram 4.8. DS246 Connections Ds230_03a_oi_e.doc / Jun-15 Page 12 / 100...

  • Page 13: Description Of Connections

    5. Description of Connections This chapter describes only the electrical connections and their general function. For a detailed technical information please refer the chapter 11. Name Description see chapter X1 | RELAY OUT 5.10 Relay-Output X2 | CONTROL OUT 5.9 Control-Outputs X3 | 24V IN 5.1 Power Supply X4 | ANALOG OUT...

  • Page 14: Power Supply

    5.1. Power Supply If the unit is connected to a DC power supply network, which supplies further devices or systems, it must be ensured that no voltages ≥ 60 V can occur at the terminals X3:1 and X3:2. If this cannot be ensured, the unit must be supplied by a separate DC power pack, which may not be connected to further devices or systems.

  • Page 15: Encoder Supply

    5.2. Encoder Supply The unit offers an auxiliary voltage output to power the used encoder resp. sensors. The power supply of the encoders must be carried out directly from the safety unit (see chapter 5.2.1) or in use of an external power supply via a relay (see chapter 5.2.2). Encoder supply: SinCos inputs [X6] [X7] Encoder supply: RS422 inputs [X8] [X9] HTL encoders or sensors must also be connected to the encoder supply of the RS422 inputs...
  • Page 16 5.2.1. Direct Encoder Supply The unit provides an auxiliary encoder supply for each sensor channel (HTL encoders must be supplied by the encoder supply for the RS422 inputs). The level of the supply voltage is approximate 2 V below the 18 … 30 VDC power supply at terminal [X3].
  • Page 17 5.2.2. External Encoder Supply An external encoder supply must be done in each case via a relay which is triggered by the auxiliary voltage of the unit. This is necessary, because the encoder supply will only be activated after the safety unit has successfully completed its initialization and self-test.
  • Page 18 Continuation “External Encoder Supply” Example of an external encoder supply (2 encoders are switched via 1 relay)  An external encoder supply must be done in each case via a relay which is triggered by the auxiliary voltage of the unit. ...

  • Page 19: Sincos-Inputs

    5.3. SinCos-Inputs If the operational mode is set for using SinCos encoders (see chapter 7.4.1 / Parameter 000), the unit will accept SinCos input signals with 1 Vpp and 2.5 V DC-offset at the 9-pin SUB-D connectors [X6] and [X7]. It is mandatory to connect up always all existing signal lines (SIN+, SIN-, COS+ and COS-).

  • Page 20: Rs422-Inputs

    5.4. RS422-Inputs (Only DS230 and DS236) If the operational mode (see chapter 7.4.1 / Parameter 000) is set for RS422 encoder use, the unit will accept differential input signals from an incremental encoder in RS422 format at the terminal strips [X8] and [X9]. The RS422 input channels (A and /A resp. B and /B) are internally terminated by a dynamic terminating circuit (220 pF / 120 ohm).

  • Page 21: Htl / Control Inputs

    5.5. HTL / Control Inputs The screw terminal [X10 | CONTROL IN] has two inputs for signals with HTL level and PNP switching characteristic. Each of the inputs performs complementary. Depending on the operational mode (see chapter 7.4.1 / Parameter 000), the control inputs [X10 | CONTROL IN] can be configured as frequency or as command inputs: Frequency input for HTL encoders (A / B / 90°): [X10:2] channel A...

  • Page 22: Sincos-Splitter-Output

    5.6. SinCos-Splitter-Output (only DS230 and DS240) The DS230 respective the DS240 has a safety-related SinCos-Splitter-Output. Depending on the selected operating mode (0, 1, 2 or 6), the integrated splitter function allows to reproduce the signal at input terminal [X6 | SINCOS IN 1] to the female 9-pin SUB-D connector [X5 ].

  • Page 23: Rs422-Splitter-Output

    5.7. RS422-Splitter-Output (only DS230 and DS240) The DS230 respective the DS240 has a safety-related RS422-Splitter-Output. Depending on the selected operating mode, the integrated splitter function allows to reproduce an input frequency to the output terminal X4 | RS422 OUT. Thereby the RS422 signal can be processed by a further device. The block diagrams (see chapter 4) give an overview.

  • Page 24: Analog-Output 4 To 20 Ma

    5.8. Analog-Output 4 to 20 mA One safety-related analog output is available at the screw terminal [X4]. The current output is freely scalable (see chapter 7.4.10). It delivers an output signal, which is proportional to one of the input frequency (see chapter 7.4.1 / Parameter 003) and independent from the connected sensor types.

  • Page 25: Control-Outputs

    5.9. Control-Outputs Four safety-related HTL control outputs are available at the screw terminal [X2 | CONTROL OUT]. Each of the output performs complementary (OUT1, /OUT1 to OUT4, /OUT4). The switching points and conditions are adjustable by Parameters (see chapter 7.4.5 and 7.4.6) In normal state (no error, no switching conditions active) the non-inverted outputs offers LOW level and the inverted outputs offers HIGH level.

  • Page 26: Relay-Output

    5.10. Relay-Output The safety-related relay-output consists of two independent relays with force guided contacts. The normally open contacts of the two relays (NO) are internally connected in series. At the 2-pin screw terminal [X1 | RELAY OUT] the series-relay-contact can be tapped for integration into a safety circuit. The contacts are only closed during normal and disturbance-free operation.

  • Page 27: Dil Switch

    5.11. DIL switch The 3-position DIL switch [S1] is located at the front of the unit (only accessible, if no display-unit is connected). 3-pos DIL switch [S1] The following unit-states can be set by the DIL switch: Slider Condition Unit-State „Normal Operation“...

  • Page 28: Interface For Display Unit Bg230

    5.12. Interface for Display Unit BG230 The serial interface serves for communication between the unit and an optional programming- and display unit „BG320“, which can be plugged on the front. 8-pin female connector [X11] The programming and display unit BG230 and the safety unit will be connected by plugging the BG230 on the female 8-pin connector [X11] at the front.

  • Page 29: Usb Interface For The Os6.0 Operator Surface

    5.13. USB Interface for the OS6.0 Operator Surface For communication between the unit and a PC or a super ordinate controller, a serial interface simulation is accessible at the USB port. For connection a standard USB-cable with a „Type B“ connector is used.

  • Page 30: Leds / Status Indication

    5.14. LEDs / Status Indication Two status LEDs are located at the front of the unit. The green one is marked as [ON] and the yellow one as [ERROR]. Status LEDs The green status LED uses the following two conditions: LED (green) Condition Power off - no power supply voltage...

  • Page 31: Operational Modes

    6. Operational Modes 6.1. Operational Modes of DS23x types The operational modes can be specified in the Main Menu (see chapter 8.4.1 / Parameter 000). Mode Sensor1 Sensor2 Control1 Control2 SinCos encoder at SinCos encoder at available for control available for control [X6 | SINCOS IN 1] [X7 | SINCOS IN 2] signals...

  • Page 32: Operational Mode Of Ds24X Types

    6.2. Operational Mode of DS24x types In Case of DS24x, only “operational mode = 0” (see chapter 8.4.1 / Parameter 000) has to be used. Mode Sensor1 Sensor2 Control1 Control2 SIL3/PLe SinCos encoder Sensor1 and Sensor2 are available for control available for control [X6 | SINCOS IN 1] internally bridged...

  • Page 33: Achievable Safety Levels Of Ds23X

    6.3. Achievable Safety Levels of DS23x To achieve a maximum of SIL3/PLe on system-level, no certificated sensors are required to fulfil the integrity of the device. When using standard sensors, only the required safety level (by complying the safety-related characteristics SFF, HFT, Type A/B, PFH, PFD resp. category, DCavg and MTTFd) and systematic safety integrity must be ensured for the entire protection circuit.

  • Page 34: Achievable Safety Level Of Ds24X

    6.4. Achievable Safety Level of DS24x To achieve a maximum of SIL3/PLe on system-level, a SIL3/PLe certificated sensor is required to fulfil the integrity of the device. The required safety level (by complying the safety-related characteristics SFF, HFT, Type A/B, PFH, PFD resp. category, DCavg and MTTFd) and systematic safety integrity must be ensured for the entire protection circuit.

  • Page 35: Operational Mode" = 0 (Ds23X)

    6.5. „Operational Mode“ = 0 (DS23x) Mode Sensor1 [X6 | SINCOS IN 1] SinCos encoder (SIN+, SIN-, COS+, COS-) Sensor2 [X7 | SINCOS IN 2] SinCos encoder (SIN+, SIN-, COS+, COS-) Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 [X10 | CONTROL IN] HTL/PNP control signal...

  • Page 36: Operational Mode" = 0 (Ds24X)

    6.6. „Operational Mode“ = 0 (DS24x) Mode Sensor1 [X6 | SINCOS IN 1] SinCos encoder (SIN+, SIN-, COS+, COS-) Sensor2 Sensor1 and Sensor2 are internally bridged Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Speed...

  • Page 37: Operational Mode" = 1

    6.7. „Operational Mode“ = 1 Mode Sensor1 [X6 | SINCOS IN 1] SinCos encoder (SIN+, SIN-, COS+, COS-) Sensor2 [X10 | CONTROL IN] Incremental HTL encoder (A, B, 90°) Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 Control signal input not available Speed ...

  • Page 38: Operational Mode" = 2

    6.8. „Operational Mode“ = 2 Mode Sensor1 [X6 | SINCOS IN 1] SinCos encoder (SIN+, SIN-, COS+, COS-) Sensor2 [X10 | CONTROL IN] Incremental HTL encoder (A) single channel Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 Control signal input not available Speed ...

  • Page 39: Operational Mode" = 3

    6.9. „Operational Mode“ = 3 Mode Sensor1 [X10 | CONTROL IN] Incremental HTL encoder (A, B, 90°) Sensor2 [X10 | CONTROL IN] Incremental HTL encoder (A, B, 90°) Control1 Control signal input not available Control2 Control signal input not available Speed ...

  • Page 40: Operational Mode" = 4

    6.10. „Operational Mode“ = 4 Mode Sensor1 [X10 | CONTROL IN] Incremental HTL encoder (A, B, 90°) Sensor2 [X10 | CONTROL IN] Incremental HTL encoder (A) single channel Control1 Control signal input not available Control2 Control signal input not available Speed ...

  • Page 41: Operational Mode" = 5

    6.11. „Operational Mode“ = 5 Mode Sensor1 [X10 | CONTROL IN] Incremental HTL encoder (A) single channel Sensor2 [X10 | CONTROL IN] Incremental HTL encoder (A) single channel Control1 Control signal input not available Control2 Control signal input not available Speed ...

  • Page 42: Operational Mode" = 6

    6.12. „Operational Mode“ = 6 Mode Sensor1 [X6 | SINCOS IN 1] SinCos encoder (SIN+, SIN-, COS+, COS-) Sensor2 [X9 | RS422 IN 2] Incremental RS422 / TTL encoder (A, /A, B, /B) Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 [X10 | CONTROL IN]...

  • Page 43: Operational Mode" = 7

    6.13. „Operational Mode“ = 7 Mode Sensor1 [X8 | RS422 IN 1] Incremental RS422 / TTL encoder (A, /A, B, /B) Sensor2 [X9 | RS422 IN 2] Incremental RS422 / TTL encoder (A, /A, B, /B) Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2...

  • Page 44: Operational Mode" = 8

    6.14. „Operational Mode“ = 8 Mode Sensor1 [X8 | RS422 IN 1] Incremental RS422 / TTL encoder (A, /A, B, /B) Sensor2 [X9 | RS422 IN 2] Incremental HTL encoder (A, B, 90°) Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 Control signal input not available...

  • Page 45: Operational Mode" = 9

    6.15. „Operational Mode“ = 9 Mode Sensor1 [X8 | RS422 IN 1] Incremental RS422 / TTL encoder (A, /A, B, /B) Sensor2 [X9 | RS422 IN 2] Incremental HTL encoder (A) single channel Control1 [X10 | CONTROL IN] HTL/PNP control signal (complementary) Control2 Control signal input not available...

  • Page 46: Start-Up The Unit

    7. Start-Up the Unit The following chapter describes the various options for setting and configuring the unit. In order to put the unit into operation or to change settings and Parameters, the following measures must be taken:  Connect the unit to a 18 … 30 VDC power supply source ...

  • Page 47: Setup By Pc

    The parameterization of the safety device can be done by the operator software OS6.0. The operator software is included in the delivery on CD and is also available for download on www.motrona.com. After a successful installation of the operator software OS6.0 and the USB driver (see document “installation USB driver”) the PC can be connected via a USB cable to the safety device.

  • Page 48: Setup By The Programming Module Bg230

    7.2. Setup by the Programming Module BG230 The parameterization of the safety device also can be done by the programming module BG230. The optional display- and programming module BG230 is used for Parameter settings and diagnosis without a PC. It is easily connectable by plugging onto the front of the safety unit. Parameterization by BG230 The functions of the BG230 programming- and display unit are described in the BG230 manual.

  • Page 49: Parameter / Menu Overview

    7.3. Parameter / Menu Overview This section provides an overview of the menus and their assignments to the different unit functions. The menu names are printed bold and associated Parameters are arrayed directly under the menu names. Menu / Parameter Menu / Parameter Main Menu Preselect Menu...
  • Page 50 Continuation “Parameter / Menu Overview”: Menu / Parameter Menu / Parameter Switching Menu Command Menu Switch Mode OUT1 Input2 Function Switch Mode OUT2 Input2 Configuration Switch Mode OUT3 Input2 Function Switch Mode OUT4 Input2 Configuration Switch Mode REL1 Reserved Pulse Time OUT1 Reserved Pulse Time OUT2 Serial Menu...

  • Page 51: Parameter Description

    7.4. Parameter Description 7.4.1. Important notes for DS240 / DS246 When using a DS240 resp.DS246 variant, the following hints must be noted: Parameter Hints for DS240 /. DS246 Operational Mode Exclusively „Mode = 0“ may be used F1-F2 Selection Both settings have the same effect Direction1 Direction1 and Direction2 must be equal Multiplier1...
  • Page 52 7.4.2. Main Menu Parameter Range Default Operational Mode: 0 - 9 Important notes for DS240 / DS246 see chapter 7.4.1 This parameter determines which frequency input ([X6] up to [X10]) is assigned to the sensor channel Sensor1 and Sensor2. Depending on the assignment, up to two control inputs (Control1 resp.
  • Page 53 Continuation “Main Menu”: Parameter Range Default Sampling Time: 0,001 - 9,999 0,001 (sec.) The configured value corresponds to the minimum measurement time. The Parameter is used as a filter in case of irregular frequencies. This Parameter has a direct influence to the reaction time of the unit. The setting is valid for both inputs channels.
  • Page 54 Continuation “Main Menu”: Parameter Range Default F1-F2 Selection 0 - 1 (Basic Frequency Selection) Important notes for DS240 / DS246 see chapter 7.4.1 This Parameter determines, which of both input frequencies of sensor1 or sensor2 (see parameter 000) is monitored and processed as basic frequency.
  • Page 55 Continuation “Main Menu”: Parameter Range Default Div. Switch %-f 0 - 999.99 100.00 (Divergence switching point %-Hz) (Hz) The unit constantly compares the frequencies of sensor1 and Sensor2 to the adjusted, maximum allowed divergence. Usually the comparison works percentages. Application-specific with lower frequencies a percentages comparison can be problematic, so that a direct monitoring of the difference frequency in Hz can deliver better results.
  • Page 56 Continuation “Main Menu”: Parameter Range Default Div. Filter: 0 - 20 The exact function will be described soon!!! This digital filter parameter evaluates the divergence between sensor1 and sensor2. The filter is not active: The unit reacts immediately to each frequency deviation.
  • Page 57 Continuation „Main Menu“: Parameter Range Default Error Simulation: 0 - 2 This Parameter is only allowed in the “Programming Mode” (see chapter 5.11) and serves only for test purposes during the commissioning procedure. It allows to simulate and prevent the following error messages: Error state: Sets the unit into error status.
  • Page 58 7.4.3. Sensor1 Menu Parameter Range Default Direction1: 0 - 1 Important notes for DS240 / DS246 see chapter 7.4.1 Parameter to assign a direction for Sensor1 No changes Changes the sign of the direction This allows to reverse the direction of Sensor1 in order to adapt Sensor1 to the direction of Sensor2.
  • Page 59 Continuation “Sensor1 Menu”: Parameter Range Default Position Drift1 (drift monitoring at standstill): 0 - 100 000 Important notes for DS240 / DS246 see chapter 7.4.1 This Parameter handles drift movements at standstill. If the period time of the input frequency exceeds the adjusted „Wait-Time“ (see parameter 002), the sensor is assigned to frequency = 0, even if a slow drift movement is present.
  • Page 60 7.4.4. Sensor2 Menu Parameter Range Default Direction2: 0 - 1 The description of the Multiplier2: 1- 10 000 sensor2 Parameters is Divisor2: identically with the sensor1 1 - 10 000 menu, but all settings are Position Drift2: 0 - 100 000 related to sensor2 which is specified by the „Operation Phase Err Count2:...
  • Page 61 7.4.5. Preselect Menu This menu is used to set the switching points of the following outputs: 1 x relay output [X1 | RELAY OUT] 4 x control output [X2 | CONTROL OUT] All settings are related to the selected basic frequency (see parameter 003) considering to the adjusted scaling factor of the basic sensor (see chapter 7.4.3).
  • Page 62 „Preselect Menu“ Parameter Range Default Preselect OUT1.H: 10 000 Upper switching point of output OUT1 [X2:1-2] -500 000.0 Preselect OUT1.L: 20 000 Lower switching point of output OUT1 [X2:1-2] 500 000.0 Preselect OUT2.H: 30 000 (Hz) Upper switching point of output OUT2 [X2:3-4] (see basic Preselect OUT2.L: 40 000...
  • Page 63 7.4.6. Switching Menu This menu is used to set the switching conditions of the following outputs: 1 x relay output [X1 | RELAY OUT] 4 x control output [X2 | CONTROL OUT] The following form of writing is used: = absolute value of the basic frequency (see parameter 003) |Preselection| = absolute value of the switching point (see parameter 027, ff.) = direction dependent, direction signed basic frequency (see parameter 003) Preselection = direction dependent, direction signed switching point (see parameter 027, ff.)
  • Page 64 „Switching Menu“: Parameter Range Default Switch Mode OUT1 (switching condition for OUT1) |f| >= |Preselection| {S, H} Output switches in event of overspeed |f| <= |Preselection| {S, H, A} Output switches in event of underspeed |f| == |Preselection| {S, H, A} Output switches in event of leaving the frequency band (Preselection +/- Hysteresis) Standstill (see parameter 056)
  • Page 65 Parameter Range Default Switch Mode REL1 0 - 8 (switching condition for relay output) |f| >= |Preselection| {S, H} Output switches in event of overspeed |f| <= |Preselection| {S, H, A} Output switches in event of underspeed |f| == |Preselection| {S, H, A} Output switches in event of leaving the frequency band (Preselection +/- Hysteresis)
  • Page 66 Continuation “Switching Menu”: Parameter Range Default Pulse Time OUT1 0 - 9.999 (Wipe Signal Period of OUT1) (sec.) static wipe signal ≠0: wipe signal period in seconds Pulse Time OUT2 (Wipe Signal Period of OUT2) Settings are analogous to „Pulse Time OUT1“ Pulse Time OUT3 (Wipe Signal Period of OUT3) Settings are analogous to „Pulse Time OUT1“...
  • Page 67 Continuation “Switching Menu”: Parameter Range Default Start-up Mode 0 - 9 (start-up delay time window) Delay time window until the monitoring function is activated. Only useful in combination with switching mode 1 and 5 (see chapter 7.4.6). To use the start-up delay, it must be assigned to an output (see parameter 055).
  • Page 68 Continuation “Switching Menu”: Parameter Range Default Standstill Time 0 - 9.999 (delay time until „standstill“) (sec.) This parameter defines the delay time until the unit detects „standstill“ after detecting „frequency = 0“. Prior condition is that both input frequencies are detected as „Zero“ = 0).
  • Page 69 Continuation “Switching Menu”: Parameter Range Default Action Output 0 - 31 (output selection for overwriting) The function to set fixed output conditions by overwriting is only effective in the “Programming Mode” (see chapter 5.11). It is used for test purposes and allows to force each output to a defined switching condition.
  • Page 70 Continuation “Switching Menu”: Parameter Range Default Action Polarity 0 - 511 (setting the output conditions) This setting-function is only effective in the “Programming Mode” (see chapter 5.11) and requires a selection of the corresponding outputs (see parameter 058). For security reasons the 4 digital outputs are complementary, which means that each output has one direct track and an inversed one (marked by a slash „/“).
  • Page 71 7.4.7. Control Menu This chapter describes the features and configuration options of the control inputs. Depending on the operating mode (see chapter ), up to two HTL/PNP control inputs (Control1 and Control2) are 7.4.1 available at terminal [X10 | CONTROL IN]. Control1 X10 | CONTROL IN, Pin 2, 3 Control2...
  • Page 72 „Control Menu“ No. Parameter Range Default 062 Input 1 Function 0 - 16 (assigns a control function to input „Control1“) Important notes for DS240 / DS246 see chapter 7.4.1 The switching conditions (active HIGH or active LOW) can be defined by parameter 063.
  • Page 73 Continuation „Control Menu“ No. Parameter Range Default 063 Input 1 Config 0 - 3 (switching condition of input Control1) static function, active LOW: [X10:2] = Lo, [X10:3] = Hi static function, active HIGH: [X10:2] = Hi, [X10:3] = Lo dynamic function, active when moving from HIGH to LOW [X10:2] and simultaneously moving from LOW to HIGH [X10:3] dynamic function,...
  • Page 74 7.4.8. Serial Menu Parameter Range Default Serial Unit No. 11 - 99 (assigns a serial unit number) The devices can be assigned by unit numbers between 11 and 99 (default setting = 11). Unit numbers which contain a “0“ are forbidden because these are used for group- or bulk-addressing.
  • Page 75 Continuation „Serial Menu“: Parameter Range Default Serial Page 0 - 11 (serial page number of a variable) The Parameter serves only for diagnosis purposes by the manufacturer. Serial Init: 0 - 1 This parameter determines the baud rate (see parameter 069) for the transmission of the initialization values to the operator surface OS6.0 respectively to the BG230 programming and display unit.
  • Page 76 7.4.9. Splitter Menu (Looping of Sensor Signals for further Target Units) The Splitter function is only integrated in DS230 and DS240. Parameter Range Default RS Selector 0 - 1 (determination of the RS422 output source) Important notes for DS240 / DS246 see chapter 7.4.1 This parameter defines which input frequency (sensor1 or sensor2) is exported at terminal [X4 | RS422 OUT].
  • Page 77 7.4.10. Analog Menu (Analog Output Configuration) The setting of the F1-F2-Selection (Parameter 003) determines, which frequency (sensor1 or sensor2) is used to generate the analog output signal. Parameter Range Default Analog Start (initial value of the conversion range in Hz) -500 000.0 Defines the initial frequency, at which the analog output should set its initial value of 4 mA.

  • Page 78: Start-Up The Plant

     All wirings must be executed in accordance with the general provisions for wiring (see www.motrona.com). In order to prevent simultaneous damages to the cables by external influences, the encoder resp. sensor lines must be kept physically separate from one another.

  • Page 79: Parametrization

    8.2. Parametrization In order to ensure proper functionality the parameters must be set appropriate values. The next two chapters 8.2.1 8.2.2 will describe important parameters, which must be set or checked in each case. The parameters of the subsequent chapters must be set or checked only when the respective outputs are used.
  • Page 80 8.2.3. SinCos Output Settings Depending on the version and the operational mode, the unit is equipped with a SinCos output. The SinCos output cannot be configured. 8.2.4. RS422 Output Settings These parameter may be used only, if the RS422 output is used. The RS422 output essentially depends on the following parameters: Parameter Notice...
  • Page 81 8.2.6. Control Output Settings These parameter may be used only, if control outputs are used. The control outputs are essentially dependent on the following parameters: OUT1: Parameter Notice Operational Mode F1-F2 Selection Preselect OUT1.H Preselect OUT1.L Switch Mode OUT1 Pulse Time OUT1 Hysteresis OUT1 Startup Mode Startup Output...
  • Page 82 Continuation „Control Output Settings“: OUT3: Parameter Notice Operational Mode F1-F2 Selection Preselect OUT3.H Preselect OUT3.L Switch Mode OUT3 Pulse Time OUT3 Hysteresis OUT3 Startup Mode Startup Output Lock Output Input1 Function Input1 Configuration Input2 Function Input2 Configuration OUT4: Parameter Notice Operational Mode F1-F2 Selection Preselect OUT4.H...
  • Page 83 8.2.7. Relay Output Settings These parameter may be used only, if relay outputs are used. The relay outputs are essentially dependent on the following parameters: Parameter Notice Operational Mode F1-F2 Selection Preselect REL1.H Preselect REL1.L Switch Mode REL1 Pulse Time REL1 Hysteresis REL1 Startup Mode Startup Output...

  • Page 84: Preparation Before First Start-Up

    8.3. Preparation before first start-up Before first start-up  the unit must be in a perfect technical condition, properly installed and wired  the unit must be set to the unit-state “Programming Mode” by setting the DIL switch slider 3 “OFF”...

  • Page 85: Checklist For Parameter Settings

    8.4. Checklist for Parameter Settings General settings: 1. Does Parameter 000 (Operational Mode) correspond to the selected encoder types? 2. Are correct preset values defined in the „Preselection Menu“ (Parameter 027, et seq.)? 3. Are all outputs and relays adjusted in accordance to the demanded switching conditions? (see chapter …) Optional settings: 1.

  • Page 86: Sensor Channel Adaption

    8.6. Sensor Channel Adaption When using two sensors with a different number of pulses or in case of a mechanical speed reduction between both encoders, then the higher frequency must be adjusted to the lower one. For this calculation the scaling factors (see chapter 7.4.3) are used.
  • Page 87 By scaling the frequency 1 both internally calculated frequencies are approximately equal and the calculated ratio is close to "0". Ds230_03a_oi_e.doc / Jun-15 Page 87 / 100...

  • Page 88: Completion Of Commissioning

    8.7. Completion of Commissioning Finally all application-dependent Parameters should be checked for plausibility again. The digital outputs and relays can be tested for their correct behavior by using the parameter 058 "Output Action" from the menu "Switching Menu". The safety-related relay output opens in case of failures or if a programmed switching condition (see chapter 7.4.5) is reached.

  • Page 89: Error Detection

    9. Error Detection In order to ensure a maximum of operational safety and reliability, the units are equipped with several and profound monitoring-functions. The monitoring allows an immediate recognition and messaging of possible failures and malfunctions. In case of errors: ...

  • Page 90: Initial Error

    9.2. Initial Error These monitors / tests are processed automatically when switching the unit on. Error code Error Instruction BG230 Operator Software OS6.0 H‘ 0000 0001 ADC Error Error of the analog output. See runtime error, error code H‘ 0000 0400 H‘...

  • Page 91: Runtime Error

    9.3. Runtime Error These monitors / tests are processed automatically and continuously in the background. Error code Error Instruction BG230 Operator Software OS6.0 H‘ 0000 0001 SIN/COS Channel 1 Error Error of the input SINCOS IN 1. Faulty SinCos-encoder, faulty wiring or internal error of the unit.
  • Page 92 Continuation „Runtime Error“: Error code Error Instruction BG230 Operator Software OS6.0 H‘ 0000 0400 Sequence Analog Output Error Error of the analog output. Switch off the unit. Remove the wiring and link X4:2 and X4:3 Switch on the unit. If error code is off  external error e. g. faulty wiring or open circuit.

  • Page 93: Error Clearing

    9.4. Error Clearing Error states can generally be cleared by switching the power off and on again (after removing the error source). 9.5. Error Detection Time Basically it is not possible to specify an exact error detection time because the error detection depends on many factors.

  • Page 94: Parameter List

    10. Parameter List Parameter Min. Value Max. Value Default Characters Decimal Places Serial Code Operational Mode Sampling Time 9999 Wait Time 9999 1000 F1-F2 Selection Div. Switch %-f 99999 10000 Div. %-Value Div. f-Value 9999 3000 Div. Calculation Div. Filter Error Simulation Power-up Delay 1000...
  • Page 95 Continuation „Parameter List“: Parameter Min. Value Max. Value Default Characters Decimal Places Serial Code Switch Mode OUT1 Switch Mode OUT2 Switch Mode OUT3 Switch Mode OUT4 Switch Mode REL1 Pulse Time OUT1 9999 Pulse Time OUT2 9999 Pulse Time OUT3 9999 Pulse Time OUT4 9999...
  • Page 96 Continuation „Parameter List“: Parameter Min. Value Max. Value Default Characters Decimal Places Serial Code Analog Start -5000000 5000000 Analog End -5000000 5000000 100000 Analog Gain 1000 Analog Offset -100 Reserved 10000 1000 Ds230_03a_oi_e.doc / Jun-15 Page 96 / 100...

  • Page 97: Technical Specifications

    11. Technical Specifications Power supply: Input voltage: 18 ... 30 VDC with reverse polarity protection Protective circuit: reverse polarity protection Ripple: max. 10 % at 24 VDC Power consumption: approx. 150 mA (unloaded) Protection: external fuse (2.5 A, medium time lag) necessary Connections: X3, screw terminal, 2-pin, 1.5 mm²...
  • Page 98 Continuation „Technical Specifications“: USB interface: Version: USB 1.0 Connection: X12, USB-B (female) Display: Green LED: „ON“ Yellow LED: „ERROR“ Switches: DIL switch: 1 x 3-pin Marking: Conformity and standards: MD2006/42EC EN ISO 13849-1 EN 61508 EN 62061 LV 2006/95/EC: EN 61010-1 EMC 2004/108/EC: EN 61000-6-2 EN 61000-6-3...

  • Page 99: Dimensions

    11.1. Dimensions (inclusive BG230 at front) Front: Rear: DS230 BG230 (option) Ds230_03a_oi_e.doc / Jun-15 Page 99 / 100...

  • Page 100: Certificate

    12. Certificate Ds230_03a_oi_e.doc / Jun-15 Page 100 / 100...

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