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.., DRU.., DR2.., EDR.., EDRN.. AC Motors
Functional Safety
Edition 12/2021
*27777383_1221*
   
27777383/EN

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  • Page 1 *27777383_1221* Drive Technology \ Drive Automation \ System Integration \ Services Addendum to the Operating Instructions     Safety Encoders and Safety Brakes DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors Functional Safety Edition 12/2021 27777383/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 Checklists..........................  50 Checklist for encoder assembly .................. 50 Checklist for BE03 brake assembly ................ 52 Checklist for BE05 – 32 brake assembly .............. 53 Index ............................  55 Glossary ..........................  56 Addendum to the Operating Instructions – DR.., DRN.., DRU.., 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.., DRU.., 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 encoders • The safety encoders described in this documentation are intended for use with DR.., DRN.., DRU.., 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 brakes • The safety brakes described in this documentation are intended for use with DR.., DRN.., DRU.., 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 is carried out at your own risk. The operator is responsible and liable for the proper fulfillment of the work described in the relevant documentation.

  • 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 improve the safety of your machines by implementing safety functions in relation to their speed, direction of rotation, idle state, relative posi- tion or absolute 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 TÜV NORD Systems GmbH & Co. KG A copy of the TÜV certificate can be obtained from SEW-EURODRIVE. Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors...

  • Page 14: Safety Functions

    Functional safety (FS) Safety functions Safety functions 3.6.1 Safety functions of the safety encoder INFORMATION For AK8W, AS7W, AG7W, AK8Y, AS7Y and AG7Y encoders, the multi-turn absolute interface is not part of the PL d/SIL 2 approval. The absolute interface may not be used solely for implementing safety functions.

  • Page 15: Initializing The Safety Encoder

    Functional safety (FS) Initializing the safety encoder 3.6.2 Safety functions of the safety brake The implementation of a safety function with brakes requires that the brake be 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 Where safety encoders are used for safety-related reasons, follow-up electronics are needed to monitor the signals of the rotary encoder and check their validity. When a malfunction is detected, a fault response (e.g. the safe state) must be triggered in the overall system.
  • Page 17 Functional safety (FS) Requirements for the follow-up electronics 3.8.2 Add-on encoders: EK8S, AK8W, AK8Y Designation Requirement Safety requirements ≥ SIL 2 Diagnostic coverage (DC) ≥ 90% Error presumptions According to IEC 61800-5-2:2016, table Monitoring of the phasor length "r" with a = A – A for cosine signals and b = B –...

  • Page 18: Brake Test

    Functional safety (FS) Brake test Brake test In applications with brakes, the braking torque represents an important criterion for the functional and performance capability of the brake. If the braking torque is reduced or lost, the functionality of the application, the safety of the machine, and/or personal safety can be limited.

  • Page 19: Motor Combinations

    Functional safety (FS) Motor combinations 3.10 Motor combinations 3.10.1 Safety encoders The safety encoders described below are intended for use with DR.., DRN.., DRU.., DR2.., EDR.., and EDRN.. motors. It is not permitted to mount them on other motors. Safety encoders on DR.., DRN.., DRU.., DR2.. AC motors INFORMATION A built-in encoder with an add-on encoder, designed as a safety encoder, can also be combined at the drive, e.g.
  • Page 20 Functional safety (FS) Motor combinations Safety encoders on EDR.., EDRN.. explosion-protected AC motors Motors Part number coders without with connection cover EDR..71 – EDR..132 ES7S 13642715 13642898 EDRN80 – EDRN132S AS7W 13643878 13643916 AS7Y 13643851 13643908 EDR..160 – EDR..280 EG7S 13642782 13642952 EDRN132M – EDRN280 AG7W 13643886 13643924 AG7Y 13643894 13643932...
  • Page 21 Functional safety (FS) Motor combinations (E)DR.. – – – (E)DRN../DRU.. 132M – 132S 132L DR2.. 132M – – 132S 132L BE32 BE60 BE62 BE120 BE122  Combination available  Optionally available as safety brake Addendum to the Operating Instructions – DR.., DRN.., DRU.., 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 3.11 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 is reached for each implemented safety function. To validate the safety integrity level you can use the "SISTEMA"...

  • 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: 76646 Bruchsal/Germany RF87 DRN100L4/BE5HR/TF/EK8S 01.41027997609.0001.21 Inverter duty VPWM 3 ~IEC60034 Hz 50 r/min 1456/52 V 230/400Δ/Y kW 3 S1 A 11.2/6.4 Cos φ...
  • 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 mark: 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. Temperature sensor /TF If you use a safety brake, you must also use and evaluate the temperature sensor /TF. INFORMATION If several motors with safety brake are operated with one frequency inverter (multi- motor operation), an external switching device for monitoring the temperature...

  • Page 28: 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 29: 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 30 Inspection/maintenance Inspection and maintenance intervals INFORMATION The amount of wear depends on many factors and may therefore be high. The sys- tem manufacturer must determine the required inspection/maintenance intervals indi- vidually in accordance with the project planning documents. INFORMATION SEW‑EURODRIVE recommends ordering the SEW‑EURODRIVE service to carry out the maintenance work.

  • Page 31: Removing/Installing The Encoder

    Inspection/maintenance Removing/installing the encoder Type of work Work permitted? Comments Retrofitting brake monitor- Replacement of safety brake neces- sary. /DUB Replacing brake – monitoring /DUB Setting brake monitoring – /DUB (switching point). 1) Insofar as the option is available. Removing/installing the encoder WARNING Loss of the safety functions due to a faulty mechanical connection between the mo- tor shaft and the encoder.
  • Page 32 Inspection/maintenance Removing/installing the encoder 7.2.3 Reassembly A detailed description including pictures and the associated item numbers can be found in the operating instructions of the motor. In the case of safety encoders, note the following working steps and the tightening torques specified in the table. ®...

  • Page 33: Measuring Wobbling

    Inspection/maintenance Measuring wobbling Measuring wobbling Fault exclusion of the mechanical motor-encoder connection according to IEC 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 34 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 35: 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 36: Inspection Of (E)Dr

    Inspection/maintenance Inspection of (E)DR..71 – 225, (E)DRN../DRU../DR2..63 – 225 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- Quan- Place...
  • Page 37 Inspection/maintenance Inspection of (E)DR..71 – 225, (E)DRN../DRU../DR2..63 – 225 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 38 Inspection/maintenance Inspection of (E)DR..71 – 225, (E)DRN../DRU../DR2..63 – 225 brakemotors 23652168459 Addendum to the Operating Instructions – DR.., DRN.., DRU.., DR2.., EDR.., EDRN.. AC Motors...

  • Page 39: Brake Replacement

    Inspection/maintenance Brake replacement Brake replacement A precise description of the brake replacement can be found in the relevant operating instructions. In the case of safety brakes, observe the following tightening torques and ® use LOCTITE to lock the threads: ® Motors Screw Tightening torque in Nm...
  • Page 40 Inspection/maintenance Diagnostic unit /DUE and /DUB for function and wear monitoring INFORMATION Set the DIP switches only in a de-energized state. 7.7.3 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: Wear limit BE1 –...

  • Page 41: 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 for ES7S, EG7S Characteristic safety values according to IEC 62061/IEC 61508 ISO 13849-1...
  • Page 42 Technical data Safety encoders Characteristic safety values for EK8S Characteristic safety values according to IEC 62061/IEC 61508 ISO 13849-1 Classification SILCL2/SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 7.8 × 10  1/h = 7.8 FIT (T ≤ 45 °C) (without mounting on the motor) 1.2 ×...
  • Page 43 Technical data Safety encoders Characteristic safety values for AS7W, AG7W, AS7Y, AG7Y Characteristic safety values according to IEC 62061/IEC 61508 ISO 13849-1 Classification SILCL2/SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 9.3 × 10 1/h = 9.3 FIT (T ≤...

  • Page 44: Safety Brakes

    Technical data Safety brakes Characteristic safety values for AK8W, AK8Y Characteristic safety values according to IEC 62061/IEC 61508 ISO 13849-1 Classification SILCL2/SIL2 PL d System structure HFT = 1 2-channel (Cat. 3) value 6.97 × 10 1/h = 6.97 FIT (T ≤ 45 °C) 1.04 ×...
  • Page 45 Technical data Safety brakes 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 BE20 1000 1000 BE30 1500 1500 BE32...
  • Page 46 Technical data Safety brakes 8.2.2 Working air gap The following values apply for design of the brake as a safety brake: Brake Working air gap Brake lining carrier min. max. min. BE03 0.25 0.65 – BE05 0.25 0.25 0.25 0.25 BE11 12.5 BE20...
  • Page 47 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 48 Technical data Safety brakes 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 the control cabinet Type designa- Voltage range BE03 BE05 BE11 BE20 BE30 tion BE32 BST 0.6S...
  • Page 49 Technical data Safety brakes 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 50: 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 51 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 52: 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)DRN../DRU../DR2..63...

  • Page 53: 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../(E)DRN../DRU../DR2..71 -...
  • Page 54 Checklists Checklist for BE05 – 32 brake assembly (E)DR..71 – 80 (E)DR..90 – (E)DR..160 –  132  225 (E)DRN../ DRU../DR2..71 (E)DRN../ (E)DRN../ Performed task – 80 DRU../DR2..90 DRU../ – 132S DR2..132M – Brake connector [698] connected – – □ Brake connected in terminal box □ □ □ Addendum to the Operating Instructions –...

  • Page 55: Index

    Index Index Symbols (Dis)assembly work .......... 29 Maintenance ............ 29 (Dis)assembly, encoder........ 31 Maintenance intervals .........  29 /TF ...............  27 Mechanical installation ........ 26 Manual brake release /HR...... 26 Motor maintenance, preliminary work .... 36 BE.. brake Motor/brake assignment ........ 20 Motor combinations.

  • Page 56: Glossary

    Glossary Glossary Number of cycles until 10% of the components Safe Direction safety function have failed dangerously (for pneumatic and elec- tromechanical components) Cat. Category Safety integrity level SILCL Common cause failure SIL claim limit (for a subsystem) SISTEMA Diagnostic coverage Software of the Institute for Occupational Safety and Health of the German Social Accident Insur- ance (IFA) for determining the performance level...
  • Page 60 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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