MOVISAFE® UCS..B Safety Modules / Operating · PDF fileOperating Instructions – MOVISAFE® UCS..B Safety Module 7 2 General information Safety Notes 2 Safety Notes The following

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MOVISAFE® UCS..B Safety Modules

Operating InstructionsEdition 12/200816733215 / EN

SEW-EURODRIVE – Driving the world

1 General Information ............................................................................................... 51.1 How to use the operating instructions ............................................................ 51.2 Structure of the safety notes .......................................................................... 51.3 Rights to claim under limited warranty ........................................................... 61.4 Exclusion of liability ........................................................................................ 61.5 Copyright notice ............................................................................................. 6

2 Safety Notes ........................................................................................................... 72.1 General information ....................................................................................... 72.2 Target group .................................................................................................. 72.3 Designated use .............................................................................................. 82.4 Transport, storage.......................................................................................... 82.5 Installation...................................................................................................... 82.6 Electrical connection ...................................................................................... 82.7 Operation ....................................................................................................... 92.8 Definitions ...................................................................................................... 92.9 Other applicable documentation .................................................................... 9

3 Unit Design ........................................................................................................... 103.1 Nameplate of UCS..B................................................................................... 103.2 Scope of delivery ......................................................................................... 103.3 Unit design of basic modules ....................................................................... 11

3.3.1 UCS10B............................................................................................. 113.3.2 UCS11B............................................................................................. 123.3.3 UCS12B............................................................................................. 13

3.4 Unit design of I/O expansion module ........................................................... 143.4.1 UCS23B............................................................................................. 14

3.5 Unit design of diagnostic module ................................................................. 153.5.1 UCS25B............................................................................................. 15

4 Mechanical Installation........................................................................................ 164.1 General installation information.................................................................... 164.2 Assembly information................................................................................... 16

4.2.1 Dimension drawing for mounting rail.................................................. 174.2.2 Mounting position............................................................................... 174.2.3 Installation clearance ......................................................................... 184.2.4 Backplane bus connector .................................................................. 184.2.5 Step-by-step instruction for installing MOVISAFE® UCS..B .............. 194.2.6 Step-by-step instruction for removing MOVISAFE® UCS..B ............. 20

5 Electrical Installation ........................................................................................... 215.1 Connection and terminal description of basic modules UCS10B/11B/12B.. 215.2 Connection and terminal description for expansion module UCS23B ......... 235.3 Connection and terminal description of diagnostic module UCS25B........... 255.4 Measures for electromagnetic compatibility (EMC)...................................... 265.5 External DC 24 V voltage supply ................................................................. 275.6 Connecting binary inputs DI1 to DI14 .......................................................... 275.7 Connecting the position and velocity sensors .............................................. 33

5.7.1 Combination of various encoder types............................................... 345.7.2 Voltage supply for encoder systems.................................................. 345.7.3 Connecting proximity sensors............................................................ 355.7.4 Connecting encoders......................................................................... 355.7.5 Configuring the measuring distances................................................. 355.7.6 Prefabricated cables .......................................................................... 405.7.7 Wiring diagrams for direct encoder connection to MOVISAFE®........ 48

Operating Instructions – MOVISAFE® UCS..B Safety Modules 3

4

5.7.8 Wiring diagrams for encoders parallel on the inverter and UCS.B option ..................................................................................... 49

5.8 Connecting binary outputs ........................................................................... 515.8.1 Example of how to use the binary outputs for safe stop .................... 525.8.2 Single-pole switching P binary output without check ......................... 535.8.3 Single-pole switching M binary output without check......................... 535.8.4 Single-pole switching P binary output with external contact

monitoring .......................................................................................... 545.8.5 Single-pole switching M binary output with external contact

monitoring .......................................................................................... 555.8.6 Dual-channel switching binary output DO0 with external monitoring. 565.8.7 Single-pole switching relay output without check............................... 575.8.8 Single-pole switching relay output with external contact monitoring.. 585.8.9 Double-channel switching relay output with external monitoring

(general checkback) .......................................................................... 595.8.10Dual-channel switching relay output with external monitoring

(specific checkback)........................................................................... 605.8.11Connecting an auxiliary output .......................................................... 61

6 Startup................................................................................................................... 626.1 General startup information.......................................................................... 626.2 Switch-on sequences................................................................................... 636.3 LED display .................................................................................................. 636.4 Validation report ........................................................................................... 64

7 Validation .............................................................................................................. 657.1 Procedure .................................................................................................... 657.2 Functional test.............................................................................................. 65

8 Maintenance ......................................................................................................... 668.1 Replacing a system...................................................................................... 668.2 Modification / changes to the unit ................................................................ 668.3 Waste disposal............................................................................................. 67

9 Diagnostics ........................................................................................................... 689.1 Description of the 7-segment display ........................................................... 689.2 Description of the LED status....................................................................... 689.3 Diagnostic module UCS23B with CAN interface.......................................... 699.4 Types of errors ............................................................................................. 719.5 Error messages............................................................................................ 719.6 Alarm messages .......................................................................................... 78

10 Technical Data...................................................................................................... 9610.1 General technical data ................................................................................. 9610.2 Safety characteristics of MOVISAFE® ......................................................... 96

11 Appendix............................................................................................................... 9711.1 Response times of MOVISAFE®.................................................................. 9711.2 Description of the input elements................................................................. 9811.3 List with encoders recommended by SEW-EURODRIVE.......................... 10011.4 Absolute encoders that can be used for master and slave modes ............ 101

12 Index .................................................................................................................... 102

Operating Instructions – MOVISAFE® UCS..B Safety Modules

1 How to use the operating instructionsGeneral Information

Betriebsanleitung1 General Information1.1 How to use the operating instructions

The operating instructions are an integral part of the product and contain importantinformation for operation and service. The operating instructions are written for allemployees who assemble, install, startup, and service this product.The operating instructions must be accessible and legible. Make sure that personsresponsible for the system and its operation, as well as persons who work independentlyon the unit, have read through the operating instructions carefully and understood them.Consult SEW-EURODRIVE if you have any questions or if you require further informa-tion.

1.2 Structure of the safety notesThe safety notes in these operating instructions are structured as follows:

Symbol SIGNAL WORDNature and source of hazard.Possible consequence(s) if disregarded.• Measure(s) to prevent the hazard.

Symbol Signal word Meaning Consequences if disregarded

Example:

General danger

Specific danger,e.g. electric shock

DANGER Imminent danger Severe or fatal injuries

WARNING Possible hazardous situation Severe or fatal injuries

CAUTION Possible hazardous situation Minor injuries

NOTICE Potential damage to property. Damage to the drive system or its environment

TIP Useful information or tip.Simplifies handling of the drive system.

Operating Instructions – MOVISAFE® UCS..B Safety Module
5

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1 ights to claim under limited warranty eneral Information

1.3 Rights to claim under limited warrantyAdhering to the operating instructions is a prerequisite for fault-free operation and thefulfillment of any right to claim under warranty. Therefore, read the operating instructionsbefore you start working with the unit.

1.4 Exclusion of liabilityYou must comply with the information contained in these operating instructions toensure safe operation of the MOVISAFE® UCS..B safety modules and to achieve thespecified product characteristics and performance requirements. SEW-EURODRIVEassumes no liability for injury to persons or damage to equipment or property resultingfrom non-observance of these operating instructions. In such cases, any liability fordefects is excluded.

1.5 Copyright notice© 2008 – SEW-EURODRIVE. All rights reserved.Copyright law prohibits the duplication, modification, distribution, and use of any part ofthis document for ulterior purposes.

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2 General informationSafety Notes

2 Safety NotesThe following basic safety notes must be read carefully to prevent injury to persons anddamage to property. The operator must ensure that the basic safety notes are read andobserved. Make sure that persons responsible for the plant and its operation, as well aspersons who work independently on the unit, have read through the operating instruc-tions carefully and understood them. If you are unclear about any of the information inthis documentation, or if you require further information, please contactSEW-EURODRIVE.

2.1 General informationNever install or start up damaged products. Submit a complaint to the shipping companyimmediately in the event of damage.During operation, drive inverters can have live, bare and movable or rotating parts aswell as hot surfaces, depending on their degree of protection.Removing covers without authorization, improper use as well as incorrect installation oroperation may result in severe injuries to persons or damage to property.Refer to the documentation for additional information.

2.2 Target groupOnly qualified personnel are authorized to install, start up, repair or service the units(observe IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and IEC 60664 orDIN VDE 0110 as well as national accident prevention guidelines).Qualified personnel in the context of these basic safety notes are all persons familiarwith installation, assembly, startup, programming, parameterization and operation of theproduct who possess the necessary qualifications. They must also be familiar with therelevant safety regulations and laws, especially with the requirements of category4/performance level e according to EN ISO 13849 and all other standards, directivesand laws specified in this documentation. The persons mentioned must have theauthorization expressly issued by the company, to operate, program, configure, labeland ground units, systems and circuits in accordance with the standards of safetytechnology.Any activities regarding transportation, storage, operation, and disposal must be carriedout by persons who have been instructed appropriately.

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2 esignated use afety Notes

2.3 Designated useMOVISAFE® UCS..B safety modules are components intended for installation inelectrical systems or machines.When a MOVISAFE® UCS..B safety module is to be installed in a machine (i.e. start ofdesignated operation) do not startup the unit until it has been determined that the ma-chine meets the requirements stipulated in the EC Directive 2006/42/EC (machineguideline); observe EN 60204.Startup (i.e. the start of designated use) is only permitted under observance of the EMC(2004/108/EC) directive. The EMC test specifications EN 61000-4-2, EN 61000-4-3,EN 61000-4-4, EN 61000-4-6 and EN 61000-6-2 must be taken into account duringstartup.You must observe the technical data and information on the connection requirementsas provided on the nameplate and in the documentation.

2.4 Transport, storageObserve the notes on transportation, storage and proper handling. Observe the climaticconditions as stated in the chapter "Technical Data."

2.5 InstallationThe units must be installed and cooled according to the regulations and specificationsin the corresponding documentation.Protect MOVISAFE® UCS..B safety modules from improper strain. Ensure that compo-nents are not deformed and/or insulation spaces are maintained, particularly duringtransportation. Avoid contact with electronic components and contacts.MOVISAFE ® UCS..B safety modules contain components that can be damaged byelectrostatic energy and could suffer irreparable damage in case of improper handling.Prevent mechanical damage or destruction of electric components (may pose healthrisk!)The following applications are prohibited unless the unit is explicitly designed for suchuse:• Use in potentially explosive atmospheres• Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.,• In non-stationary applications

2.6 Electrical connectionObserve the applicable national accident prevention guidelines when working on liveMOVISAFE® UCS..B safety modules (e.g. BGV A3).Electrical installation is to be carried out in compliance with pertinent regulations (e.g.cable cross sections, fusing, protective conductor connection). For any additional infor-mation, refer to the applicable documentation.You will find notes on EMC-compliant installation, such as shielding, grounding,arrangement of filters and routing of lines, in the documentation of the safety module.The manufacturer of the system or machine is responsible for maintaining the limitsestablished by EMC legislation.Preventive measures and protection devices must meet the regulations in force (e.g.EN 60204).

DS


2 OperationSafety Notes

2.7 OperationSystems with integrated MOVISAFE® UCS..B safety modules must be equipped withadditional monitoring and protection devices, if necessary, according to the applicablesafety guidelines, such as the law governing technical equipment, accident preventionregulations, etc.Keep all covers and doors closed during operation.If the operation LED and other display elements are no longer illuminated, this does notindicate that the unit has been disconnected from the power supply and no longercarries any voltage.Mechanical blocking or internal safety functions of the unit can cause a motor standstill.Eliminating the cause of the problem or performing a reset may result in the drive re-starting automatically. If, for safety reasons, this is not permitted for the driven machine,disconnect the unit from the supply system before correcting the fault.

2.8 Definitions• The designation MOVISAFE® is used as a generic term for all derivatives of the

MOVISAFE® UCS..B product series. If a particular design variant is referred to in theoperating instructions, the complete designation is used.

• The term "safe" in this document refers to the classification as a safe function up tocategory 4/performance level e (Pl e) according to EN ISO 13849-1 and SIL3 accord-ing to EN 61508.

• PROFIsafe is a technology standard for a safe fieldbus system.• The "MOVISAFE® CONFIG" parameter setting software is a programing and config-

uration tool for the MOVISAFE® UCS..B unit series.• Internally, the components of the MOVISAFE® unit series consist of two independent

processing units. They are referred to as system A and system B in this document.

2.9 Other applicable documentation

Description Reference

Configuration of the MOVISAFE® UCS..B safety module (without fieldbus) using the "MOVISAFE® "CONFIG" parameter setting software.

MOVISAFE® CONFIG online help (→ MOVISAFE® Software ROM, item number 11566604)

Validation report of the implemented configuration Technical safety check.This can be generated by the MOVISAFE® CONFIG/ parameter setting software and serves as acceptance protocol.

Approval • TÜV certificate for MOVISAFE® UCS..B (see MOVISAFE® software ROM, edition 10/2008, item number 1156 6604)

• Prototype testing for two-hand controls (MOVISAFE® software ROM, item number 1156 6604)

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3 ameplate of UCS..B nit Design

3 Unit Design3.1 Nameplate of UCS..B

The nameplate is attached to the side of the unit and contains the following information:• Unit designation• Part number• Serial number• Version status• Input data• Output data• Degree of protection• Information about response times

3.2 Scope of delivery• MOVISAFE® UCS..B module• Connector for all signal terminals without encoder connection• Only relevant for UCS2.B: Backplane bus connector (part number: 1822 244 7)

64450AXX

EN ISO 13849-1 Kat.4 / PI eIEC 61508 / IEC 62061 SIL3EN 50178

DO0, DO1I = 100mADO2, DO3I = 250mA

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3 Unit design of basic modulesUnit Design

3.3 Unit design of basic modules3.3.1 UCS10B

64451AXX

[1] X11: Connection for voltage supply DC 24 V[2] X12: Connection of voltage suppy for encoder / binary outputs DO0, DO1[3] X22: Connection for binary inputs DI01 - DI04[4] LED STATUS: Display of the system status[5] LED 01 - 04: Status of binary inputs DI01 - DI04[6] LED 05 - 08: Status of binary inputs DI05 - DI08[7] LED 09 - 12: Status of binary inputs DI09 - DI12[8] X32: Connection for binary inputs DI05 - DI08[9] X42: Connection for binary inputs DI09 - DI12[10] X41: Connection for relay outputs K1, K2[11] X31: Connection for binary outputs DO2, DO3[12] LED K1, K2: Status of relay outputs K1, K2

LED 02, 03: Status of binary outputs DO2, DO3[13] X6: Connection for service interface[14] Status of 7-segment display[15] ENTER button[16] LEDs 13, 14: Status of binary inputs DI13, DI14

LEDs P1, P2: Status of clock signals P1, P2[17] X21: Connection for binary inputs DI13, DI14 and clock signals P1, P2

1314 P1 P2

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS10B

X11X21

X31X41

X32X42

X12X22

IN IN

IN

IN

K1K2 02 03OUT

[1] [2]

[3]

[4]

[5]

[6][12]

[13]

[14]

[15]

[16]

[17]

[7]

[8]

[9][10]

[11]

11

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3 nit design of basic modules nit Design

3.3.2 UCS11B

64452AXX

[1] X11: Connection for voltage supply DC 24 V[2] X12: Connection of voltage suppy for encoder / binary outputs DO0, DO1[3] X22: Connection for binary inputs DI01 - DI04[4] LED STATUS: Display of the system status[5] LED 01 - 04: Status of binary inputs DI01 - DI04[6] X7: Connection for incremental, sin/cos or absolute encoder[7] LED 05 - 08: Status of binary inputs DI05 - DI08[8] LED 09 - 12: Status of binary inputs DI09 - DI12[9] X32: Connection for binary inputs DI05 - DI08[10] X42: Connection for binary inputs DI09 - DI12[11] X41: Connection for relay outputs K1, K2[12] X31: Connection for binary outputs DO2, DO3[13] LED K1, K2: Status of relay outputs K1, K2

LED 02, 03: Status of binary outputs DO2, DO3[14] X6: Connection for service interface[15] Status of 7-segment display[16] ENTER button[17] LEDs 13, 14: Status of binary inputs DI13, DI14

LEDs P1, P2: Status of clock signals P1, P2[18] X21: Connection for binary inputs DI13, DI14 and clock signals P1, P2

1314 P1 P2

X7

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS11B

X11X21

X31X41

X32X42

X12X22

IN

IN

IN

IN

K1K2 02 03OUT

[1] [2]

[3]

[4]

[5]

[7][13]

[14]

[15]

[16]

[17]

[18]

[8]

[9]

[10][11]

[12]

[6]

UU


3 Unit design of basic modulesUnit Design

3.3.3 UCS12B

64453AXX

[1] X11: Connection for voltage supply DC 24 V[2] X12: Connection for voltage suppy for encoder (X7) / binary outputs DO0, DO1[3] X13: Connection for voltage supply for encoder (X8)[4] X22: Connection for binary inputs DI01 - DI04[5] LED STATUS: Display of the system status[6] LED IN 01 - 04: Status of binary inputs DI01 - DI04[7] X7: Connection for incremental, sin/cos or absolute encoder[8] X8: Connection for incremental, sin/cos or absolute encoder[9] LED IN 05 - 08: Status of binary inputs DI05 - DI08[10] LED IN 09 - 12: Status of binary inputs DI09 - DI12[11] X32: Connection for binary inputs DI05 - DI08[12] X42: Connection for binary inputs DI09 - DI12[13] X41: Connection for relay outputs K1, K2[14] X31: Connection for binary outputs DO2, DO3[15] LED OUT K1, K2, 02, 03: Status of outputs K1, K2, DO2, DO3[16] X6: Connection for service interface[17] Status of 7-segment display[18] ENTER button[19] LED IN 13, 14, P1, P2: Status of binary inputs DI13, DI14 / clock signals P1, P2[20] X21: Connection for binary inputs DI13, DI14 and clock signals P1, P2

1314 P1 P2

X7 X8

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS12B

X11X21

X31X41

X32X42

X12X22

X13

IN IN

IN

IN

[1] [2]

[3]

[4]

[5]

[6]

[7]

[9][15]

[16]

[17]

[18]

[19]

[20]

[10]

[11]

[12][13]

[14]

[8]

K1K2 02 03OUT

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3 nit design of I/O expansion module nit Design

3.4 Unit design of I/O expansion module3.4.1 UCS23B

64454AXX

[1] X15: Connection for voltage supply DC 24 V[2] X16: Connection for binary outputs DO2, DO3[3] X26: Connection for binary inputs DI01 - DI04[4] LED STATUS: Display of the system status[5] LED IN 01 - 04: Status of binary inputs DI01 - DI04[6] LED IN 05 - 08: Status of binary inputs DI05 - DI08[7] LED IN 09 - 12: Status of binary inputs DI09 - DI12[8] X36: Connection for binary inputs DI05 - DI08[9] X46: Connection for binary inputs DI09 - DI12[10] X45: Connection for binary inputs/outputs DI19 - DI22 / DO7 - DO10[11] X35: Connection for binary inputs/outputs DI15 - DI18 / DO3 - DO6[12] LED I/O: 07 - 10: Status of binary inputs/outputs DI19 - DI22 / DO7 - DO10[13] LED I/O: 03 - 06: Status of binary inputs/outputs DI15 - DI18 / DO3 - DO6[14] LED I/O: 01, 02: Status of binary inputs DI01, DI02

LED I/O: P1, P2: Status of clock signals P1, P2[15] X25: Connection for binary inputs/outputs DI13, DI14, DO1, DO2

Connection for clock signals P1, P2

0102 P1P2 0102 03 04

05 06 07 08

09 10 11 12

STATUS

UCS23B

X15X25

X35X45

X36X46

X16X26

I/O IN

IN

IN

03 0405 06I/O

070809 10I/O

[1] [2]

[3]

[4]

[5]

[6][13][12]

[14]

[15]

[7]

[8]

[9][10]

[11]

UU


3 Unit design of diagnostic moduleUnit Design

3.5 Unit design of diagnostic module3.5.1 UCS25B

64478AXX

[1] X49: CAN connection

X49 [1]

UCS25B

15

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4 eneral installation information echanical Installation

4 Mechanical Installation4.1 General installation information

4.2 Assembly information

TIPS• Install the units vertically only. Do not install them horizontally, tilted or upside down.• Ensure the correct unit enclosure (IP20) when installing MOVISAFE® UCS..B in a

control cabinet.• Leave 10 mm clearance above and below for optimum cooling. Make sure air can

circulate freely.• There is no need for clearance at the sides of the unit.• Route signal cables for analog signals separately from cables for connecting digital

inputs and contact monitoring functions.• Route power cables separately from signal cables.

NOTICEObserve the following points to prevent MOVISAFE® UCS..B from being damaged:Switch off the power supply before you insert or remove MOVISAFE® UCS..B.

TIPS• The individual safety modules are installed on a mounting rail. They are connected

using backplane bus connectors. The bus connector is placed into the profile railthat carries the modules.

• Always install the safety modules directly next to each other. Gaps between themodules are not permitted, else the backplane bus will be interrupted.

• A safety module is not properly installed and electrically connected until it locks inplace in the backplane connector.

GM


4 Assembly informationMechanical Installation

4.2.1 Dimension drawing for mounting rail

You can use the following 35 mm standard profile rail (see following figure) for installa-tion. SEW-EURODRIVE recommends to use version II to ensure sufficient space for theretaining screws under the backplane bus connector.

4.2.2 Mounting position

You can install a maximum of 1 basic module [1] vertically and additionally a maximumof 2 expansion modules [2] and a diagnostic module [2] (see following figure). Observethe permitted ambient temperature of 0 °C to 50 °C.

61989AXX

35

35

27 27

7.5

1

15

1.5

I II

64514AXX

[2][1]

1314 P1 P2

X7 X8

X6

K1K20203

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS12B

X11X21

X31X41

X32X42

X12X22

X13

IN IN

OUT IN

IN

0102 P1 P2 0102 03 04

05 06 07 08

09 10 11 12

STATUS

UCS23B

X15X25

X35X45

X36X46

X16X26

I/O IN

IN

IN

03 0405 06I/O

070809 10I/O

0102 P1 P2 0102 03 04

05 06 07 08

09 10 11 12

STATUS

UCS23B

X15X25

X35X45

X36X46

X16X26

I/O IN

IN

IN

03 0405 06I/O

070809 10I/O

X49

UCS25B

TIPSTo use the expansion modules, you have to register them in MOVISAFE® CONFIGusing the serial number (see nameplate of UCS..B).

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4 ssembly information echanical Installation

4.2.3 Installation clearance

Ensure a minimum clearance of 110 mm above and 60 mm below the middle of thebackplane connector when installing the components.

4.2.4 Backplane bus connector

Insert the backplane bus connector (see following figure) into the mounting rail for com-munication of the safety modules. The individual module slots are indicated by guiderails.

Each expansion and diagnostic module is supplied with a backplane bus connector. Thebackplane bus connects a basic module with an expansion or diagnostic module. Allbackplane bus connector sockets always have to be connected. Several basic modulescannot be connected.

64246AXX60m

m110m

m

64456AXX

TIPSThe scope of delivery of the basic module does not include backplane bus connectors.If you use expansion or diagnostic modules, order the required backplane bus connec-tors by quoting part number 1822 244 7.

AM


4 Assembly informationMechanical Installation

4.2.5 Step-by-step instruction for installing MOVISAFE® UCS..B

Proceed in the following order:

1. Install the mounting rail. Ensure the minimum clearance of at least 110 mm aboveand 60 mm below the middle of the profile rail.

2. Insert the backplane bus connector into the profile rail until it locks in place. The busconnections protrude from the rail.

3. Plug in the basic module farthest left. Next plug in the required expansion modulesto the right of the basic module.

4. Place the module you want to install from top at an angle of approx. 45 degrees ontothe mounting rail. Move the safety module downwards until it locks in place on themounting rail (see following figure). Only then will the module be properly connectedwith the backplane bus.


62026AXXCLACK

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4 ssembly information echanical Installation

4.2.6 Step-by-step instruction for removing MOVISAFE® UCS..BProceed as follows to remove modules:

1. The housing of the safety module is fitted with a spring-loaded clip at the bottom bywhich the module can be removed from the rail.

2. Insert a suitable screwdriver into the slot. The safety module is unlocked (see follow-ing figure, pos. I).

3. First pull the safety module forward and then upward away from the mounting rail(see following figure, pos. II).


TIPThe backplane bus is interrupted by removing MOVISAFE® UCS..B.

62027AXX

I

II

AM


5 Connection and terminal description of basic modules UCS10B/11B/12BElectrical Installation

5 Electrical Installation5.1 Connection and terminal description of basic modules UCS10B/11B/12BPart numbers • MOVISAFE® UCS10B: 1822 235 8

• MOVISAFE® UCS11B: 1822 236 6• MOVISAFE® UCS12B: 1822 237 4

TIPMOVISAFE® UCS..B must be supplied with DC 24 V.

64235AXX

1314 P1 P2

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS10B

X11X21

X31X41

X32X42

X12X22

MOVISAFE® UCS10B

IN IN

IN

IN

1314 P1 P2

X7

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS11B

X11X21

X31X41

X32X42

X12X22

MOVISAFE® UCS11B

IN

IN

IN

IN 1314 P1 P2

X7 X8

X6

0102 03 04

05 06 07 08

09 10 11 12

ENTER

STATUS

UCS12B

X11X21

X31X41

X32X42

X12X22

X13

MOVISAFE® UCS12B

IN IN

IN

IN

K1K2 02 03OUT K1K2 02 03OUT K1K2 02 03OUT

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5 onnection and terminal description of basic modules UCS10B/11B/12B lectrical Installation

Terminal description of basic modules UCS10B, UCS11B, UCS12B

Description LED/terminal Function

LED STATUS:

LED IN 01 - 14LED P1, P2LED OUT 01 -04

STATUS

01 - 14P1, P201 -04

The LED shows the status of the option UCS..B(see section "Local disgnostics").

Function key ENTER Error reset; displays CRC in status "4."

X6: Connection for service interface X6 Service interface, baud rate 38.4 kBaudFor point-to-point connection only

X7, X8: Connection for incremental, sin/cos or absolute encoder (encoder 1)

X7 (X8):1 - 9 Assignment depending on the connected encoder (see chapter "Technical Data")

X11: Connection for voltage supply DC 24 V

X11:1X11:2X11:3X11:4

DC 24 VDC 24 VReference potential 0V24Reference potential 0V24

X12: Connection for encoder supply voltage for encoder interface X7

X12:1 U_ENC_1 X12:2 GND_ENC_1X12:3 DO0X12:3 DO1

Encoder supply voltage for encoder interface X7Reference potential for encoder supply voltageSignal and auxiliary output DO0Signal and auxiliary output DO1

X13: Connection for encoder supply voltage for encoder interface X8

X13:1 U_ENC_2 X13:2 GND_ENC_2X13:3 NCX13:4 NC

Encoder supply voltage for encoder interface X8 (UCS12B)Reference potential for encoder supply voltage

X21: Connection for binary inputs DI13, D14Clock outputs P1, P2

X21:1 DI13X21:2 DI14X21:3 P1X21:4 P2

Binary input 13Binary input 14Clock signal 1 for safe inputs; DC+24V clockedClock signal 2 for safe inputs; DC+24V clocked

X22: Connection for binary inputs DI01-DI04

X22:1 DI01X22:2 DI02X22:3 DI03X22:4 DI04

Binary input 1 (suitable for OSSD)Binary input 2 (suitable for OSSD)Binary input 3 (suitable for OSSD)Binary input 4 (suitable for OSSD)

X31: Connection for auxiliary outputs DO0, DO1

X31:1 DO2_PX31:2 DO2_MX31:3 DO3_PX31:4 DO3_M

HISIDE auxiliary output 2 DC 24 V, Imax: 100 mALOSIDE auxiliary output 2 DC 24 V, Imax: 100 mAHISIDE auxiliary output 3 DC 24 V, Imax: 100 mALOSIDE auxiliary output 3 DC 24 V, Imax: 100 mA


X32:1 DI05X32:2 DI06X32:3 DI07X32:4 DI08

Binary input 5Binary input 6Binary input 7Binary input 8

X41: Connection for relay outputs X41:1 K1.1X41:2 K1.2X41:3 K2.1X41:4 K2.2

Relay output 1

Relay output 2


X42:1 DI09X42:2 DI10X42:3 DI11X42:4 DI12


CE


5 Connection and terminal description for expansion module UCS23BElectrical Installation

5.2 Connection and terminal description for expansion module UCS23BPart number MOVISAFE® UCS23B: 1822 241 2

64365AXX

0102 P1 P2 0102 03 04

05 06 07 08

09 10 11 12

STATUS

UCS23B

X15X25

X35X45

X36X46

X16X26

MOVISAFE® UCS23B

I/O IN

IN

IN

03 0405 06I/O

0708 09 10I/O

23

24

5 onnection and terminal description for expansion module UCS23B lectrical Installation

Terminal description of expansion module UCS23B


LED STATUS:

LED IN 01 - 12LED P1, P2LED I/O 01 -10

STATUS

IN 01 - 12I/O P1, P2I/O 01 -10

The LED shows the status of the option UCS23B(see section "Local diagnostics").

X15: Connection for voltage supply DC 24 V

X15:1X15:2X15:3X15:4

DC 24 VDC 24 VReference potential 0V24Reference potential 0V24

X16: Connection for auxiliary outputs DO11, DO12

X16:1 N. C.X16:2 N. C.X16:3 DO11X16:2 DO12

Signal and auxiliary output DO11 and DO12

X25: Connection for binary inputs DI13, DI14 or binary outputs DO1, DO2 as well as clock outputs P1, P2

X25:1 DI13 / DO1X25:2 DI14 / DO2X25:3 P1X25:4 P2

Binary input 13 / binary output 1Binary input 14 / binary output 2Clock signal 1 for safe inputs; DC+24V clockedClock signal 2 for safe inputs; DC+24V clocked

X26: Connection for binary inputs DI01 -DI04

X26:1 DI01X26:2 DI02X26:3 DI03X26:4 DI04


X35: Connection for binary inputs DI15 - DI18 or binary outputs DO3 - DO6

X35:1 DI15 / DO03X35:2 DI16 / DO04X35:3 DI17 / DO05X35:4 DI18 / DO06

Binary input 15 / binary output 3Binary input 16 / binary output 4Binary input 17 / binary output 5Binary input 18 / binary output 6


X36:1 DI05X36:2 DI06X36:3 DI07X36:4 DI08

Binary input 5Binary input 6Binary input 7Binary input 8

X45: Connection for binary inputs DI19 - DI22 or binary outputs DO07 - DO10

X45:1 DI19 / DO07X45:2 DI20 / DO08X45:3 DI21 / DO09X45:4 DI22 / DO010

Binary input 19 / binary output 7Binary input 20 / binary output 8Binary input 21 / binary output 9Binary input 22 / binary output 10


X46:1 DI09X46:2 DI10X46:3 DI11X46:4 DI12


CE


5 Connection and terminal description of diagnostic module UCS25BElectrical Installation

5.3 Connection and terminal description of diagnostic module UCS25BPart number MOVISAFE® UCS25B: 1822 243 9

Terminal description of diagnostic module UCS25B

64479AXX

X49

UCS25B

MOVISAFE® UCS25B


X49: CAN connection X49:1 DGNDX49:2 CAN_HIghX49:3 CAN_LowX49:4 N.C.

CAN reference potentialCAN HighCAN Low-

25

26

5 easures for electromagnetic compatibility (EMC) lectrical Installation

5.4 Measures for electromagnetic compatibility (EMC)MOVISAFE® is designed for use in industrial applications (based on the EMC testspecifications EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-6 andEN 61000-6-2). MOVISAFE® can be installed in a control cabinet together with invertertechnology without any problems. Prerequisite for safe installation is that the electro-magnetic compatibility of the entire system must be ensured by taking appropriatemeasures. The following measures must be taken to comply with the designatedoperation of MOVISAFE®:• Make sure that the MOVISAFE® voltage supply cables and the converter’s

"switching cables" are routed separately.• Route the converter’s signal cables and power cables in separate cable ducts. The

minimum distance between the cable ducts should be 10 mm.• All contactors in the immediate vicinity of MOVISAFE® must be equipped with

appropriate suppressors or protective diodes.• Make sure that the converter technology in the immediate vicinity of MOVISAFE®

complies with the EMC guidelines. Check the routing and design of the shielding forthe motor cable and braking resistor connection. You must comply with the installa-tion guidelines of the converter manufacturer.

• Only use shielded cables to connect the position and velocity sensors. The cable fortransmitting signals must be suitable for EIA485 standard (previously RS485).

• Make sure the shield is connected correctly in the 9-pole D-sub connectors of theposition and velocity sensors and on the sensor end of the cable. Only use metal ormetallized connectors.

• For splitting signals from positions and velocity sensors, only use prefabricatedcables from SEW-EURODRIVE (see chapter "Prefabricated cables)"

ME


5 External DC 24 V voltage supplyElectrical Installation

5.5 External DC 24 V voltage supplyThe MOVISAFE® UCS..B safety modules require a voltage supply of DC 24 V (seeSELV or PELV, EN 50178). During project planning and installation of the power supplyunit, the following conditions must be taken into account:• It is essential that you observe the minimum and maximum tolerance of the supply

voltage.

• To achieve a rather low residual ripple of the supply voltage, we recommend using a3-phase power supply unit or an electronically controlled unit. The power supply unitmust satisfy the requirements of EN 61000-4-11 (voltage dip).

• The external DC 24 V supply of MOVISAFE® supplies the internal electronics. Whenusing encoders, the encoder voltage supply must be provided separately.

• Safe electrical isolation against the voltage supply system (e.g. AC 230 V) mustalways be ensured. For this purpose, select power supply units that comply withDIN VDE0551, EN 60742 and DIN VDE0160. When selecting the unit, make sure ithas equipotential bonding between PE and DC 0 V on the secondary side.

• Provide external protection for MOVISAFE® by installing a 2 A fuse. Observe localregulations when dimensioning the connection cables.

5.6 Connecting binary inputs DI1 to DI14MOVISAFE® has 14 binary inputs (DI1 - DI14). They are suitable for connecting single-or dual-channel sensors with or without clocking.The connected signals must have a "high" level of DC 24 V (DC+15 V ... DC+30 V) anda "low" level of DC 0 V (DC–3 V ... DC+5 V). The inputs are fitted with input filters.An internal diagnostic function checks cyclically whether the binary functions, includingthe input filters, are working properly. When a fault is detected, MOVISAFE® goes intoalarm status. At the same time, all MOVISAFE® outputs are deactivated.

Tolerance

Minimum (–15 %) Maximum (+15 %)

Nominal voltage = DC 24 V DC 24 V – 15 % = DC 20.4 V DC 24 V + 15 % = DC 27.6 V

TIPS• Permitted OSSD outputs (Output Signal Switching Device) can be connected to

binary inputs DI1 - DI4 and DI9 - DI14.• No OSSD outputs must be connected to binary inputs DI5 - DI8 because the

requirements according to EN 61131-2 type 2 are not met.

27

28

5 onnecting binary inputs DI1 to DI14 lectrical Installation

Using clock out-puts P1 and P2

In addition to binary inputs DI1 to DI14, MOVISAFE® has two clock outputs P1 and P2to check for cross faults in the binary inputs and monitor external switching contacts. TheP1 and P2 clock outputs are switching DC 24 V outputs that are intended exclusively formonitoring the binary inputs (DI1 - DI14). The switching frequency for each output is125 Hz. For project planning, note that the maximum total current permitted for the out-puts is 250 mA.

Each binary input of MOVISAFE® can be configured separately for the following signalsources:• Binary input is assigned to pulse P1• Binary input is assigned to pulse P2• Binary input is assigned to DC 24 V continuous voltage

The following sample circuits and their characteristic architecture are decisive for theassignment to a category/performance level according to EN ISO 13849-1.The resulting maximum possible performance levels according to EN ISO 13849-1remain to depend on the following factors of the external components:• Structure (single or redundant)• Detection of common cause failure (CCF)• Diagnostics coverage if requested (DCavg)• Mean time to failure of a channel (MTTFd)

TIPNote that external measures, particularly suitable cable routing, must be taken toprevent short circuits in the external wiring between different inputs and against thesupply voltage of MOVISAFE®.

TIP• The following sample circuits assume that the switching elements are configured in

accordance with the required approval according to the required performance levelaccording to EN ISO 13849-1 or SIL according to EN 61508.

• The safety regulations and EMC directive must be strictly observed.• For excluded faults, refer to the tables under D in the annex of EN ISO 13849-2.• Classification in category/performance level (PL) according to EN ISO 13849-1

CE


5 Connecting binary inputs DI1 to DI14Electrical Installation

Single-channel sensor, unchecked

64438AXX

DI1

DI2

DI3

DI4

X22

1

2

3

4

L+

L-

TIPThe single-channel sensor is connected to MOVISAFE® without pulsing. MOVISAFE®

cannot detect cross faults or interruptions in the signal line. Note that this configurationis not permitted for safe applications without external measures. Category 1/perfor-mance level b according to EN ISO 13849-1 can maximally be reached.

64439AXX

DI1

DI2

DI3

DI4

L+

L-

X22

1

2

3

4

TIPUsing dual-channel homogeneous sensors without clocking or without cross faultmonitoring might lead to problems. Short circuits cannot be detected in the signal lineof the dual-channel sensor (e.g. in the cable). Safe operation can only be achieved byrouting the cables separately and making sure the terminals cannot short circuit. Thisconnection type is not recommended for safety applications outside the control cabinet.Category 4 / performance level e according to EN ISO 13849-1 can maximally bereached when cross faults can be excluded.

29

30


Dual-channel sensor, unchecked

Before using dual-channel sensors (homogeneous or diversified), check whether theyhave been approved for the intended purpose.

MOVISAFE® can operate safely with dual-channel diversified sensors without pulsing.

64441AXX

64442AXX

DI1

DI2

DI3

DI4

L+

L-

X22

1

2

3

4

DI1

DI2

DI3

DI4

L+

L-

X22

1

2

3

4

TIPMOVISAFE® can operate safely with dual-channel complementary sensors withoutpulsing or without cross fault monitoring. Category 4 / performance level e accordingto EN ISO 13849-1 can be reached when cross faults are excluded.

CE


5 Connecting binary inputs DI1 to DI14Electrical Installation

Single-channel sensor, checked

Check whether the sensor is approved for use in fail-safe applications.

When using a single-channel sensor with pulsing, the sensor must be connected to theclock output P1 or P2. The clock cycle must then be assigned on MOVISAFE®.The following faults are detected if you use a single-channel sensor with pulsing:• Short circuit against the DC 24 V supply voltage• Short circuit on DC 0 V• Cable interruption (power interruption is a safe state!)However, a short circuit in the cable between the two sensor connections is notdetected. A short circuit between P1 and DI1 is also not detected.

64220AXX

P1

P2

DI1

DI2

DI3

DI4

DI13

DI14

P1

P2

L+

L-

X22

X21

1

2

3

4

1

2

3

4

TIP• Performance level e according to EN ISO 13849-1 can be achieved if the short

circuit between DI1 and P1, and the short circuit between the sensor connectionscan be excluded. Faults can be excluded in accordance with EN ISO 13849-2, tableD8.

• With a suitable component and careful wiring of the sensor, category 2/performancelevel d according to EN ISO 13849-1 can be achieved.

31

32


Dual-channel sensor, checked

All cross fault connections and connections to DC 24 V and DC 0 V can be detectedwhen two independent clock signals are used on a homogeneous sensor. Only use NCcontacts for safety applications.

64221AXX

P1

P2

DI1

DI2

DI3

DI4

DI13

DI14

P1

P2

L+

L-

X22

X21

1

2

3

4

1

2

3

4

TIPNote that when connecting a diversified sensor (see following figure), only the NOcontact is tested regularly. As with the homogeneous sensor, all types of faults aredetected in the supply line.

64222AXX

P1

P2

DI1

DI2

DI3

DI4

DI13

DI14

P1

P2

L+

L-

X22

X21

1

2

3

4

1

2

3

4

TIPCategory 4/performance level e according to EN ISO 13849-1 can be achieved in bothcases when using permitted, positive opening switching elements.

CE


5 Connecting the position and velocity sensorsElectrical Installation

5.7 Connecting the position and velocity sensorsBefore you start

Depending on the type, MOVISAFE® UCS..B has up to two encoder interfaces forconnecting standard incremental, sin/cos and absolute encoders. Besides, 2 sensorsthat generate incremental signals (such as proximity switches) can be connected to thepulse count inputs of MOVISAFE®. The signals have to be read-in with normal andcomplemetary tracks (e.g. A and A)

Incremental, sin/cos or absolute encoders (binary or Gray Code) can be connected andoperated via the same encoder interface. Sin/cos encoders operate in the same way asincremental encoders.Observe the following notes:• MOVISAFE® usually provides the connector sensors with the voltage supply. This

voltage is led to the encoder connector and is monitored by an internal diagnosticprocess.If the sensors are powered by an external voltage supply,– then the voltage must be led via the encoder connector. The relevant terminals

X12 and X13 on MOVISAFE® remain unassigned– the possibility of a voltage supply failure has to be taken into account in the

possible sources of error for the whole systemParticularly with shared external voltage supplies, you must document that this faultwill be detected when the minimum operating voltage of the encoder system is notmaintained.

• Check that EMC measures, such as shielding, etc. (see chapter "Measures forelectromagnetic compatibility (EMC)") have been applied.

• The two encoders must not impact on each other. This refers to both the electricaland mechanical part.

• If both encoders are connected to the monitoring system with the same mechanicalparts, the connection must be positive and may not include any parts that are subjectto wear (chains, toothed belts, etc.). However, if parts subject to wear are used, youmust install additional monitoring systems to check the mechanical connection of thesensors (e.g. monitoring function for a toothed belt).

• If position processing is activated, you must connect at least one absolute encoder.

NOTICEDo not plug in or remove encoder connections during operation.Doing so can cause irreparable damage to the electrical components on the encoder.Disconnect MOVISAFE® before you plug in or remove the encoder connections.

TIPSEW-EURODRIVE recommends using the encoders listed in the appendix.

33

34

5 onnecting the position and velocity sensors lectrical Installation

• Encoder 1 functions as a process sensor and encoder 2 as a reference sensor. If youare using encoders with different resolutions, configure the encoder with the higherresolution as "Encoder 1" (X7) and the encoder with the lower resolution as "Encoder2" (X8.

• An internal number format is used in the input fields 'Position', 'Velocity' and'Acceleration' when the monitoring functions are configured. This can cause thevalues to be rounded.

5.7.1 Combination of various encoder types

Encoder types can be combined depending on the specific application. Note thefollowing limitations:• If monitoring functions are used with position processing, at least one sensor must

be assigned as an absolute encoder.• If you change the encoder configuration at a later date, the existing parameters for

the monitoring functions may no longer be compatible with the new encoderconfiguration. In this case, check the parameter settings and value ranges of all themonitoring functions in use. SEW-EURODRIVE recommends using the encoderslisted in the appendix.

• The following applies to the use of absolute encoders:In slave mode, the clock signal is generated by an external process and is read-inwith the data signal from MOVISAFE®. This type of scan generates a scanning erroras follows:F = (sampling time of the encoder due to external system in ms / 8 ms) × 100 %You must take the size of the scan error F into account when determining thethreshold in the monitoring functions because this error cannot be compensated.

5.7.2 Voltage supply for encoder systems

MOVISAFE® supports the following encoder voltages; 5 V, 8 V, 10 V, 12 V and 24 V.The encoder voltage parameter is set in the software user interface and is thenmonitored by the system. The encoder voltage must be connected on MOVISAFE® onterminals X12 / X13.

CE



5.7.3 Connecting proximity sensors

Proximity sensors are connected using terminal X32 (DI05 - DI08). The inputs aredebounced accordingly. When using HTL encoders, make sure that tracks A and B, andA and B must be combined with one another accordingly. Signal tracks A and B musthave a phase difference of 90°. The maximum counting frequency that can be read is10 kHz.

5.7.4 Connecting encoders

Absolute encoder Only SSI absolute encoders (binary or Gray code) can be read. If the encoder isconnected directly (master mode), the SSI signal will be received at a maximum clockrate of 150 kHz. If the encoder is connected to a frequency inverter, for example, the encoder will haveto be operated in slave mode. This means that MOVISAFE® monitors the data and clockspeed only. In this case, the maximum permitted clock rate is 200 kHz. The clock pauseinterval must not be higher than 2 ms and lower than 30 μs.

Incremental encoder

– Encoder with signal level to RS422– Measuring signal A/B track with 90 degree phase difference– Maximum frequency of the input pulses: 200 kHz

SIN/COS encoder – Encoder with AC 1 Vss– Measuring signal A/B track with 90 degree phase difference– Maximum frequency of the input pulses: 200 kHz

5.7.5 Configuring the measuring distances

The most important input parameters for the MOVISAFE® monitoring functions are:• Position• Velocity• AccelerationThese input parameters are generated in a dual-channel from the connected encodersystems. To achieve category 4 / performance level e according to EN ISO 13849-1,always two independent encoder systems are required. To achieve category 3 /performance level d according to EN ISO 13849-1, one encoder system can besufficient for certain applications (e.g. only velocity monitoring).

Terminal HTL / Proxy 1Z1)

1) Designation according to the software user interface of MOVISAFE CONFIG

Proxy 2Z1)

X32:5 A A

X32:6 B B

X32:7 A

X32:8 B

35

36


Measuring distances A and B must be configured accordingly for internal signalprocessing. This can be done using the encoder dialog box in the programming inter-face.Note the following parameters when configuring the measuring distance:• Measuring distance type

For the measuring distance, you can choose between the types "linear" or "rotatory".

• Measuring distance unitsFor a linear measuring distance, you can choose 'mm/sec' or 'm/sec' as the unit forvelocity. For rotary measuring sections, you can choose 'mgrad/sec', 'rps' or 'rpm' asthe unit for velocity. The selected resolution should correspond to the physics of themeasuring section to prevent rounding problems in the configuration.

• Measuring lengthThe measuring length determines the permitted position range for position process-ing. If you do not define a measuring length, only monitoring functions with velocityprocessing properties will be permitted during configuration. Monitoring functionswith position processing properties will be deactivated in the dialog box. Once youhave activated the measuring length window, i.e. allowed position processing, notethat the current position of the drive must be within the measuring length window.The measuring length has a range of 1 ... 1000000 and is normalized with the unitspecified for the measuring section.

• Safety-related switch-off thresholdsThe basic check is to perform a plausibility test between the two measuring channelsA and B of the MOVISAFE® UCS..B safety module to compare the current positionand velocity values with the configured thresholds.– The "incremental" switch-off threshold is the deviation in position permitted

between the two recording channels A and B in the unit of the measuring length.– The 'velocity' switch-off threshold is the deviation in velocity permitted between

the two recording channels A and B.Diagnostic functions are provided in the SCOPE dialog box of the configuration toolto determine the optimum parameter values.

• Measurement methodsThe velocity is recorded– up to a frequency of 500 Hz in the frequency measurement procedure– at a frequency of < 500 Hz in the time measurement procedureRecording errors might occur at traveling velocities in the range of 500 Hz. Themeasurement result can be optimized by choosing a suitable encoder resolution.

CE



• Mean value filterFor applications with limited resolution and/or time variance of the scan signal, theperformance of the monitoring functions used can be improved by using a meanvalue filter. The mean value filter "smoothens" any digital interference of theencoders. This is achieved, however, at the cost of an increased response time ofthe entire system.You can set the filter time to any value between 0 and 64 ms. To determine theresponse time of the entire system, you have to add the filter times to the specifiedresponse times of the MOVISAFE® system (see "Appendix").

Conversion example

The ramp times of the MOVIDRIVE® B inverter are based on a setpoint step change ofΔn = 3000 rpm. The acceleration value a is calculated using the following formula:

Example: In MOVITOOLS®, P137 Emergency ramp is set to 2 seconds.

Conversion to 1/s2:

The values that are entered in the MOVISAFE® CONFIG/ASSIST program are basedon the measuring distance. This means that the motor revolutions still have to beconverted to the measuring distance.• Rotatory system:

59723AEN

59725AXX

59726AXX

11464AXX

av

t

aRamp time

=

= [ ][ ]

3000 1

60

/min

min

a = [ ][ ] =

3000 1

2

60

90000 1 2/min

min[ /min ]

as s

s= =×

=90000 190000 160 60

25 122

2[ /min ][ /min ]

[ ] [ ][ / ]

37

38


Calculating the velocity:

Calculating the acceleration:

• Linear system:

Calculating the velocity:

59728AEN

vmotor = Motor speed [rpm]igear unit = Gear unit ratioiadditional gear = Gear ratio of the additional gear

59729AEN

amotor = Motor accelerationigear unit = Gear unit ratioiadditional gear = Gear ratio of the additional gear

11465AXX

59731AEN

v = Speed [m/min]vmotor = Motor speed [rpm]igear unit = Gear unit ratioiadditional gear = Gear ratio of the additional gearDdrive wheel = Drive wheel diameter [m]

vv

i i

Motor

gear unit add. gear

=×

aa

i i

Motor

gear unit add. gear

=×

v

i iDMotor

gear unit add. gear

drive wheel=

×× ×π

CE



Calculating the acceleration:

In many cases, the data in millimeters or minutes exceed the input’s value range. In thiscase, you have to scale the values from millimeters to meters (for linear systems) or fromminutes to seconds (for rotatory systems).Velocity:

Acceleration:

59731AEN

a = Acceleration [m/min2]amotor = Acceleration motor [rpm2]igear unit = Gear unit ratioiadditional gear = Gear ratio of the additional gearDdrive wheel = Drive wheel diameter [m]

59734AXX

59735AXX

v

i iDMotor

gear unit add. gear

drive wheel=

×× ×π

v m s v mm s

v U s v U

[ / ][ / ]

[ / ][ /min]

=

=

1000

60

a m s a mm s

a U s a U a U

[ / ][ / ]

[ / ][ /min ] [ /min ]

22

22 2

1000

60 60 3600

=

=×

=

39

40


5.7.6 Prefabricated cables

Overview For connecting an encoder to both a MOVIDRIVE® B / MOVIAXIS® and the USC..Boption, you can order prefabricated cables from SEW-EURODRIVE.

Encoder cable

Type designation Part number

DAE50B 1811 447 4

DAE51B 1811 448 0

DAE52B 1811 449 0

DAE53B 1811 450 4

DAE54B 1811 451 2

DAE55B 1811 452 0

DAE56B 1811 464 4

DAE57B 1811 465 2

DAE58B 1811 466 0

CE



DAE50B/51B Prefabricated cables DAE50B (without TF evaluation) and DAE51B (with TF evaluation)are suited for the following encoders:• Incremental encoder• Sin/cos encoderWith the DAE50B/51B prefabricated cables, you can split the encoder signal and in thisway make it available to the UCS..B option and MOVIDRIVE® B, terminal X14.

64487AXX

Termi-nal

[A] [B] [C]

Encoder connection15-pin D-sub socket

MDX B: X1415-pin D-sub socket

UCS11B/12B: X7/X89-pin D-sub connector

1 COS + (signal track A) COS + (signal track A) -

2 SIN + (signal track B) SIN + (signal track B) DGND

3 - (signal track C) - (signal track C) -

4 DATA + DATA + SIN – (signal track B)

5 - - COS + (signal track A)

6 TF/TH/KTY – (only with DAE51B)

TF/TH/KTY– COS – (signal track A)

7 - - -

8 DGND DGND SIN + (signal track B)

9 COS – (signal track A) COS – (signal track A) US

10 SIN – (signal track B) SIN – (signal track B) -


12 DATA– DATA– -

13 - - -

14 TF/TH/KTY + (only with DAE51B)

TF/TH/KTY+ -

15 US US -

A

B

C

41

42


DAE52B/53B Prefabricated cables DAE52B (without TF evaluation) and DAE53B (with TF evaluation)are suited for the following encoders:• Incremental encoder• Sin/cos encoderYou can use the prefabricated DAE52B/53B cables to split the encoder signal to makeit available to the UCS..B option and the following terminals: • MOVIDRIVE® B: Terminal X15• MOVIAXIS®: Terminals X13/X63/X64.

64487AXX

Termi-nal

[A] [B] [C]

Encoder connection15-pin D-sub socket

MDX B: X15MX: X13/X63/X6415-pin D-sub connector





4 DATA + DATA + SIN – (signal track B)

5 - - COS + (signal track A)

6 TF/TH/KTY – (only with DAE51B)

TF/TH/KTY– COS – (signal track A)

7 - - -

8 DGND DGND SIN + (signal track B)

9 COS – (signal track A) COS – (signal track A) US




13 - - -

14 TF/TH/KTY + (only with DAE51B)

TF/TH/KTY+ -

15 US US -

A

B

C

CE



DAE54B With the DAE54 prefabricated cable, you can split the SSI encoder signal and in this waymake it available to the UCS..B option and MOVIDRIVE® B, terminal X62.

64490AXX

Termi-nal

[A] [B] [C]

SSI encoder connection9-pin D-sub socket

MDX B: X629-pin D-sub connector


1 DATA + DATA + -

2 - - DGND

3 Cycle + Cycle + -

4 - - Cycle –

5 DGND DGND DATA +

6 DATA – DATA – DATA –

7 - - -

8 cycle – cycle – Cycle +

9 DC 24 V DC 24 V DC 24 V

A

B

C

43

44


DAE55B With the DAE55B prefabricated cable, you can split the SSI encoder signal and in thisway make it available to the UCS..B option and MOVIAXIS®, terminal X64.

64487AXX

[A] [B] [C]

Terminal SSI encoder15-pin D-sub socket

MX: X6415-pin D-sub connector




3 Cycle + Cycle + -

4 DATA + DATA + cycle –

5 - - DATA +

6 TF/TH/KTY+ TF/TH/KTY+ DATA–

7 - - -

8 GND GND Cycle +

9 COS – (signal track A) COS – (signal track A) Us


11 cycle – cycle – -


13 - - -

14 TF/TH/KTY– TF/TH/KTY– -

15 Us Us -

A

B

C

CE



DAE56B The prefabricated DAE56B cable serves for connection to MOVIAXIS®, terminal X62, ifyou use X62 as "incremental encoder simulation" output.

64488AXX

Terminal

[A] [B]

Incremental encoder emulationMX: X629-pin D-sub socket


1 Signal track A -

2 Signal track B DGND (jumpered with terminal 4, X14 (MDX B) or X62 (MX)

3 - -

4 Jumpered with X7/X8 (UCS11B/12B), terminal 2

Signal track B

5 DGND Signal track A

6 Signal track A Signal track A

7 Signal track B -

8 - Signal track B

9 DC 24 V DC 24 V

A B

45

46


DAE57B The prefabricated DAE57B cable serves for • connection to MOVIDRIVE® B, terminal X14 , if you use X14 as 'incremental encoder

simulation' output• direct connection of a sin/cos or incremental encoder to MOVISAFE®

64491AXX

Terminal

[A] [B]

Incremental encoder simulation Sin/cos encoder connection15-pin D-sub socket


1 COS + (signal track A) -

2 SIN + (signal track B) DGND, jumpered with X14 terminal 7

3 - -

4 - SIN – (signal track B)

5 - COS + (signal track A)

6 - COS – (signal track A)

7 Changeover, jumpered with X7/X8 terminal 2 -

8 DGND SIN + (signal track B)

9 COS – (signal track A) US

10 SIN – (signal track B) -

11 - -

12 - -

13 - -

14 - -

15 US -

AB

CE



DAE58B The prefabricated DAE58 B cable is suited for connecting an SSI absolute encoderdirectly to MOVISAFE®.

64491AXX

[A] [B]

Terminal SSI absolute encoder connection15-pin D-sub socket


1 - -

2 - DGND

3 Cycle + -

4 DATA + cycle –

5 - DATA +

6 - DATA–

7 - -

8 DGND Cycle +

9 - US

10 - -

11 cycle – -

12 DATA– -

13 - -

14 - -

15 US -

AB

47

48


5.7.7 Wiring diagrams for direct encoder connection to MOVISAFE®

Connecting an SSI absolute encoder

Connecting an incremental encoder

Connecting a sin/cos encoder

NOTEOnly the connection variants depicted in the diagrams are permitted.

64494AXX

1

5

6

9

5

6

8

4

9

2

max. 100 m

DC 24 V

DC 0 V

DATA -

DATA+

Takt +

Takt -

MOVISAFE®

X7/X8

120

64493AXX

1

5

6

9

MOVISAFE®

X7/X8max. 100 m

8

4

5

6

2

9DC 24 V

DC 0 V

B

B

A

A

120

64492AXX

max. 100 m

1

5

6

9

5

6

8

4

9

2

DC 24 V

DC 0 V

COS -

COS +

SIN +

SIN -

X7/X8

120

MOVISAFE®

CE



5.7.8 Wiring diagrams for encoders parallel on the inverter and UCS.B option

Connecting an absolute encoder in slave mode

In this type of connection, the pulse signals and data are read. In this example, UCS..Boption does not supply a voltage to the encoder.

TIPConnecting an encoder in parallel on the encoder input of the inverter and the UCS.Boption is only tested and approved with SEW products.

64585AXX

1

6

3

8

9

5

DATA +

max. 100 m

DC 24 V

DC 0 V

Takt -

Takt +

DATA -

4

8

6

5

1

5

6

9

1

5

6

9

MOVISAFE®

UCS11B/12B

X7/X8

MOVIDRIVE® B

X62

� �

��

9

2

49

50


Connecting a sin/cos or incremental encoder in listener mode

An individual sin/cos encoder can be used for applications up to performance level d. Inthis case, the signal outputs of the encoder are distributed to X15 (with MOVIDRIVE®

B) or X13/X63/X64 (with MOVIAXIS®) and to X7/X8 of the UCS11B/12B option (seefollowing figure).

64495AEN

1

9

2

10

3

11

4

12

6

5

6

8

4

2

14

1

8

9

15

MOVIDRIVE®

B

X15:

MOVIAXIS®

X13/X63/64

max. 100 m

Encoder

COS +/ A

COS -/ A

SIN +/ B

SIN -

C

C

DATA +

DATA -

TF/TH/KTY +

TF/TH/KTY -

1

5

6

9

MOVISAFE®

X7/X8

9

15

8DC 0 V

DC 24 V

/ B

TIPS• Mechanical faults, such as shaft breakage and slip, are not detected and have to

be ruled out by appropriate measures in the system design. • The design of the mechanical system and of the encoder must be subjected to a

failure mode and effect analysis based on the system.

CE


5 Connecting binary outputsElectrical Installation

5.8 Connecting binary outputsBasic module The basic MOVISAFE® module provides 8 binary outputs. They can be connected

individually or in groups:

The binary outputs (except for DO0 and DO1) are subjected to a plausibility test in alloperating modes. When switched on, all binary outputs (except for DO0 and DO1) aretested for correct functioning using a cyclical test pulse. The binary output is switched toits inverse value for the duration of the test (< 300 μs), i.e. a P binary output is switchedbriefly to DC 0 V potential, and an M binary output is switched briefly to DC 24 Vpotential.The binary output test function (except for DO0 and DO1) is performed for group andindividual control.The relay outputs are monitored for plausibility during each switching cycle. The relayoutputs have to be tested (switched) cyclically to maintain the safety function. A testshould be carried out at least once a year. For increased requirements, the test cyclehas to be specified depending on the application.

Binary output Meets perfor-mance level e according to EN ISO 13849-1

Comment

DO0- Only functional

DO1

DO2_P and DO2_M X Complete shutdown channel according to PL e to EN ISO 13849-1

DO2_P- Only functional

DO2_M

DO3_P and DO3_M X Complete shutdown channel according to PL e to EN ISO 13849-1

DO3_P- Only functional

DO3_M

K1 and K2 X Complete shutdown channel according to PLe to EN ISO 13849-1

K1- Only functional

K2

Binary output Output voltage Output current

DO2_PDO2_M

DC 24 V

0.25 ADO3_PDO3_M

DO0, DO1 0.1 A

K1, K22.0 A

K1, K2 AC 230 V

TIPS• For safety-relevant applications, use only external switching elements with a

minimum holding current of >1.2 mA at the relay outputs.• Cross and short circuits in the external wiring of the binary outputs are not detected.

For safe outputs, cross faults and short circuit have therefore to be preventedaccording to EN ISO 13849-2 table D.4.

51

52

5 onnecting binary outputs lectrical Installation

5.8.1 Example of how to use the binary outputs for safe stop

The binary outputs can be used for control of the safe stop function (X17) ofMOVIDRIVE® B, MOVITRAC® B and MOVIAXIS® (see following figures).

64539AXX

64518AXX

MOVIDRIVE® B / MOVITRAC® B

DGND

VO24

SOV24

SVI24

1

2

3

4

X17

DO2_P

DO2_M

DO3_P

DO3_M

X31

1

2

3

4

MOVISAFE® UCS..B

X31

X21

1

2

3

4

1

2

3

4

NC

C

RGND

+24V

4

3

2

1

X7

MOVISAFE® UCS..B MOVIAXIS®

DO2_P

DO2_M

X22

1

2

3

4

DI1

DI2

DI3

DI4

DI13

DI14

P1

P2

DO3_P

DO3_M

TIPTwo-pole disconnection with monitoring of the external safety contact is permitted forsafety applications up to category 3 / performance level d according to EN ISO 13849-1.

CE



5.8.2 Single-pole switching P binary output without check

You can use external contactors to connect multi-phase applications or in applicationswith an increased current consumption. Note that with single-pole connection without anexternal check, one or more external MOVISAFE® contacts will not be detected. Thefollowing sample circuit is not suitable for safety applications.

5.8.3 Single-pole switching M binary output without check

Similar to the previous wiring example, the following sample circuit shows a single-poleM binary output without test. The following sample circuit is not suitable for safetyapplications.

64223AXX

DO2_P

DO2_M

DO3_P

DO3_M

L+

L-

X31

1

2

3

4

64462AXX

DO2_P

DO2_M

DO3_P

DO3_M

L+

L-

X31

1

2

3

4

53

54


5.8.4 Single-pole switching P binary output with external contact monitoring

Similar to the previous wiring example, the following sample circuit shows a single-poleP binary output with check. The prerequisite for this solution is a switching element withtested forced contacts and test contact (NC contact). The monitoring contact is fed viaclock output P1 and read via any input. The EMU (Emergency Monitoring Unit) must beconfigured correctly for this solution to function properly.

64463AXX

DI3

DI4

DO2_P

DO2_M

DO3_P

DO3_M

DI1

DI2

L+

L-

X31

X22

1

2

3

4

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

TIPSingle-pole disconnection with monitoring of the external safety contact is notpermitted for safety applications from category 3 / performance level d accord-ing to EN ISO 13849-1. Up to performance level d according to EN ISO 13849-1, thestatus of the signal contact can be displayed and evaluated by means of anotherbinary output (e.g. DO3_P).

CE



5.8.5 Single-pole switching M binary output with external contact monitoring

Similar to the previous wiring example, the following sample circuit shows a single-poleM binary output with check. The prerequisite for this solution is a switching element withtested forced contacts and test contact (NC contact). The monitoring contact is fed viaclock output P1 and read via any input. The EMU (Emergency Monitoring Unit) must beconfigured correctly for this solution to function properly.

64464AXX

DI3

DI4

DO2_P

DO2_M

DO3_P

DO3_M

DI1

DI2

L+

L-

X31

X22

1

2

3

4

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

TIPSingle-pole disconnection with monitoring of the external safety contact is notpermitted for safety applications from category 3 / performance level d accord-ing to EN ISO 13849-1. Up to performance level d according to EN ISO 13849-1, thestatus of the signal contact can be displayed and evaluated by means of anotherbinary output (e.g. DO3_M).

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56


5.8.6 Dual-channel switching binary output DO0 with external monitoring

For safety applications from catagory 3 / performance level d according to EN ISO13849-1, two complementary binary outputs are connected as a group to control twoexternal power contactors. The two external monitoring contacts are connected inseries. They are supplied by the clock signal P1 and read via binary input DI1. BinaryDI1 is used as read-back input but any other binary input can be assigned instead.

64465AXX

DI3

DI4

DO2_P

DO2_M

DO3_P

DO3_M

DI1

DI2

X31

X22

1

2

3

4

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

TIPFor increased requirements, it is important that at least one switching operation takesplace every 24 hours to test the switching capability of the external power contactor.

CE



5.8.7 Single-pole switching relay output without check

For connecting multi-phase applications or applications with increased currentconsumption, it is important that welding of one or more external contacts will not bedetected by MOVISAFE®. The following sample circuit is not suitable for safetyapplications.

64466AXX

L+

L-

K2

K2

K1

K1

X41

1

2

3

4

TIPSingle-pole disconnection with monitoring of the external safety contact is permittedfor safety applications up to category 2 / performance level c according to EN ISO13849-1. Up to category 2 / performance level c, the status of the signal contact canbe displayed and evaluated via binary ouputs DO0/DO1 or via the fieldbus interface.

57

58


5.8.8 Single-pole switching relay output with external contact monitoring

Similar to the previous wiring example, the following sample circuit shows a single-polerelay output with check. The prerequisite for this solution is a switching element withtested forced contacts and test contact (NC contact). The monitoring contact is fed viaclock output P1 and read via any binary output (e.g. DI1). The EMU (EmergencyMonitoring Unit) and the binary input must be configured correctly for this solution tofunction properly. The following sample circuit is not suitable for safetyapplications.

64467AXX

L+

L-

DI3

DI4

DI1

DI2

X22

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

K2

K2

K1

K1

X41

1

2

3

4

TIPSingle-pole disconnection with monitoring of the external safety contact is not permit-ted for safety applications from category 3 / performance level d according toEN ISO 13849-1. Up to category 2 / performance level c according to EN ISO 13849-1, the status of the signal contact can be displayed and evaluated via binary ouputsDO0/DO1 or via the fieldbus interface.

CE



5.8.9 Double-channel switching relay output with external monitoring (general checkback)

For safety applications from category 3 / performance level d according to EN ISO13849-1, two relays of MOVISAFE® and two external power contactors are used.

64468AXX

DI3

DI4

DI1

DI2

X22

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

L+

L-

K2

K2

K1

K1

X41

1

2

3

4

TIPThe two external monitoring contacts are connected in series. They are supplied byclock signal P1 and read by binary input DI1 (configured as EMU input). For applica-tions with increased demands, note that a switching operation must take place at leastevery 24 hours.

59

60


5.8.10 Dual-channel switching relay output with external monitoring (specific checkback)

For safety applications from category 3 / performance level d according to EN ISO13849-1, two relays of MOVISAFE® and two external power contactors are used.

External monitoring contact 1 is fed by clock signal P1 and read in by binary input DI2.This operating mode allows specific checkback to identify which external switchingelement has triggered an error.

64469AXX

DI3

DI4

DI1

DI2

X22

1

2

3

4

P1

P2

DI13

DI14

X21

1

2

3

4

L+

L-

K2

K2

K1

K1

X41

1

2

3

4

TIPFor applications with increased demands, note that a switching operation must takeplace at least every 24 hours.

CE



5.8.11 Connecting an auxiliary output

Both auxiliary outputs implemented on MOVISAFE® can be connected for functionalapplications. The outputs are not pulsed.

64470AXX

DO0

DO1

L-

L+

X12

1

2

3

4

GND_ENC_1

U_ENC_1

TIPApplications with auxiliary outputs are not permitted for safety applications.

61

62

6 eneral startup information tartup

6 Startup6.1 General startup informationPrerequisites • The following prerequisites must be fulfilled to ensure successful startup

– The system must be configured correctly– The MOVISAFE® CONFIG parameter setting software must be installed. You find

the latest software version on the SEW home page or on the MOVISAFE®

software ROM, part number 1156 6604.For detailed project planning information and a description of the parameters, referto the online help in the MOVISAFE® CONFIG parameter setting software.

• Prerequisites for using the MOVISAFE® CONFIG parameter setting software:– MOVISAFE® CONFIG must be activated with a USB dongle (part number

1058 5834)– Operating system: Microsoft Windows® 2000 or XP– Required hard disk space: Approximately 100 MB– RAM: Min. 256 MB, recommended 512 MB or more

Startup steps • Make sure that– the MOVISAFE® installation– the cabling– the terminal assignment and– the safety cut-outshave been configured correctly and are suited to the application.

• Prevent unintentional starting of the motor using suitable measures. Integrateadditional safety features depending on the application to prevent possible injuriesand damages to machines.

• Switch on the mains voltage and, if necessary, the DC 24 V supply voltage.• Configure and program MOVISAFE® to suit your application.• Perform a validation (see section "Validation"). Create a validation report (see

section "Validation report").

GS

00

I


6 Switch-on sequencesStartup

6.2 Switch-on sequencesEach time MOVISAFE® is restarted successfully, the following phases are run throughand displayed in the 7-segment display on the front of the unit.

6.3 LED displayLED status

LED IN 01 - 14

LED P1, P2

LED OUT 01 - 04

7-segment display

Mode Description

1 STARTUP Synchronization between both processor systems and check of the configuration/firmware data.

2 SEND CONFIG Distribution of the configuration/firmware data and another check of this data. Next, range check of the configuration data.

3 STARTUP BUS If applicable, the bus system is initialized (PROFIsafe).

4 RUN Watchdog is active, which means that all outputs (DO1, DO2 and K1... K4) can be switched.

TIPThe firmware automatically disables the outputs for all operating modes except forRUN. In "RUN" mode (display "4"), the implemented PLC program or fieldbus can beused to intervene.

LED display Description

Flashing green System ok, configuration validated

Flashing yellow System ok, configuration not validated yet

Flashing red Alarm

Flashing red Fatal error


Flashing green Signal present at binary input.


Flashing green The pulse output is available.


Flashing green The binary output has switched.


00

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64

6 alidation report tartup

6.4 Validation reportTo make sure that the implemented safety functions function correctly, the user mustcheck and document the parameters and connections after startup and configuration.This is supported by the validation wizard of the programming interface. (TheMOVISAFE® CONFIG configuration tool is supported).You can call up the validation report directly from the programming interface under themenu item [File] / [Configuration report].The first page of the validation report can be used for general information about thesystem (plant, customer, supplier, setter, etc.). On the second page of the validationreport, you can enter more detailed information about the system/machine. This data isfor information only, but the content and scope must be checked with the approvalauthorities/inspector.The last page of the validation report contains the itemization for the safety check.Here, you must enter the following information:• Serial number (identical with the serial number on the nameplate)• Correspondence between the serial number read off and the serial number on the

nameplate of MOVISAFE®.• Identity of the subassembly

Here, the inspector of the safety subassembly confirms that the CRC displayed in theprogramming interface is identical to the one in MOVISAFE®. This CRC signaturecomprises a five-digit number that is displayed in the connection dialog box of theconfiguration tool in the diagnostic system information section. In this case,MOVISAFE® must have an active connection.

Once all header data has been entered, you can generate the validation report by press-ing the 'Save' button. The configuration tool creates a text file (.TXT) with the file nameof the parameter/parameter data record. The text file includes the following information:• The 3 pages of the header data edited above• Encoder configuration• Parameters of the monitoring functions

Monitoring functions not required are also listed. These functions must also bechecked.

TIPS• The correct program data and parameter data must be loaded to create the valida-

tion report.• All listed parameters and program instructions must be validated at the

system/machine and confirmed manually written in the validation report• The inspector must validate all configured data again in a printout of the validation

report.• All limit values set for the monitoring functions must be checked.• For versions without PROFIsafe, the AWL code specified in the validation report

must be validated.

VS

00

I


7 ProcedureValidation

7 Validation7.1 Procedure

The MOVISAFE® concept is based on the following conditions:Parameter and PLC data stored in the MOVISAFE® flash memory cannot changeautomatically. Online tests and corresponding signatures ensure this by implementingbasic measures on the subassembly. However, the configured parameters cannot beevaluated by the subassembly. This affects parameters for the sensors, thresholds andlimit values.The user must confirm that the data of the test protocol matches the parameters in thesubassembly. The user must validate and protocol the parameterized values for themeasuring section, sensors and monitoring functions individually by performing afunction test. In addition, the user must validate and protocol the connection of eachprogrammed PLC function by inspecting the code.The MOVISAFE® CONFIG parameter setting software generates a suitable output formand stores it in a text file (.txt).

The program enters the following information in the text file:• Manufacturer: SEW-EURODRIVE GmbH & Co KG• Type: MOVISAFE• Version of the hardware and activated functions

You must enter the following data in the text file:• Serial number (identical with the serial number on the nameplate)• Correspondence between the read-off serial number and the serial number on the

nameplate of the unit

The text file can then be printed out. Any other entries must be made manually:• Date the configuration data record was created• CRC signature from the data record

7.2 Functional testThe proper functioning of the safety functions has to be checked once a year to ensurethe safety of the subassembly. The functions of the components used in the configura-tion have to be tested.

65

66

8 eplacing a system aintenance

8 Maintenance8.1 Replacing a system

If MOVISAFE® has to be replaced, proceed as follows:• First, switch off the voltage supply to the unit. Disconnect MOVISAFE® from the

supply voltage.• Disconnect all signal connections (inputs/outputs, encoder connection)• Remove the MOVISAFE® subassembly from the mounting rail.• Mount the new MOVISAF® E subassembly onto the mounting rail• Reestablish all connections (inputs/outputs, encoder connection)• In a final step, switch on the supply voltage• Configure MOVISAFE®

8.2 Modification / changes to the unit• Hardware modifications

Only SEW-EURODRIVE is authorized to make changes to MOVISAFE®.• Firmware modifications

Only SEW-EURODRIVE is authorized to make changes to the firmware.• Repair

Only SEW-EURODRIVE is authorized to repair the MOVISAFE® subassembly.• Warranty

NOTICEDo not plug in or remove encoder connections during operation.Doing so can cause irreparable damage to the electrical components on the encoder.De-energize MOVISAFE® before plugging or removing the encoder connections.

TIPThe safety certification and any right to claim under limited warranty become void if theuser manipulates the unit internally (e.g. replacing components, welding parts).

RM


8 Waste disposaMaintenance

8.3 Waste disposal

Please observe the applicable national regulations.Dispose of the following materials separately in accordance with the country-specificregulations in force, as:• Electronics scrap• Plastic• Sheet metal• Copper


l

67

68

9 escription of the 7-segment display iagnostics

9 Diagnostics9.1 Description of the 7-segment display

The 7-segment display is used to indicate the status of MOVISAFE®.

9.2 Description of the LED statusLED status The LED status indicates the system status of MOVISAFE®.

7-segment display

Mode Description

1 STARTUP Synchronization between both processor systems and check of the configuration/firmware data.

2 SEND CONFIG Distribution of the configuration/firmware data and another check of this data. Next, range check of the configuration data.

3 STARTUP BUS If applicable, the bus system is initialized (PROFIsafe).

4 RUN Watchdog is active, which means that all outputs (DO0, DO1 and K1, K2) can be switched.

5 STOP In STOP mode, parameters and program data can be loaded externally.

A ALARM An alarm can be reset via binary input or by pressing the acknowledge-ment button on the front panel.

E ECS alarm An ECS alarm can be reset via binary inputs or by pressing the acknowledgement button on the front panel.

F Fault A fault can only be reset by switching the subassembly off and then on again.

TIPFor operating states 1, 2 and 3, the outputs are automatically switched off by theirmware. In "RUN" operating mode (display "4"), the outputs are controlled by themplemented PLC program.


Flashing green System ok, configuration validated

Flashing yellow System ok, configuration not validated yet

Flashing red Alarm

Flashing red Fatal error

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9 Diagnostic module UCS23B with CAN interfaceDiagnostics

9.3 Diagnostic module UCS23B with CAN interfaceThe UCS23B diagnostic module can be used for non-safe communication via CAN witha higher-level controller, e.g. MOVI-PLC®. The transmission of up to 2 CAN telegramswith 8 bytes each can be set by software configuration. The first CAN telegram is alwaystransmitted and contains variable logic data from the logic diagram. The second CANtelegram can be transmitted optionally and contains configurable process data. TheCAN ID assigned to the data frame can be freely configured.A data frame is structured as follows:

Structure of CAN telegram 1

Byte 7 (bits 0-3) of the logic data always contains the current status of the basicmodules. This status is also indicated on the 7-segment display.

Byte 7 Byte 6 Byte 5 Byte 4 Byte 3 Byte 2 Byte 1 Byte 0

Assignment in operating state

Byte Bit 2, 3, 4 6, 7

7

0-3

Operating state1 = STARTUP

2 = SEND CONFIG3 = STARTUP BUS

4 = RUN5 = STOP

6 = ERROR7 = ALARM

4 0x1 (fixed value)

5-7 Life bit

6 0-7 Logic data (data bit: 48-55)





10-6 Logic data (data bit: 24-30) Error code high byte

7 "0" (status bit) "1" (status bit)

0 Logic data (data bit: 16-23) Error code low byte

TIPIf the unit is in alarm state, the error message will be signaled in bytes 0 and 1 (databits 16-30). The status bit (byte 1, bit 7) changes to "1". This means that any configuredlogic data information is overwritten.


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9 iagnostic module UCS23B with CAN interface iagnostics

Structure of CAN telegram 2

The following information can be chosen as process data in the MOVISAFE® CONFIGsoftware:

You can freely set the parameters for the frequency at which CAN telegrams will beupdated. You can choose between cyclic and acyclic transmission. Cyclic transmission is carried out based on the cycle time of the basic module (seesection "Response times of MOVISAFE®") plus a freely selectable factor X (X: 1-255).Acyclic transmission means a new CAN telegram will be transmitted if the datacontent of the entire telegram is changed. The CAN telegrams are resent every 500 mseven if no change was made.

Byte Bit Assignment in operating states 2, 3, 4,6, 7

7 0-7 Process data (data bit: 56-63)








Process data Axis Data length in bits

Current position

1 or 2

16, 20, 24

Current velocity 08, 12, 16

SLP position (teach-in) 16, 20, 24

Analog value of input 08

Analog value of filter 08

Analog value of adder 08

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9 Types of errorsDiagnostics

9.4 Types of errorsMOVISAFE® basically distinguishes between the following types of errors.

9.5 Error messages

Display of error messages

Errors in the "FATAL ERROR" class should not occur during normal operation of thesubassembly. Error messages on MOVISAFE® are distinguished as shown in thefollowing overview.

Type of error

Description Impact on the system

Reset condition

Fatal error Fatal error or activation of an internal safety function. Due to reasons of safety, a cyclical program run is no longer possible. Last active process is that the 7-segment display is operated by system A. System B is in STOP mode.

All outputs are switched off

Switch MOVISAFE® off and on again

Alarm Functional error caused by an external process. Both systems continue to run cyclically and meet all requirements of the communication interfaces. Scan of the external process is also maintained. The monitoring function triggers an ALARM, but the subassembly remains in standby mode.

Set input parameters

ECS alarm When using the ECS function in the programming interface, encoder alarm messages will be identified with "E" instead of "A".

The ECS function block returns "0" as result

TIPSShould the unit issue an error message that is not described here, proceed as follows:• Under which conditions did the error occur?• Save the current configuration record• Take a note of the error code• Contact SEW-EURODRIVE service

Error message Meaning

F, A, E _ _ _ _ A 4-digit error message is issued if only one MOVISAFE® basic module is used.

F, A, E _ _ _ _ _ A 5-digit error message is issued if one MOVISAFE® basic module and additional expansion or diagnostic modules are used.The first digit of the error code has the following meaning:• 0: Basic module• 1: Expansion module with logic address 1• 2: Expansion module with logic address 2


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9 rror messages iagnostics

Error table

Fatal error code F 1001

Error message Error during transfer of configuration data to the monitoring unit

Cause Interruption in connection during program download

Remedy Send the configuration files again


Error message Configuration data for software version of the subassembly is invalid.

Cause Subassembly configured with incorrect software version of the programming interface.

Remedy Configure subassembly with permitted version of the programming interface. Then switch subassembly off and on again.


Error message Unit was programmed with incorrect programming interface.

Cause Program or configuration data was loaded into the unit with an incorrect programming interface.

Remedy Check the design of the subassembly. Configure it again with a valid programming interface. Then switch the unit off and on again.

Fatal error code F 1403 / F1404

Error message Invalid CRC of the configuration data.

Cause Faulty transmission of configuration data.

Remedy Transmit configuration data again.


Error message Faulty EMU range check.


Error message Faulty PSC range check.


Error message Faulty ESS range check.


Error message Faulty ELC range check.


Error message Faulty OLC range check.


Error message Faulty ZSC range check.

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9 Error messagesDiagnostics


Error message Faulty MSC range check.


Error message Faulty DMC range check.


Error message Faulty JSS range check.


Error message Faulty PLC range check.


Error message Faulty range check of shutdown channel.


Error message Faulty range check of outputs.


Error message Faulty range check of binary inputs.


Error message Faulty range check of encoder type.


Error message Faulty range check of encoder processing.


Error message Faulty range check of encoder position.


Error message Faulty PDM range check.


Error message Faulty DC 24 V supply voltage of the subassembly.

Cause • The DC 24 V supply voltage of the subassembly is not correct.• Faulty component in the subassembly

Remedy • Check supply voltage of subassembly• Switch units off and on again


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Error message Plausibility error for position changeover

Cause For the position changeover, ZSC, JSS or DMC is permanently activated

Remedy • Check ZSC activation• Check JSS activation• Check DMC activation (only for monitoring via position)


Error message Encoder alignment axis 1 error.

Cause Faulty position triggered by system A.

Remedy • Check encoder configuration• Switch unit off and on again



Cause For the position changeover, ZSC, JSS or DMC is permanently activated.

Remedy • Check ZSC activation• Check JSS activation• Check DMC activation (only for monitoring via position)



Cause Faulty position triggered by system A.

Remedy • Check encoder configuration• Switch unit off and on again


Error message Faulty switching of K1 relay

Cause Programming via PSC outputs can cause the relay to flatter

Remedy Check the activation of relay K1 in the user program


Error message Faulty switching of K2 relay

Cause Programming via PSC outputs can cause the relay to flatter

Remedy Check the activation of relay K2 in the user program


Error message Faulty writing of "0 V" driver DO1_L.

Cause Faulty output switching status.

Remedy Switch unit off and on again.

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Error message Faulty writing of "24 V" driver DO1_H.




Error message Faulty switching of "0 V" driver DO2_L.




Error message Faulty switching of "24 V" driver DO2_H.




Error message Faulty testing of "0 V" driver DO1_L.

Cause Short circuit of the output with "0 V".



Error message Faulty testing of the "24 V" driver DO1_H.




Error message Faulty testing of the "0 V" driver DO2_L.




Error message Faulty testing of the "24 V" driver DO2_H.




Error message Faulty switching of output EAAx.1.

Cause Short circuit of the output with "24 V" or "0 V".



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Error message Faulty testing of output EAAx.1.




























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9 larm messages iagnostics

9.6 Alarm messages













Alarm code A 2101 / A2102

Alarm message Timeout receive telegram UCS23B (address 1).

Cause Expansion module has received telegram too late.

Remedy Check connection with expansion module.


Alarm message CRC error in the send telegram of UCS23B (address 1).

Cause Faulty send telegram.

Remedy Check configuration of serial number of UCS23B option.


Alarm message CRC error in the send telegram.


Remedy • Check configuration of serial number of UCS23B option.• Check connection with expansion module.


Alarm message CRC error in the receive telegram.

Cause Faulty receive telegram.

Remedy • Check configuration of serial number of UCS23B option.• Check connection with expansion module.

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9 Alarm messagesDiagnostics

Alarm code A 2111

Alarm message Timeout of communication with expansion module UCS23B (address 1).

Cause Expansion module installed incorrectly.


Alarm code A 2113

Alarm message Expansion module UCS23B (address 1) installed but not configured.

Cause Faulty configuration

Remedy Check configuration.


Alarm message Timeout receive telegram UCS23B (address 2).

Cause Expansion module has received telegram too late.



Alarm message CRC error send telegram UCS23B (address 2)


Remedy Check configuration of UCS23B serial number.

Alarm code A 2131

Alarm message Timeout of communication with expansion module UCS23B (address 2).

Cause Expansion module installed incorrectly.


Alarm code A 2133

Alarm message Expansion module UCS23B (address 2) installed but not configured.

Cause Faulty configuration

Remedy Check configuration.


Alarm message Pulse 1 plausibility error at expansion input EAEx.1.

Cause The configured pulse 1 voltage is not present at this input.

Remedy • Check configuration of the binary input according to configuration and wiring diagram

• Check wiring





• Check wiring


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Alarm message Faulty 24 V signal at EAEx.1.

Cause The 24 V voltage is not permanently present at the input.

Remedy • Check voltage at binary input• Check wiring• Check whether pulse 1 or pulse 2 is present





• Check wiring





• Check wiring









• Check wiring





• Check wiring





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• Check wiring





• Check wiring









• Check wiring





• Check wiring









• Check wiring


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• Check wiring





• Check wiring





• Check wiring

Alarm code A 3071/ A3072








• Check wiring





• Check wiring





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• Check wiring





• Check wiring









• Check wiring





• Check wiring






Alarm message Pulse 1 plausibility error at binary input DI01.

Cause No pulse 1 voltage is present at the DI01 binary input.

Remedy • Check configuration of the DI01 binary input according to configuration and wiring diagram

• Check the wiring


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Cause No pulse 1 voltage is present at binary input DI02

Remedy • Configure binary input DI02 in accordance with the project planning and wiring diagram



Alarm message Pulse 1 plausibility error at binary input DI03











Cause There is no pulse1 voltage at binary input DI05















Cause There is no pulse 1 voltage at binary input DI08



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Alarm message Pulse 2 plausibility error at input DI01



































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Cause No pulse 1 voltage at the DI12 binary input.





Cause No pulse 1 voltage at the DI13 binary input.





Cause No pulse 1 voltage is present at the DI14 binary input



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Alarm message Pulse 2 plausibility error at the DI10 binary input

























Alarm message Faulty 24 V signal at the DI01 binary input.

Cause The 24 V voltage is not permanently present at the binary input.

Remedy • Check voltage at binary input• Check the wiring• Check whether pulse 1 or pulse 2 is present


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Alarm message Faulty OSSD input check.

Cause Faulty OSS test

Remedy Check 24 V input voltage of all OSSD inputs.


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Alarm message Fault encoder supply voltage X7

Cause • Encoder supply voltage does not correspond with configured threshold• Faulty component in the subassembly

Remedy • Check the configuration• Check the encoder supply voltage• Switch unit off and on again


Alarm message Faulty encoder supply voltage X8

Cause • Encoder supply voltage does not correspond with configured threshold• Faulty components in the subassembly

Remedy • Check the configuration• Check the encoder supply voltage• Switch unit off and on again


Alarm message Faulty plausibility test of encoder supply voltage

Cause Encoder voltage value

Remedy • Check the encoder supply voltage• Check the encoder supply voltage cabling


Alarm message Wire breakage monitoring has triggered

Cause Wire breakage monitoring active

Remedy • Check configuration/activation of sensor• Check sensor connection


Alarm message Plausibility error in the velocity detection of axis 1

Cause The difference between the two velocity sensors is higher than the configured speed cut-off threshold.

Remedy • Check the theory of the track using the data set for the encoder configuration• Check the velocity sensor• Use the SCOPE function to set speed signals so that they are congruent


Alarm message Plausibility error in the position detection of axis 1

Cause The difference between the two position signals is higher than the configured value

Remedy • Check the theory of the track with the data configured for the encoder setting• Check position signal• Are all signals connected correctly to the 9-pin encoder connector?• Check the encoder connector for correct wiring. Is the jumper between pin 1 and

pin 2 on the 9-pin encoder connector closed (SSI absolute encoder)?• Use the SCOPE function to set positions signals so that they are congruent


Alarm message Plausibility error faulty position range of axis 1

Cause The current position is outside of the configured range

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Remedy • Check the theory of the track with the data configured for the encoder setting• Check position signal, correct offset if necessary• Use the SCOPE function to read off the position and set in ratio to the configured

values


Alarm message Plausibility error faulty velocity of axis 1

Cause The current velocity exceeds the configured maximum velocity.

Remedy • The drive moves outside the permitted and configured velocity range• Check configuration (set max. velocity)• Analyze the velocity development using the SCOPE function


Alarm message Configuration error acceleration axis 1.

Cause Current acceleration is outside of the configured acceleration range

Remedy • The drive has exceeded the permitted acceleration range• Check the configuration (maximum acceleration)• Analyze the course of the acceleration using the SCOPE function


Alarm message SSI sensor error

Cause Encoder jump SSI value within a cycle too great.

Remedy • Check encoder cabling• Check encoder configuration


Alarm message Plausibility error in the velocity detection of axis 2

Cause The difference between the two velocity sensors is higher than the configured speed cut-off threshold.

Remedy • Check the theory of the track using the data set for the encoder configuration• Check the velocity sensor• Use the SCOPE function to set speed signals so that they are congruent


Alarm message Plausibility error in the position detection of axis 2

Cause The difference between the two position signals is higher than the configured value

Remedy • Check the theory of the track with the data configured for the encoder setting• Check position signal• Are all signals connected correctly to the 9-pin encoder connector?• Check the encoder connector for correct wiring. Is the jumper between pin 1 and

pin 2 on the 9-pin encoder connector closed (SSI absolute encoder)?• Use the SCOPE function to set positions signals so that they are congruent


Alarm message Plausibility error faulty position range of axis 2

Cause The current position is outside of the configured range

Remedy • Check the theory of the track with the data configured for the encoder setting• Check position signal, correct offset if necessary• Use the SCOPE function to read off the position and set in ratio to the configured

values



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Alarm message Plausibility error faulty velocity of axis 2

Cause The current velocity exceeds the configured maximum velocity.

Remedy • The drive moves outside the permitted and configured velocity range• Check configuration (set max. velocity)• Analyze the velocity development using the SCOPE function


Alarm message Faulty configuration of acceleration of axis 2.

Cause Current acceleration is outside of the configured acceleration range

Remedy • The drive has exceeded the permitted acceleration range• Check the configuration (maximum acceleration)• Analyze the course of the acceleration using the SCOPE function


Alarm message Plausibility error sin/cos encoder

Cause Incorrect encoder type connected.

Remedy • Check the configuration• Check encoder assignment


Alarm message Difference level RS485 driver 1 (error INC_B or SSI_CLK) faulty

Cause No encoder connection, incorrect encoder type

Remedy Check the encoder connection


Alarm message Faulty difference level RS485 driver 2 (error INC_A or SSI_DATA)

Cause No encoder connection, incorrect encoder type



Alarm message Incremental counter deviation (X7).

Cause Faulty plausibility monitoring of the individual tracks.



Alarm message Incremental counter deviation (X8).

Cause Faulty plausibility monitoring of the individual tracks.



Alarm message Sensing head error WCS encoder system axis 1.

Cause WCS sensing head has detected an error.

Remedy Read error types of WCS encoder system.

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Alarm message Sensing head error WCS encoder system axis 2.

Cause WCS sensing head has detected an error.

Remedy Read error types of WCS encoder system.


Alarm message CCW and CW monitoring (in DCM1 module) was activated simultaneously.

Cause Multiple activation

Remedy Only one direction of rotation can be activated in the DMC1 module


Alarm message CCW and CW monitoring (in DCM2 module) was activated simultaneously


Remedy Only one direction of rotation can be activated in the DMC2 module


Alarm message CW and CCW monitoring range of the OLC1 activated simultaneously


Remedy Only one enable may be activated in the programming.


Alarm message CW and CCW monitoring range of the OLC2 activated simultaneously




Alarm message OLC1 Teach-in status error

Cause SET and QUIT input have faulty switching sequence.

Remedy • Check the configuration• Check the switching sequency


Alarm message OLC2 Teach-in status error

Cause SET and QUIT input have faulty switching sequence.

Remedy • Check the configuration• Check the switching sequency


Alarm message OLC1 Teach-in position error.

Cause Teach-in position outside measuring range.

Remedy Check position.


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Alarm message OLC2 Teach-in position error.

Cause Teach-in position outside measuring range.

Remedy Check position.


Alarm message OLC1 Teach-in ZSC activation error

Cause Drive has moved during teach-in (ZSC error).

Remedy • The drive must be at standstill when using the teach-in function.• Check whether ZSC has already triggered


Alarm message OLC2 Teach-in ZSC activation error

Cause Drive has moved during teach-in (ZSC error).

Remedy • The drive must be at standstill when using the teach-in function.• Check whether ZSC has already triggered


Alarm message CCW and CW monitoring (in JSS1 module) was activated simultaneously












Alarm message Test deactivation of binary inputs 01 -14 faulty.

Cause Binary inputs are still faulty after deactivation.

Remedy Check the binary input wiring.


Alarm message Timeout error MET

Cause Input element with time monitoring is faulty

Remedy • Check wiring of input element• Input element is faulty

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Alarm message Timeout error MEZ

Cause Two-hand operation with time monitoring is faulty

Remedy • Check wiring of input element• Input element is faulty


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10 eneral technical data echnical Data

10 Technical Data10.1 General technical data

10.2 Safety characteristics of MOVISAFE®

MOVISAFE® All sizes

Protection class IP20

Ambient temperature 0 °C - 50 °C

Climate class 3 according to DIN 50178

Operating life 90000 h at ambient temperature of 50 °C

Safety characteristics

Highest possible safety category • SIL 3 according to EN 61508 / EN 62061• Category 4 / performance level e according to

EN ISO 13849-1

System structure 2 channels with diagnostics (1002)

Type of operating mode "High demand" rate according to EN 61508

Probability of dangerous failure per hour (PFH value)

<1.4E-08 (14 FIT)

Proof test interval (EN 61508) 20 years, after which the component must be replaced with a new one

Safe condition Value "0" for all safety-oriented F-DO process values (output disabled)

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11 Response times of MOVISAFE®Appendix

11 Appendix11.1 Response times of MOVISAFE®

The following table lists the response times of MOVISAFE®.The calculation of response times is based on the cycle time of the system. The cycletime (T_cycle) for MOVISAFE® is 8 ms during operation. The specified response timescorrespond to the maximum run time for the specific application within MOVISAFE®.Depending on the application, additional application-specific response times for thesensors and actuators used have to be added to get the total run time.

Fast channel Fast channel refers to a property of MOVISAFE® to respond faster than would bepossible with processing the safety programs with the standard cycle (= 8 ms). Thesampling time of the fast channel is 2 ms.The following response time can be specified:• 6 ms (worst case condition)

Function Response time ms

Explanation

Activating a monitoring function with ENABLE and subsequent switchoff via digital output.

241)

1) When activated, the response time will increase according to the filter value

Activating a safety function with the ENABLE signal.Activating a monitoring function with

ENABLE with subsequent switchoff via relay output.

471)

Response of an already activated monitoring function including PLC processing for position and velocity processing via digital output.

161)For a monitoring function that has been activated via ENABLE, MOVISAFE® needs one cycle to calculate the current speed value. In the next cycle, after the monitoring function has been calculated, the information is further processed and output by the PLC. That is, once the programmed logic has been performed, this can lead, e.g. to the switching of an output.

Response of an already activated monitoring function including PLC processing for position and velocity processing via relay output.

391)

Activating digital output via digital input.

16 Activating an input and switching the output.

Activating relay output via digital input. 26 Activating an input and switching the output.

Deactivating digital output via digital input

16 Deactivating an input and in this way deactivating the output.

Deactivating relay output via digital input.

47 Deactivating an input and in this way deactivating the output.

Mean value filter 0 - 64 Group run time of the mean value creator. This run time only affects monitoring functions in conjunc-tion with position/velocity/acceleration, not the logic processing.

TIPWhen using the fast channel, it is important that switchoff for the above mentioned timefor a specified velocity threshold is only possible with sufficient resolution of the sensorinformation. The smallest switching threshold of the fast channel that can be resolvedneeds at least two edge changes at the relevant chosen sensor system within 2 ms.

97

98

11 escription of the input elements ppendix

11.2 Description of the input elementsGeneral information

The individual switches of the following input elements can be assigned to the digitaloutputs DI1 to DI8 as required.

Operation mode selection switch

Light curtain

Emergency stop

Start/reset

Sensor

Switch type Remark Classification to EN ISO 13849-1

Classification to EN 61508

2 settings Operating mode selection switch, monitored PL e SIL3

3 settings

TIPWhen changing the position of the operating mode selection switch, use the Safe PLCprogram that is to be created to ensure that the outputs of MOVISAFE® aredeactivated (EN 60204-1).



2 NC contacts Light curtain for increased demands PL e SIL3

2 NC contacts for time monitoring

Light curtain, monitored PL e SIL3

1 NO + 1 NC contact Light curtain for increased demands PL e SIL3

1 NO + 1 NC contact, time-monitored

Light curtain, monitored PL e SIL3



1 NC contact Emergency stop, simple PL d1)

1) Observe fault exclusion and limiting conditions according to EN ISO 13849-2.

SIL2

2 NC contacts Emergency stop for increased demands

PL e SIL3


Emergency stop, monitored PL e SIL3



1 NO contact Alarm reset, simple1)

1) The alarm/reset input is edge controlled andcan always be operated with a DC -24 V voltage.

- -

1 NO contact Logic reset, simple Pl d SIL2

1 NO contact Start monitoring, simple (special function)

- -



1 NC contact Sensor input, simple PL d SIL2

1 NO contact Sensor input, simple PL d SIL2

DA


11 Description of the input elementsAppendix

Door monitoring

Confirmation button

Two-hand button

2 NC contacts Sensor input for increased demands PL e SIL3


Sensor input, monitored PL e SIL3

1 NO + 1 NC contact Sensor input for increased demands PL e SIL3


Sensor input, monitored PL e SIL3





2 NC contacts Door monitoring for increased demands

PL e SIL3


Door monitoring, monitored PL e SIL3

1 NO + 1 NC contact Door monitoring for increased demands

PL e SIL3



2 NO + 2 NC contacts Door monitoring for increased demands

PL e SIL3



3 NC contacts Door monitoring for increased demands

PL e SIL3

3 NC contacts, time-monitored




1 NC contacts Confirmation button, simple PL d SIL2

1 NO contact Confirmation button, simple PL d SIL2

2 NC contacts Confirmation button for increased demands

PL e SIL3


Confirmation button, monitored PL e SIL3



2 changers Two-hand button, increased demands according to EN 574 type III C

PL e SIL3

2 NO contacts Two-hand button, monitored in accor-dance with EN 574 type III A

PL e SIL1

TIPUsers cannot change the fixed pulse assignment specified for these input elements.

99

100

11 ist with encoders recommended by SEW-EURODRIVE ppendix

11.3 List with encoders recommended by SEW-EURODRIVEIncremental encoders

SIN/COS encoders

SIN/COS encoders and encoders that make such signal tracks available can be used insingle encoders solutions up to category 3/performance level d according to EN ISO13849-1. There are no additional safety requirements for the encoder electronics.

Hiperface® and SIN/COS encoders

With Hiperface® encoders, only the SIN/COS tracks are evaluated by MOVISAFE®.The voltage supply for Hiperface® encoders is provided via the DEH11B/21B optioncard of MOVIDRIVE® B.

Combination encoders RS485 and SIN/COS

Combination encoder MSSI and SIN/COS

Combination encoders MSSI and TTL

Type designation Supply voltage Output signal

EH1R, ES1R, ES2R, EV1RES7R, EG7R DC 24 V According to RS422

(1024 increments/revolution)


ES1S, ES2S, EH1S, EV1SES7S, EG7S, EH7S

DC 24 V

AC 1 Vpp SIN/COS(1024 increments/revolution)

EI7S AC 1 Vpp SIN/COS(24 increments/revolution)


ES1H, AS1HES3H, ES4H, AS3H, AS4HEV1H, AV1H

DC 12 V AC 1 Vpp SIN/COS(1024 increments/revolution)

Positive connection Hiperface® encoder:• AV6H• AF1H• EF1H

Type designation Supply voltage Output signalES7W

DC 7 - 30 V AC 1 Vpp SIN/COS(1024 increments/revolution)

EG7WAS7WAG7W


AV1Y DC 24 V • AC 1 Vpp sin/cos(512 increments/revolution)

• 4096 × 4096 increments SSI-Gray

AS7YDC 7 - 30 V+

AG7Y


AH7Y DC 9 - 30 According to RS422 (1024 increments/revolution)

LA


11 Absolute encoders that can be used for master and slave modesAppendix

Internal encoder simulation MOVIDRIVE® B

11.4 Absolute encoders that can be used for master and slave modesConnect only those encoders listed in the following table to MOVISAFE® UCS..B. Youmust check whether other encoders are suitable and released for use by SEW-EURODRIVE.If an absolute encoder is used in slave mode with MOVISAFE® UCS.B, you must setP952 Clock rate (in MOVIRIVE® B) according to the following table. The UCS..B optioncan process a maximum clock rate of 200 kHz in slave mode.


MDX61B backplane bus - 4096 increments/revolution

Manufacturer Encoder designation Absolute encoder in slave mode:P952 Clock rate setting

Comments

Hübner HMG161-S24 H2048 (AH7Y) ≤ 50 % Rotary encoder

Heidenhain ROQ 424 (AV1Y) ≤ 50 % Rotary encoder

Leuze-electronic

Leuze BPS37 ≤ 50 % Barcode measuring system

Leuze OMS1 ≤ 50 % Laser distance measuring instrument

Leuze OMS2 Laser distance measuring instrument

Sick / Stegmann

Sick ATM60 Rotary encoder

Sick DME 4000 Laser distance measuring instrument

Sick DME 5000 ≤ 60 % Laser distance measuring instrument

Pepperl & Fuchs WCS3A/B ≤ 60 % Barcode distance sensor

101

102

Index

AAbsolute encoders that can be used for master and slave modes ......................................................101Alarm messages .................................................78Appendix .............................................................97

Response times of MOVISAFE® .................97Assembly information for UCS..B .......................16

BBackplane bus connector ....................................18

CCombination of various encoder types ................34Configuring the measuring distances ..................35Confirmation button .............................................99Connecting a sin/cos encoder .............................48Connecting an absolute encoder in slave mode .49Connecting an incremental encoder ...................48Connecting binary inputs DI1 to DI14 .................27

Dual-channel sensor, checked .....................32Dual-channel sensor, unchecked .................30Single-channel sensor, checked ..................31Single-channel sensor, unchecked ..............29Using clock outputs P1 and P2 ....................28

Connecting binary outputs ..................................51Connecting an auxiliary output .....................61Dual-channel switching binary output DO0

with external monitoring ..................56Dual-channel switching relay output DO0

with external monitoring (generalcheckback) ......................................59

Dual-channel switching relay output DO0 with external monitoring (specificcheckback) ......................................60

Single-pole switching M binary output withexternal contact monitoring .............55

Single-pole switching M binary output without check ...............................................53

Single-pole switching P binary output withexternal contact monitoring .............54

Single-pole switching P binary output without check ...............................................53

Single-pole switching relay output with external contact monitoring .............58

Single-pole switching relay output without check ...................................57

Connecting position and velocity sensorsPrefabricated cables .....................................40

Connecting the binary outputsExample of how to use the binary outputs for

safe stop ..........................................52Connecting the position and velocity sensors .....33

Before you begin ..........................................33Combination of various encoder types .........34Configuring the measuring distance .............35

Connection and terminal description expansion module UCS23B ................................................ 23Connection and terminal description of basic modules UCS10B/11B/12B ................................ 21Connection and terminal description of diagnostic module UCS25B ............................... 25Copyright notice ................................................... 6

DDAE50B/51B ...................................................... 41DAE52B/53B ...................................................... 42DAE54B ............................................................. 43DAE55B ............................................................. 44DAE56B ............................................................. 45DAE57B ............................................................. 46DAE58B ............................................................. 47Definitions ............................................................ 9Description of the 7-segment display ................. 68Description of the status LED ............................ 68Diagnostic module UCS23B with CAN interface 69

Structure of CAN telegram 1 ....................... 69Structure of CAN telegram 2 ....................... 70

Diagnostics ........................................................ 68Alarm messages .......................................... 78Description of the 7-segment display .......... 68Description of the status LED ...................... 68Diagnostic module UCS23B with CAN

interface .......................................... 69Error and alarm classes ............................... 71Error messages ........................................... 71Status display .............................................. 68

Dimension drawing mounting rail ....................... 17Display of error messages ................................. 71

EElectrical Installation .......................................... 21Electrical installation

Connecting binary inputs DI1 to DI14 .......... 27Connecting binary outputs ........................... 51Connecting the position and velocity

sensors ........................................... 33Connection and terminal description

expansion module UCS23B ........... 23Connection and terminal description of

basic module UCS10B/11B/12B ..... 21Connection and terminal description of

diagnostic module UCS25B ............ 25External DC 24 V voltage supply ................. 27Measures for electromagnetic compatibility 26

Encoder list (recommended by SEW-EURODRIVE) ......................................... 100

Electrical nterfaces MSSI + TTL ................ 100Hiperface® encoders (SIN/COS share) ..... 100Incremental encoders ................................ 100


Index

Internal encoder simulation MOVIDRIVE® B ............................101

RS485 encoders (SIN/COS share) ............100SIN/COS encoders .....................................100SSI absolute encoders

(combination encoders) .................100Error and alarm classes ......................................71Error messages ...................................................71

Display of error messages ............................71Error table .....................................................72

Error table ...........................................................72Exclusion of liability ...............................................6External DC 24 V voltage supply ........................27

GGeneral information ..............................................5

Copyright notice .............................................6How to use the operating instructions ............5

General notesExclusion of liability ........................................6Rights to claim under limited warranty ...........6Structure of the safety notes ..........................5

General technical data ........................................96

HHow to use the operating instructions ...................5IInput elements

Confirmation button ......................................99Description ...................................................98Door monitoring ............................................99Emergency stop ...........................................98Light curtain ..................................................98Operating mode selection switch .................98Sensor ..........................................................98Start/reset .....................................................98Two-hand button ..........................................99

Installation clearance ..........................................18

LLED display .........................................................63

MMaintenance .......................................................66

Disposal ........................................................67Modification / changes to the unit .................66Replacing a system ......................................66

Measures for electromagnetic compatibility ........26Mechanical Installation

General installation information ....................16Mechanical installation ........................................16

Assembly information ...................................16Backplane bus connector .............................18Dimension drawing mounting rail .................17Installation clearance ....................................18Mounting position .........................................17

Step-by-step instructions for installing MOVISAFE® UCS..B ..................... 19

Step-by-step instructions for removing MOVISAFE® UCS..B ..................... 20

Mounting position ............................................... 17

NNameplate .......................................................... 10

OOther applicable documentation .......................... 9

PPart number of diagnostic module UCS25B ...... 25Part number of expansion module UCS23B ...... 23Part numbers of basic modules UCS10B/11B/12B .............................................. 21Prefabricated cables .......................................... 40

DAE50B/51B ............................................... 41DAE52B/53B ............................................... 42DAE54B ....................................................... 43DAE55B ....................................................... 44DAE56B ....................................................... 45DAE57B ....................................................... 46DAE58B ....................................................... 47Overview ...................................................... 40

RResponse times of MOVISAFE® ....................... 97Rights to claim under warranty ............................. 6

SSafety characteristics of MOVISAFE® ............... 96Safety notes ......................................................... 7

Definitions ...................................................... 9Designated use .............................................. 8Electrical connection ...................................... 8General information ....................................... 7Installation ..................................................... 8Operation ....................................................... 9Target group .................................................. 7Transportation, putting into storage ............... 8

Scope of delivery ............................................... 10Startup ............................................................... 62

LED display ................................................. 63Prerequisites ................................................ 62Startup steps ............................................... 62Switch-on sequences .................................. 63

Startup with PC and MOVISAFE® CONFIGValidation report .......................................... 64

Status display ..................................................... 68Step-by-step instructions for installing MOVISAFE® UCS..B ......................................... 19Step-by-step instructions for removing MOVISAFE® UCS..B ......................................... 20Structure of CAN telegram 1 .............................. 69Structure of CAN telegram 2 .............................. 70Switch-on sequences ......................................... 63

Operating Instructions – MOVISAFE® UCS..B Safety Modules 103

104

Index

TTechnical data .....................................................96

General technical data .................................96Safety characteristics of MOVISAFE® .........96

Two-hand button .................................................99

UUnit design Basic modules ..................................11Unit design basic modules

UCS10B .......................................................11UCS11B .......................................................12UCS12B .......................................................13

Unit design of diagnostic module ........................15UCS25B .......................................................15

Unit design of I/O expansion module ..................14UCS23B .......................................................14

VValidation ............................................................65Validation report ..................................................64

WWiring diagrams for direct encoder connection to MOVISAFE® .......................................................48

Connecting a sin/cos encoder ......................48Connecting an incremental encoder .............48Connecting an SSI absolute encoder ...........48

Wiring diagrams for encoder in parallel on theinverter and the UCS.B option

Connecting an absolute encoder in slave mode ...............................................49

Wiring diagrams for encoder in parallel to the inverter and the UCS.B option

SIN/COS encoder or incremental encoder in listener mode .................50

Wiring diagrams for encoders in parallel to the inverter and UCS.B option ........................49


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Documents

MOVISAFE® UCS..B Safety Modules / Operating · PDF fileOperating Instructions – MOVISAFE® UCS..B Safety Module 7 2 General information Safety Notes 2 Safety Notes The following