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

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Drive Technology \ Drive Automation \ System Integration \ Services
Addendum to the Operating
Instructions
Safety Encoders and Safety Brakes
DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors
Functional Safety
Edition 11/2019
*25879146_1119*
25879146/EN

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  • Page 1 *25879146_1119* Drive Technology \ Drive Automation \ System Integration \ Services Addendum to the Operating Instructions Safety Encoders and Safety Brakes DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors Functional Safety Edition 11/2019 25879146/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 ........................ 12 Retraceability ........................ 13 Underlying standards .................... 13...
  • Page 4 Table of contents Safety brake........................ 50 Checklists..........................  55 Checklist for encoder assembly .................. 55 Checklist for BE03 brake assembly ................ 57 Checklist for BE05 – 32 brake assembly .............. 58 Index ............................  59 Glossary ..........................  60 Addendum to the Operating Instructions – DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors...

  • Page 5: General Information

    General information How to use this documentation General information How to use this documentation This addendum to the operating instructions contains special information on function- ally safe motor options (safety encoder and safety brake) of the DR.., DRN.., DR2.., EDR.., and EDRN.. motor series. In addition to the addendum to the operating instructions at hand, the following operat- ing instructions apply for motors with safety encoders and/or safety brakes: •...

  • Page 6: Safety Notes

    Safety notes Preliminary information Safety notes Preliminary information The following general safety notes serve the purpose of preventing injury to persons 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.
  • 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.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. • 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.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. • When using an AC motor in combination with a BE.. safety brake, the safety brake may be used only as a holding brake.

  • 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 also optionally available with functionally safe mo- tor 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 Functional safety (FS) Functionally safe motor options 3.1.2 Safety encoders Safety encoders from SEW‑EURODRIVE are characterized by their exceptional reli- ability as well as electronic and mechanical load capacity. Safety encoders allow you to increase the safety in your machines by implementing safety functions regarding speed, direction of rotation, idle state and relative position.

  • Page 12: Fs Mark

    Functional safety (FS) FS mark FS mark Motors from SEW‑EURODRIVE are optionally available with functionally safe motor options. These are designed for implementing safety functions. The documentation designates the respective functional safety design explicitly as safety encoder plus "type designation" or safety brake plus "type designation". SEW‑EURODRIVE labels a functionally safe motor option at the drive with an FS logo and a 2-digit number on the motor nameplate.

  • Page 13: Retraceability

    The following certificate is available for the described safety brakes: • Certificate of the TÜV NORD Systems GmbH & Co. KG The TÜV certificate is available for download on the SEW‑EURODRIVE website (www.sew-eurodrive.de). Addendum to the Operating Instructions – DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors...

  • Page 14: Safety Functions

    Functional safety (FS) Safety functions Safety functions 3.6.1 Safety functions safety encoder Add-on encoders ES7S, EG7S, EK8S, AS7W, AG7W, AK8W, AS7Y, AG7Y, AK8Y The following safety functions in accordance with EN 61800‑5‑2 regarding speed, di- rection of rotation, idle state, and relative position can be implemented in functionally safe systems with the sine/cosine interface of the safety encoders, such as: •...
  • Page 15 Functional safety (FS) Safety functions 3.6.2 Safety functions of the safety brake The implementation of a safety function with brakes requires that the brake is applied on request. The safety function is activated when the brake is applied. The brake coil has to be de-energized and the energy stored in the brake coil reduced.

  • Page 16: Requirements For The Follow-Up Electronics

    Functional safety (FS) Requirements for the follow-up electronics Requirements for 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 17 Functional safety (FS) Requirements for the follow-up electronics 3.7.2 Add-on encoders: EK8S, AK8W, AK8Y 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 18: 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 19: 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.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. Safety encoders at the DR.., DRN.., DR2.. AC motors Motors Part number coders...
  • Page 20 Functional safety (FS) Motor combinations Motors Part number coders without with Connection cover EDR..160 – EDR..280 EG7S 13642782 13642952 EDRN132M – EDRN280 AG7W 13643886 13643924 AG7Y 13643894 13643932 1) For motor design with brake/safety brake, the AG7W/AG7Y encoders are available up to size EDR../ EDRN225.
  • Page 21 Functional safety (FS) Motor combinations  Design not available as safety brake.  Design available as safety brake. Addendum to the Operating Instructions – DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors...
  • Page 22 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 size. The following table shows the available graduations: Brake (M BE03 BE05 BE11 BE20 Bmax (3.4 Nm) (5 Nm)

  • Page 23: Acceptance

    Functional safety (FS) Acceptance 3.10 Acceptance 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 24: 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 25 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 26: Mechanical Installation

    Mechanical installation General information Mechanical installation General information 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 27: Electrical Installation

    Electrical installation General information Electrical installation General information 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: Pin 5:...

  • Page 28: 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 29: Temperature Sensor /Tf

    Electrical installation Temperature sensor /TF 6.3.5 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 30: 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 31: Inspection/Maintenance

    Inspection/maintenance Inspection and maintenance intervals Inspection/maintenance Inspection and maintenance intervals 7.1.1 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. The safety encoders are maintenance-free for a service life of 20 years. This also in- cludes the ball bearings that are equipped with a maintenance-free lubrication for the entire service life.
  • Page 32 Inspection/maintenance Inspection and maintenance intervals INFORMATION SEW‑EURODRIVE recommends ordering the SEW‑EURODRIVE service to carry out the maintenance work. This applies in particular to all steps that require the marked, safety-relevant connections to be opened. If you perform maintenance work yourself, the responsibility and the liability for the proper fulfillment of the work described in the relevant documentation is passed to the user, see chapter "Functional safety (FS)" (→ 2 10).

  • Page 33: Removing/Installing The Encoder

    Inspection/maintenance Removing/installing the encoder Removing/installing the encoder WARNING Loss of the safety functions due to a faulty mechanical connection between the mo- tor and the encoder. Severe or fatal injuries • To ensure the exclusion of any errors in the mechanical connection between the drive component and the encoder, comply with the following points in accordance with EN 61800-5-2: →...
  • Page 34 Inspection/maintenance Removing/installing the encoder 7.2.3 Reassembly A detailed description can be found in the operating instructions of the motor. In the case of safety encoders, please note the following working steps and the tightening torques specified in the table. ® •...

  • Page 35: 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 ES7S, AS7W, or AS7Y encoder is installed to ensure it is seated properly.
  • Page 36 Inspection/maintenance Measuring wobbling Measured value exceeded [362] [B] [G] [619] [220] [35] [34] [361] 9007201837842187 [34] Tapping screw Retaining screws on the torque bracket [35] Fan guard Central retaining screw [220] Encoder Cone [361] Safety cover Bore [362] Expansion anchor Tooth lock washer [619] Connection cover Repeat the check if the measured value is exceeded.

  • Page 37: Preliminary Work For Motor And Brake Maintenance

    Inspection/maintenance Preliminary work for motor and brake maintenance Preliminary work for motor and brake maintenance 7.4.1 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 38: Working Steps For Inspecting (E)Dr

    Inspection/maintenance Working steps for inspecting (E)DR..71 – 225, (E)DRN63 – 225, DR2..63 – 80 brakemotors 7.4.3 Order information for operating supplies and auxiliary material for maintenance The following table lists the various operating supplies and auxiliary materials that are required for correct maintenance. Manufacturer Operating sup- Part num-...
  • Page 39 Inspection/maintenance Working steps for inspecting (E)DR..71 – 225, (E)DRN63 – 225, DR2..63 – 80 brakemotors 1. If present, remove the fan guard [35], the forced cooling fan [170], and the encoder [220]. 2. Shift the sealing strip [66]. To do so, release the clamping straps [157] if neces- sary.
  • Page 40 Inspection/maintenance Working steps for inspecting (E)DR..71 – 225, (E)DRN63 – 225, DR2..63 – 80 brakemotors 23652168459 Addendum to the Operating Instructions – DR.., DRN.., DR2.., EDR.., EDRN.. AC Motors...

  • Page 41: Brake Exchange

    Inspection/maintenance Brake exchange Brake exchange A precise description of the brake exchange can be found in the relevant operating in- structions. In the case of safety brakes, observe the following tightening torques and ® use LOCTITE to lock the threads. ®...
  • Page 42 Inspection/maintenance Diagnostic unit /DUE for function and wear monitoring 7.7.1 DIP switch setting values for option /DUE The following tables show the setting values of the DIP switches for the option /DUE when the brake is designed as a safety brake or in combination with a safety encoder. Wear limit BE1 –...

  • Page 43: Technical Data

    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 and the library are available for download from www.sew-eurodrive.com. Characteristic safety values ES7S, EG7S Characteristic safety values according to EN 62061/IEC 61508...
  • Page 44 Technical data Safety encoder Characteristic safety values of EK8S Characteristic safety values according to EN 62061/IEC 61508 EN ISO 13849-1 Classification/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 7.8 × 10  1/h = 7.8 FIT (T ≤...
  • Page 45 Technical data Safety encoder Characteristic safety values AS7W, AG7W ,AS7Y, AG7Y Characteristic safety values according to EN 62061/IEC 61508 EN ISO 13849-1 Classification/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 9.3 × 10 1/h = 9.3 FIT (T ≤...
  • Page 46 Technical data Safety encoder Characteristic safety values of AK8W, AK8Y Characteristic safety values according to EN 62061/IEC 61508 EN ISO 13849-1 Classification/underlying standards SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 6.97 × 10 1/h = 6.97 FIT (T ≤...
  • Page 47 Technical data Safety encoder 8.1.2 Encoders ES7S, EG7S, EK8S, AS7Y, AG7Y, AK8Y, AS7W, AG7W, AK8W Designation Value Operating temperature of encoder -30 °C – +85 °C In potentially explosive atmospheres: -30 °C – +60 °C AG7Y, AG7W in potentially explosive atmospheres: -30 °C – +60 °C at maximum 4500 min -1 1) -30 °C – +40 °C with maximum 6000 min DR.., EDR..
  • Page 48 Technical data Safety encoder AS7Y, AG7Y, AK8Y Designation AS7Y AG7Y AK8Y Operating voltage DC 7 – 30 V Max. current consumption 150 mA 150 mA 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 bits= 4096 positions (single-turn) 12 bit = 4096 revolutions (multi-turn)
  • Page 49 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 Designation Value Max.

  • Page 50: 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 FS code – FS04, FS07 FS02 FS11 Brake BE02 – – – BE03 BE05 BE11...
  • Page 51 Technical data Safety brake 8.2.2 Working air gap The following values apply when the brake is designed as a safety brake or to brakes in combination with a safety encoder. Brake Working air gap Brake lining carrier min. max. min. BE03 0.25 0.65...
  • Page 52 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 and the library are available for download from www.sew-eurodrive.de.
  • Page 53 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 BE03 BE05 BE11 BE20 BE30 ignation BE32 BST 0.6S AC 460...
  • Page 54 Technical data Safety brake Installation in the motor wiring space Type Voltage range BE03 BE05 BE11 BE20 BE30 designa- BE32 tion BG 1.2 AC 90 – 500 – – – – – – BG 1.4 AC 230 – 575 – • • –...

  • Page 55: Checklists

    Checklists Checklist for encoder assembly Checklists The checklists allow you to document the performed and safety-related tasks when exchanging a safety brake or safety encoder. Checklist for encoder assembly Drive and encoder data Technician: Date: Drive designation: Motor serial number: Encoder part number: Encoder serial number: Required resources:...
  • Page 56 Checklists Checklist for encoder assembly Checklist for (E)DR..160 – 280/(E)DRN132M – 280 motors with EG7., AG7. encoders. Performed task Finished Retaining screws on the torque bracket [232] tightened (tightening torque 6 Nm □ ±10%) Connection cover [619] screwed in place (tightening torque 2.25 Nm ±10%) □ Safety cover [361] mounted □...

  • Page 57: Checklist For Be03 Brake Assembly

    Checklists Checklist for BE03 brake assembly Checklist for BE03 brake assembly Drive and brake data Technician: Date: Drive designation: Motor serial number: Brake: Brake identification number: Working air gap, brake 2x: Motor size Required wear parts Quantity All sizes Brake premounted [550], key [71], driver [70], retaining 1x each ring [62], flat gasket [901] (E)DRN63, DR2..63...

  • Page 58: Checklist For Be05 - 32 Brake Assembly

    Checklists Checklist for BE05 – 32 brake assembly Checklist for BE05 – 32 brake assembly Drive and brake data Technician: Date: Drive designation: Motor serial number: Brake: Brake identification number: Brake working air gap 3x: Motor size Required wear parts Quantity All sizes Brake premounted [550], key [71], driver [70], retaining 1x each ring [62] (E)DR..71 –...

  • Page 59: Index

    Index Index Symbols (Dis)assembly work .......... 31 Maintenance ............ 31 (Dis)assembly, encoder........ 33 Maintenance intervals .........  31 /TF ...............  29 Mechanical installation ........ 26 Manual brake release /HR...... 26 Motor maintenance, preliminary work .... 38 BE.. brake Motor/brake assignment ........ 20 Motor combinations.

  • Page 60: Glossary

    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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