Addendum to the Operating Instructions

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services * _0415* Addendum to the Operating Instructions Safety Rated Encoders DR , DRN AC Motors Functional Safety Edition 04/ /EN

2 SEW-EURODRIVE Driving the world

3 Contents Contents 1 General information Use of this documentation Underlying standards Structure of the safety notes Rights to claim under limited warranty Exclusion of liability Copyright notice Product names and trademarks Safety notes Preliminary information General information Target group Designated use Functional safety (FS) Transport/Storage Installation Electrical connection Startup/operation Unit structure Functional safety technology (FS) Nameplate Mechanical installation Electrical installation Connecting the EI7C FS encoder EI7C FS visual feedback Startup Requirements Inspection/maintenance Functional safety (FS) (Dis)assembling the encoder Measuring wobbling DR../DRN.. (brake)motor inspection procedure Technical data Characteristic safety values Encoders Encoder evaluation unit Work done, working air gap, braking torques of the BE.. brakes Declaration of Conformity Index Addendum to the Operating Instructions DR , DRN AC Motors 3

4 1 General information Use of this documentation 1 General information 1.1 Use of this documentation This addendum to the operating instructions contains specific includes concerning safety-rated encoders of DR.., DRN.. motors. The "DR , DRN AC Motors" operating instructions provide all the information regarding AC motors without safety-rated attachments. The documentation for a motor with safety-rated encoders comprises: "DR , DRN AC Motors" operating instructions The addendum to the operating instructions at hand The operating instructions and the addendum to the operating instructions are an integral part of the product and contain important information for operation and service. The operating instructions and the addendum to the operating instructions are intended for staff responsible for the assembly, installation, startup and maintenance of the product. The operating instructions and the addendum to the operating instructions must be legible and accessible at all times. Make sure that staff responsible for the plant and its operation, as well as persons who work independently on the unit, have read the operating instructions and the addendum to the operating instructions carefully and understood them. Make sure you always use the latest documentation and software version. The SEW EURODRIVE homepage ( eurodrive.com) provides a broad selection of documentation downloads in various languages. Consult SEW EURODRIVE if you are unclear about any of the information in this documentation, or if you require further information. You can also order the printed documentation from SEW EURODRIVE. 1.2 Underlying standards The safety assessment of the encoder is based on the following standards and safety classes: AS7W, AS7Y, AG7W, AG7Y, ES7S, EG7S Underlying standards for safety-rated encoders Safety class/underlying standard Safety Integrity Level (SIL) according to IEC Performance Level (PL) according to EN ISO EI7C FS Underlying standards for safety-rated encoders Safety class/underlying standard Safety Integrity Level (SIL) according to EN Performance Level (PL) according to EN ISO Addendum to the Operating Instructions DR , DRN AC Motors

5 General information Structure of the safety notes Structure of the safety notes Meaning of signal words The following table shows the grading and meaning of the signal words for safety notes. Signal word Meaning Consequences if disregarded DANGER Imminent hazard Severe or fatal injuries. WARNING Possible dangerous situation Severe or fatal injuries. CAUTION Possible dangerous situation Minor injuries NOTICE Possible damage to property Damage to the drive system or its environment. INFORMATION Useful information or tip: Simplifies handling of the drive system Structure of section-related safety notes Section-related safety notes do not apply to a specific action but to several actions pertaining to one subject. The hazard symbols used either indicate a general hazard or a specific hazard. This is the formal structure of a safety note for a specific section: SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregarded. Measure(s) to prevent the hazard. Meaning of the hazard symbols The hazard symbols in the safety notes have the following meaning: Hazard symbol Meaning General hazard Warning of dangerous electrical voltage Warning of hot surfaces Warning of risk of crushing Addendum to the Operating Instructions DR , DRN AC Motors 5

6 1 General information Structure of the safety notes Hazard symbol Meaning Warning of suspended load Warning of automatic restart Structure of embedded safety notes Embedded safety notes are directly integrated into the instructions just before the description of the dangerous action. This is the formal structure of an embedded safety note: SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregarded. Measure(s) to prevent the hazard. 6 Addendum to the Operating Instructions DR , DRN AC Motors

7 General information Rights to claim under limited warranty Rights to claim under limited warranty Compliance with the provisions in this addendum to the operating instructions is a prerequisite for maintaining the guaranteed functional safety properties for this drive. Performing any actions that go beyond those described in the addendum to the operating instructions, or failure to comply with the requirements, will shift the responsibility for the traceability of the safety components and the liability for functional safety to the operator. A requirement of fault-free operation and fulfillment of any rights to claim under limited warranty is that you adhere to the information in the operating instructions and the addendum to the operating instructions. Read the operating instructions and the addendum to the operating instructions before you start working with the unit. 1.5 Exclusion of liability You must comply with the information contained in the operating instructions and the addendum to the operating instructions to ensure safe operation of the electric motors and to achieve the specified product characteristics and performance features. SEW EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of the operating instructions and the corresponding addendum. In such cases, any liability for defects is excluded. 1.6 Copyright notice 2015 SEW EURODRIVE. All rights reserved. Unauthorized reproduction, modification, distribution or any other use of the whole or any part of this documentation is strictly prohibited. 1.7 Product names and trademarks The brands and product names in this documentation are trademarks or registered trademarks of their respective titleholders. Addendum to the Operating Instructions DR , DRN AC Motors 7

8 2 Safety notes Preliminary information 2 Safety notes The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The user must ensure that the basic safety notes are read and observed. Make sure that persons responsible for the system and its operation, as well as persons who work independently on the unit, have read through the entire documentation carefully and understood them. If you are unclear about any of the information in this documentation, or if you require further information, contact SEW EURODRIVE. 2.1 Preliminary information The following safety notes are primarily concerned with the use of the following components: DR../DRN.. AC motors. If you use gearmotors, also refer to the safety notes in the corresponding operating instructions for: Gear units Also observe the additional safety notes provided in the individual chapters of this document. 2.2 General information WARNING Danger of fatal injury during operation as the motors and gearmotors can have live, bare (in the event of open connectors/terminal boxes) and movable or rotating parts as well as hot surfaces. Severe or fatal injuries. All work related to transport, storage, installation, assembly, connection, startup, maintenance and repair may only be carried out by qualified personnel. For transport, storage, installation, assembly, connection, startup, maintenance and repair it is important that you adhere to the information in the following documents: Warning and safety signs on the motor/gearmotor All the project planning documents, startup instructions and wiring diagrams related to the drive System-specific regulations and requirements National/regional safety and accident prevention regulations. Never install damaged products. Never operate or energize the unit without the necessary protection covers or housing. Use the unit only for its intended purpose. Make sure the unit is installed and operated properly. This documentation provides additional information. 8 Addendum to the Operating Instructions DR , DRN AC Motors

9 Safety notes Target group Target group Any mechanical work may only be performed by adequately qualified personnel. Qualified personnel in the context of this documentation are persons familiar with the design, mechanical installation, troubleshooting and servicing of the product, who possess the following qualifications: They have completed an apprenticeship in the field of mechanical engineering (e.g. mechanic or mechatronic technician). The content of the detailed operating instructions. Any electric work may only be performed by adequately qualified personnel. Qualified electricians in the context of this documentation are persons familiar with electrical installation, startup, troubleshooting and servicing of the product, who possess the following qualifications: Completed apprenticeship in the field of electrical engineering (e.g. electric or mechatronic technician). The content of the detailed operating instructions. All persons involved in any other work, such as transportation, storage, operation and waste disposal, must be trained appropriately. All qualified personnel must wear appropriate protective clothing Functional safety (FS) 04 If you perform any work on safety-rated encoders (identified by the FS logo on the nameplate) yourself, note that disassembly and assembly work on the safety-rated encoder may only be performed by qualified personnel, and that the responsibility for the traceability of the safety-rated encoder and the liability for functional safety shifts to the operator. In addition to the qualifications listed above, these persons must be familiar with: Functional safety. The relevant safety regulations and laws, especially with the requirements of EN ISO and all other standards, directives and laws specified in this documentation. The content of the operating instructions at hand. The content of the comprehensive "DR , DRN AC Motors" operating instructions For working with safety-rated brakes, also observe the publication "Addendum to the operating instructions: "Safety-Rated Brakes Functional Safety for DR , DRN AC Motors" addendum to the operating instructions. Addendum to the Operating Instructions DR , DRN AC Motors 9

10 2 Safety notes Designated use 2.4 Designated use The DR../DRN.. motors are intended for industrial systems. For installation in machines, startup (i.e. start of designated operation) is prohibited until it is determined that the machine complies with the local laws and directives. The machinery directive, EU directive 2006/42/EC, is relevant for the respective area of application. Using these products in potentially explosive atmospheres is prohibited, unless specifically designated otherwise. Air-cooled versions are designed for ambient temperatures of -20 C to +40 C and installation altitudes 1000 m above sea level. Any differing specifications on the nameplate must be observed. The ambient conditions must comply with all the specifications on the nameplate. When using a DR../DRN.. AC motor with BE.. brake, note that you may use the brake only as holding brake. Hence, the designated use is to activate the brake in standstill (< 50 1/min, for DR..250/280, DRN250/280 < 20 1/min). Operating the motor beyond its designated use may permanently affect the encoder performance. Sporadic emergency braking processes (voltage drop, emergency switching off) can be performed without affecting the encoder. 2.5 Functional safety (FS) Observe the notes and measures described below Labeling If functional safety is integrated in the motor, this is indicated with a FS logo on the nameplate Encoder mounting The connection between the encoder and the motor is a safety-rated frictional connection. The mechanics and the corresponding connections can be included in the safety consideration as fault elimination. Observe the mechanical limits in chapter "Technical Data" ( 2 33). 10 Addendum to the Operating Instructions DR , DRN AC Motors

11 Safety notes Functional safety (FS) Encoders The safety-rated encoders described in this addendum may only be used in conjunction with the DR../DRN.. motors listed below. It is not possible to adapt them to other motors. The safety-rated use of encoders or encoder systems is necessary for implementing safety-rated functions regarding speed, direction of rotation and standstill from the encoder that is coupled directly with the motor shaft. In addition, a suitable higher-level encoder evaluation unit is required, as the encoder with its encoder-internal diagnostic function is not able to trigger responses such as initiating a safe status on its own initiative. There are higher requirements regarding the electrical and mechanical connection, e.g. the shielded twisted-pair connection lead with correct EMC-compliant wiring and the strict observance of the (dis)assembly instructions, e.g. the observance of the tightening torques for the screws. AS7W, AS7Y, AG7W, AG7Y, EG7S and ES7S encoders The RS485 interface cannot be used in connection with safety technology for transferring absolute position data and other data (nameplate, diagnostics). This information can be used for general diagnostic purposes. Motor type DR DRN80 132S DR DRN..132M 280 Encoder type without Part number Safety class Safety function with Connection cover ES7S AS7W AS7Y SIL2 according to IEC Up to PL d according to EN ISO EG7S AG7W AG7Y SLS, SDI, SLA, SS1, SS2, SOS, SLI When placing a repeat order for an encoder with functional safety technology, you can order it without connection cover. EI7C FS encoder Motor type DR DRN80 132S Encoder type EI7C FS Part number Safety class Safety function Ordering with part number not possible SIL2 according to EN Up to PL d according to EN ISO SLS, SDI, SS1 Addendum to the Operating Instructions DR , DRN AC Motors 11

12 2 Safety notes Transport/Storage 2.6 Transport/Storage Inspect the shipment for damage as soon as you receive the delivery. Report any transport damage to the shipping company immediately. If necessary, suspend startup. Tighten the eyebolts securely. They are designed to only carry the weight of the gear unit/motor/gearmotor; do not attach any additional loads. The installed lifting eyebolts are in accordance with DIN 580. The loads and regulations specified in that document must always be observed. If two or four lifting eyes or eyebolts are attached to the gear unit/motor/gearmotor, all lifting eyes or eyebolts must be used during transport. In this case, the tension force vector of the slings must not exceed a 45 angle in accordance with DIN 580. Use suitable, sufficiently rated handling equipment if necessary. Reattach these in the case of further transportation. If the gear unit/motor/gearmotor is not installed immediately, it must be stored in a dry and dust-free storage location. You must not store the gear unit/motor/gearmotor outdoors or on the fan guard. The gear unit/motor/gearmotor can be stored for up to 9 months without requiring any special measures before startup. 2.7 Installation Make sure that the supports are even, the foot and flange mounting is correct and if there is direct coupling, align with precision. Resonances between the rotational frequency and the double line frequency caused by the structure are to be avoided. Release the brake (if installed), turn rotor manually, check for unusual grinding noise. Check the direction of rotation in decoupled state. Only install or remove belt pulleys and couplings using suitable devices (heat up) and cover with a touch guard. Avoid improper belt tension. Make the pipe connections that may eventually be required. Mounting positions with shaft ends pointing upwards should be equipped with a cover to prevent foreign objects from falling into the fan. Ensure that ventilation openings are not obstructed and that exhaust air, including air from adjacent units, cannot be drawn in again straight away. 12 Addendum to the Operating Instructions DR , DRN AC Motors

13 Safety notes Electrical connection Electrical connection All work may only be carried out by qualified personnel. During work, the low-voltage machine must be at standstill, de-energized, and safeguarded against accidental restart. This also applies to auxiliary circuits (e.g. anti-condensation heating or forced cooling fan). Check whether the unit is de-energized. Exceeding the tolerances in EN (VDE 0530, part 1) voltage + 5%, frequency + 2%, curve shape, symmetry increases the heating and influences electromagnetic compatibility. Also comply with EN (where necessary, observe other applicable national regulations, such as DIN VDE 0105 for Germany). Observe the wiring information and differing data on the nameplate as well as the wiring diagram in the terminal box. The connection must be a permanently secure electrical connection (no protruding wire ends); use the cable end equipment intended for this purpose. Establish a secure protective earth connection. When the motor is connected, the distances to non-insulated and live parts must not be shorter than the minimum values according to IEC and national regulations. With low voltage, the distances should be no shorter than the following values, in compliance with IEC 60664: Nominal voltage V N 500 V 690 V Distance 3 mm 5.5 mm The connection box must be free from foreign objects, dirt and humidity. Unused cable entry openings and the box itself must be closed so that they are dust- and waterproof. Secure the key for test mode without output elements. When operating low-voltage machines with brakes, check that the brake is functioning correctly before startup. Observe the notes in chapter Electrical installation ( 2 17). 2.9 Startup/operation Whenever changes to normal operation occur in the gear unit/motor/gearmotor, such as increased temperatures, noise, vibrations, determine the cause. Consult the manufacturer if required. Never deactivate protection devices, even in test mode. Switch off the motor if you are not sure. Regularly clean air ducts in dusty or dirty environments. Addendum to the Operating Instructions DR , DRN AC Motors 13

14 3 Unit structure Functional safety technology (FS) 3 Unit structure 3.1 Functional safety technology (FS) 02 Drives from SEW EURODRIVE can optionally be supplied with safety-related components. MOVIMOT, encoders or brakes, or other accessories, can be integrated in the AC motor as safety-related components either individually or in combination. SEW EURODRIVE indicates such an integration by the FS logo and a number on the nameplate. The number is a code that indicates which components in the drive are safety-related. See the following code table for all products: Functional safety Inverter (e.g. MOVIMOT ) Brake 02 x Manual brake release monitoring Brake monitoring Motor protection Encoder/ Encoder mounting 04 x 11 x x If the FS logo on the nameplate contains the code "FS 11", for example, the motor is equipped with a combination of safety-rated brake and safety-rated encoder. If the drive bears the FS logo on the nameplate, you must adhere to the information in the following documents: Addendum to the operating instructions "Safety-Rated Encoders DR , DRN AC Motors Functional Safety" Addendum to the operating instructions "Functional Safety DR , DRN AC Motors Safety-Rated Brakes" You can determine the safety level of machines and plants using the safety parameters provided in chapter "Technical data". The characteristic safety values of components by SEW EURODRIVE are also available on the SEW EURODRIVE homepage on the Internet and in the SEW EURODRIVE library for the Sistema software of the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA, formerly BGIA). 14 Addendum to the Operating Instructions DR , DRN AC Motors

15 Unit structure Nameplate Nameplate FS logo on the nameplate of a DR.. gearmotor [2] [1] RF87 DRE100LC4BE5HF/TF/ES7S/Z/C ~IEC Hz rpm 1455/ Δ/ Y 54 TEFC kw 3 S1 A11.0/6.3 P.F.0.81 eff % 86.3 IE2 kw 3 S1 A 9.2/5.3 P.F.0.8 eff % 86.4 IE2 60 Hz rpm 1760/ Δ/ Y K.V.A.-Code L Th.Kl. 130(B) S.F. 1.0 M.L. 02 Design NEMA C IA/IN 7.5 Vbr AC i63.68 Nm 1250/1040 IM M1 Nm 40 CLP220 Miner.Oil/2.4l BGE1.5 kg AMB C DE Made in Germany [1] Serial number [2] Functional safety logo with code The labels on the upper edge of the nameplate are only present if the motor has been designed accordingly and if it includes at least one safety-rated component. The FS logo on the nameplate is based on the combination of safety-related components that is installed, see code table above. Addendum to the Operating Instructions DR , DRN AC Motors 15

16 4 Mechanical installation 4 Mechanical installation The use of safety-rated components does not affect mechanical installation. INFORMATION Note that greases and oils must not be allowed on the encoder connection during assembly or operation. 16 Addendum to the Operating Instructions DR , DRN AC Motors

17 Electrical installation Connecting the EI7C FS encoder 5 5 Electrical installation INFORMATION Observe the safety notes in chapter 2 during installation. Use switch contacts in utilization category AC-3 according to EN for switching the motor and the brake. WARNING Disabling functional safety devices. Severe or fatal injuries. Only qualified personnel is allowed to carry out work on functional safety components. Any work on functional safety components must be carried out by strictly observing the specifications in the operating instructions at hand and the respective addendum to the operating instructions. Else, the right to claim under warranty will become invalid. Note the information and explanations about correct wiring in the corresponding operating instructions. SEW EURODRIVE recommends using prefabricated cables to connect the encoders; see the AC Motors catalog. 5.1 Connecting the EI7C FS encoder There is an 8-pin M12 plug connector on the terminal box for connection. M12 AVRE male, A-coded Pin 1: +U B Pin 5: B Pin 2: GND Pin 6: B Pin 3: A Pin 7: nc Pin 4: A Pin 8: nc INFORMATION Pins 7 and 8 must not be used. The encoder cable must meet the following requirements: Maximum cable length: 30 m. Minimum core cross section: 0.25 mm 2 (AWG 23). The cable must be shielded. The shield must be connected over a large surface area at both ends. The cable must have twisted-pair conductors. Addendum to the Operating Instructions DR , DRN AC Motors 17

18 5 Electrical installation EI7C FS visual feedback 5.2 EI7C FS visual feedback The LED display, which is visible when the fan guard is removed, provides visual feedback about the signal track state. A red LED and a green LED are used as a status display for the EI7C FS safety-rated encoder. The green LED indicates the current status. The red LED is used to display the error history by means of a flash code. The error history always displays the most recent errors since the last time the encoder was switched on Indicating the normal state During normal operation, the green status LED lights up constantly. Usually, no error has occurred and the red error history LED is off. If an error already occurred before the current normal operating state, this is indicated by the flash code on the red LED described below Indicating an internal diagnostics error The EI7C FS encoder has a self-diagnostics system. If this diagnostics system has an error, the encoder enters an error status that cannot be reset by acknowledging the error. The error can only be reset by switching off the supply voltage and then switching it back on Indicating service mode If the encoder is supplied with a defined voltage range below the regular supply voltage range during startup, the encoder automatically goes into service mode. The output drivers are switched off. The red error history LED indicates service mode by lighting up constantly. The green status LED reports the distance between the encoder module and the fan wheel. Any service work necessary on the encoder may only be performed by SEW EURODRIVE employees Indicating error statuses The start of an error code is indicated by a long pulse (START). The number of brief flash pulses indicates the most recent error since the encoder was switched on. The long START signal does not count as part of this number. The figure shows the structure of the flash code. The Normal operation ( 2 19) table provides an overview of possible error statuses and the defined LED signals for these statuses. Start 1 N Addendum to the Operating Instructions DR , DRN AC Motors

19 Electrical installation EI7C FS visual feedback LED codes for the operating statuses Normal operation Displayed status Green LED (status) Red LED (error) No voltage or defective OFF OFF Internal diagnostics error ON ON NO error ON OFF No errors at the moment. Most recent error is displayed. An error has occurred. Most recent error is displayed. ON OFF Temperature error Supply voltage error ANALOG signal error Error in digital track A or B Distance difference error Output driver error Error code Error code 1x 2x 3x 4x 5x 6x Service mode Displayed status Service mode (Defined voltage range while switching on) Current sensor distance Green LED (status) Amplitude OK OFF ON Amplitude is too high Amplitude is too low Fast (approx. 0.5 Hz) Slow (approx. 2 Hz) Red LED (error) ON ON Addendum to the Operating Instructions DR , DRN AC Motors 19

20 6 Startup Requirements 6 Startup 6.1 Requirements INFORMATION Observe the safety notes in chapter 2 during installation. In case of problems, refer to chapter "Malfunctions" in the operating instructions. WARNING Disabling functional safety devices. Severe or fatal injuries. Only qualified personnel is allowed to carry out work on functional safety components. Any work on functional safety components must be carried out by strictly observing the specifications in the operating instructions at hand and the respective addendum to the operating instructions. Otherwise, the warranty will become void. INFORMATION When using the DR..250/280, DRN250/280 AC motor with the BE brake and an encoder, note the following: The brake must be used as a holding brake only. The brake may only be applied when the speed is 20 1/min. The brakes of DR.. 250/280, DRN250/280 motors may only be applied when the speed is < 50 1/min. For higher speeds, please contact SEW EURODRIVE. Emergency stops from a higher motor speed are allowed. 20 Addendum to the Operating Instructions DR , DRN AC Motors

21 Inspection/maintenance Requirements 7 7 Inspection/maintenance WARNING Risk of crushing if the hoist falls or in the event of uncontrolled unit behavior. Severe or fatal injuries. Secure or lower hoist drives (danger of falling) Safeguard and/or protect the driven machine against touching Isolate the motor, brake, and forced cooling fan, if installed, from the power supply before starting work, safeguarding them against unintentional re-start. Only use genuine spare parts in accordance with the valid spare parts list. Always install a new brake control at the same time as replacing the brake coil. WARNING Disabling functional safety devices. Severe or fatal injuries. Only qualified personnel is allowed to carry out work on functional safety components. Any work on functional safety components must be carried out by strictly observing the specifications in the operating instructions at hand and the respective addendum to the operating instructions. Else, the right to claim under warranty will become invalid. CAUTION The surfaces of the drive can be very hot during operation. Risk of burns. Let the motor cool down before you start your work. CAUTION For assembly, the ambient temperature and the oil seals themselves may not be colder than 0 C, otherwise the oil seals might be damaged. INFORMATION The contents of this section only apply to the ES7S, EG7S, AS7W, AS7Y, AG7W and AG7Y encoders. Addendum to the Operating Instructions DR , DRN AC Motors 21

22 7 Inspection/maintenance Functional safety (FS) 7.1 Functional safety (FS) Certain demands on the mechanical coupling of the encoder system to the motor must be met so that the encoder can be used for safety-relevant tasks. SEW EURODRIVE assumes responsibility for the delivered motor with safety-rated encoder in terms of compliance with the functional safety regulations. Safety-rated connection elements are sealed to ensure that the delivery condition is not changed. With the EI7C FS built-in encoder, no work may be performed on the encoder. Commission SEW EURODRIVE Service to perform any necessary work on the encoder. There are the following options for performing work on the ES7S, EG7S, AS7W, AS7Y, AG7W or AG7Y encoder or the motor during which the sealed screw connections must be opened: Ask the SEW EURODRIVE Service to perform this work. Perform the work yourself. Note that all work on the safety-rated encoder and its mechanical coupling is carried out at your own risk. This means that responsibility for the traceability of the safety-rated encoder and the safety-rated functions, particularly the connection to the motor, and liability for functional safety are transferred to the operator. Also observe the following notes regarding disassembly and assembly work on the encoder. Only qualified staff is permitted to perform disassembly and assembly work on the safety-rated encoder indicated by the FS logo on the nameplate. Those persons must be familiar with: Functional safety. The relevant safety regulations and laws, especially with the requirements of EN ISO and all other standards, directives and laws specified in this documentation. The content of the operating instructions at hand. The content of the detailed operating instructions. 22 Addendum to the Operating Instructions DR , DRN AC Motors

23 Inspection/maintenance (Dis)assembling the encoder (Dis)assembling the encoder INFORMATION When installing an encoder, observe the tightening torques specified in this documentation to avoid a faulty mechanical connection between the drive component and the rotary encoder according to EN Required tools You need the following tools to remove or install an encoder. Make sure that all the tools are available before you remove/install an encoder. New expansion anchor [362]. The expansion anchor can be ordered from SEW EURODRIVE with the part number (for ES7S, AS7W, and AS7Y encoders). Compound against contact corrosion, such as NOCO fluid Various sizes of hollow hexagon wrenches Various sizes of external hexagon wrenches Torque wrench for tightening torques of -2.0 Nm to 8.0 Nm Sensor with a measuring range of 1/100 mm for measuring the wobble Removing/installing the encoder from DR , DRN80 132S The following figure illustrates disassembly using the ES7. encoder as an example: [B] [F] [D] [362] [A] [B] [G] [619] [220] [35] [34] Tapping screw [A] Retaining screws for the torque arm [35] Fan guard [B] Central retaining screw [220] Encoder [D] Cone [361] Extended fan guard [F] Bore [362] Expansion anchor [G] Tooth lock washer [619] Connection cover [34] [361] Addendum to the Operating Instructions DR , DRN AC Motors 23

24 7 Inspection/maintenance (Dis)assembling the encoder Disassembling ES7./AS7. 1. Remove the extended fan guard [361] and, if installed, the forced cooling fan. 2. Unscrew and remove the connection cover [619]. Do not disconnect the encoder connection cable. 3. Loosen the expansion anchor [362] by removing the screws [A] from the cover grid. Dispose of the expansion anchor. 4. Unscrew the central retaining screw [B] by about 2 to 3 turns (do not remove) and unfasten the cone [D] of the spread shaft by tapping lightly on the bolt head. 5. Pull the encoder [220] from the rotor bore. If the encoder is hard to loosen, you can loosen or counterhold the encoder shaft at the bore [F]. 24 Addendum to the Operating Instructions DR , DRN AC Motors

25 Inspection/maintenance (Dis)assembling the encoder 7 Re-assembly 1. Apply a contact corrosion prevention compound, e.g. NOCO fluid to the encoder pin. 2. Install the tooth lock washer [G] and tighten the central retaining screw [B] with a tightening torque of 2.9 Nm. WARNING Disabling the functional safety device. Severe or fatal injuries. You must tighten the central retaining screw with the specified tightening torque. 3. Press the expansion anchor into the fan guard and make sure that it is fitted properly. Always use a new expansion anchor when installing the encoder again. 4. Screw the retaining screws [A] of the torque arm [362] into the expansion anchor all the way and tighten it with a tightening torque of -2.0 Nm. WARNING Disabling the functional safety device. Severe or fatal injuries. You must tighten the retaining screws for the torque arm with the specified tightening torque. 5. Install the connection cover [619]. 6. Measure the wobbling as described in chapter "Measuring wobbling" ( 2 28). 7. Install the forced cooling fan, if necessary. 8. Install the extended fan guard [361]. Addendum to the Operating Instructions DR , DRN AC Motors 25

26 7 Inspection/maintenance (Dis)assembling the encoder Removing/installing the encoder from DR , DRN132M 280 The following figure illustrates disassembly using the EG7. encoder as an example: X [E] SW17 [35] [E] [706] [657] [707] X [220] [232][619] [715] [B] [361] [33] [34] [33] Washer [657] Canopy [34] Tapping screw [706] Spacer bolt [35] Fan guard [707] Hex head screws [220] Encoder [715] Hex head screws [232] Retaining screws for the torque [B] Central retaining screw arm [361] Extended fan guard [E] Nuts [619] Connection cover Addendum to the Operating Instructions DR , DRN AC Motors

27 Inspection/maintenance (Dis)assembling the encoder 7 Disassembling EG7./AG7. 1. Perform one of the following steps depending on the housing design: Loosen the screws [707] and remove the canopy [657]. Use SW13 spacer bolts [706] to counterhold. Remove forced cooling fan, if installed. Loosen the screws [34] and remove the extended fan guard [361]. Remove forced cooling fan, if installed. 2. Unscrew and remove the connection cover [619]. 3. Remove the screws [232]. 4. Remove the fan guard [35]. 5. Force off the encoder [220] by loosening the central retaining screw [B]. If the encoder is hard to loosen, you can loosen or counterhold the encoder shaft at the installed SW17 spanner flat. Re-assembly 1. Apply a contact corrosion prevention compound, e.g. NOCO fluid to the encoder shaft. 2. Apply the encoder in the rotor bore and screw it in with the central retaining screw [B] all the way and tighten the screw with 8 Nm. WARNING Disabling the functional safety device. Severe or fatal injuries. You must tighten the central retaining screw with the specified tightening torque. 3. Remove any residues of the old thread locking compound from the threads of the retaining screws of the torque arm [232]. 4. Apply a medium thread locking compound, e.g. LOCTITE 241, to the 2 screws [232] and screw the torque plate of the encoder to the fan grille with a tightening torque of 6 Nm. WARNING Disabling the functional safety device. Severe or fatal injuries. You must tighten the retaining screws for the torque arm with the specified tightening torque. 5. Install connection cover [619]. 6. Measure the wobbling as described in chapter "Measuring wobbling" ( 2 28). 7. Install the forced cooling fan, if necessary. 8. Install the canopy [657] with the screws [707], or install the extended fan guard [361] with the screws [34]. Addendum to the Operating Instructions DR , DRN AC Motors 27

28 7 Inspection/maintenance Measuring wobbling 7.3 Measuring wobbling Wobbling must be measured each time an encoder is installed to ensure it is seated properly. Measure wobbling as described in the following chapters Encoders for DR , DRN80 132S 1. Place the sensor on the upper edge of the encoder as shown in the figure below: > 5 mm The measurement must be carried out within the marked zone (maximum width = 5 mm). 3. Turn the motor shaft. If required, start up the motor at low speed (< 60 min -1 ). 4. Check the wobble on the sensor. The maximum permitted wobble on the rotary encoder must be 0.07 mm when turning the motor shaft. Repeat the test if the measured value is exceeded. To do so, proceed as follows: 5. Loosen the central retaining screw [B] and unfasten the cone [D] by tapping lightly on the head of the retaining screw [B]. 6. Turn the motor shaft or the encoder shaft on the bore [F] by Tighten the central retaining screw [B] as described in the "Removing/installing encoder ( 2 23)" chapter. 8. Measure the wobble again. INFORMATION If it is not possible to carry out the measurement below the permitted wobble, please contact the SEW EURODRIVE Service. 28 Addendum to the Operating Instructions DR , DRN AC Motors

29 Inspection/maintenance Measuring wobbling Encoders for DR , DRN132M Place the sensor on the upper edge of the encoder as shown in the figure below: > 5 mm The measurement must be carried out within the marked zone (maximum width = 5 mm). 3. Turn the motor shaft. If required, start up the motor at low speed (< 60 min -1 ). 4. Check the wobble on the sensor. The maximum permitted wobble on the rotary encoder must be 0.1 mm when turning the motor shaft. Repeat the test if the measured value is exceeded. To do so, proceed as follows: 5. Remove the encoder as described in the "Removing/installing encoders ( 2 23)" chapter. 6. Turn the motor shaft or the encoder shaft on the SW17 spanner flat on the encoder by Install the encoder as described in the "Removing/installing encoders ( 2 23)" chapter. 8. Measure the wobble again. INFORMATION If it is not possible to carry out the measurement below the permitted wobble, please contact the SEW EURODRIVE Service. Addendum to the Operating Instructions DR , DRN AC Motors 29

30 7 Inspection/maintenance DR../DRN.. (brake)motor inspection procedure 7.4 DR../DRN.. (brake)motor inspection procedure WARNING Risk of crushing if the drive starts up unintentionally. Severe or fatal injuries. Isolate the motor and forced cooling fan, if installed, from the power supply before starting work, safeguarding them against unintentional re-start. Carefully observe the steps described below. Proceed according to the corresponding operating instructions for all steps except when working on the encoder. For all steps that require the encoder to be removed, proceed according to chapter "Removing/installing the encoder" ( 2 23) Brakemotors If the drive is equipped with a combination of a brake and a safety-rated encoder, the values regarding the maintenance intervals and the maximum working air gap differ from the standard. For the exact values, refer to the chapter "Technical data" ( 2 37). The maintenance intervals have to be recalculated with the values specified in the addendum to the operating instructions in hand. If the drive is equipped with a combination of a safety-rated brake and a safety-rated encoder, the addendum to the operating instructions "Safety-Rated Brakes DR , DRN AC Motors Functional Safety" must also be observed. 30 Addendum to the Operating Instructions DR , DRN AC Motors

31 Technical data Characteristic safety values 8 8 Technical data 8.1 Characteristic safety values The characteristic safety values of non-sew encoders must be obtained from the respective manufacturer Characteristic safety values for encoders ES7S and EG7S Characteristic safety values according to EN 62061/IEC EN ISO Safety class/underlying standards SIL2 according to EN PL d according to EN ISO System structure HFT = 1 2 channels (corresponds to category 3 according to EN ISO ) Probability of a dangerous failure /h per hour (PFH d value) 1) Mean time to dangerous failure 1306 years (MTTF d value) 2) Mission time/service life 20 years Proof test interval Not required Safe fault coverage (SSF) 95% Motor/encoder connection In the drive with FS logo Exclusion of errors according to EN ISO ) The specified value refers to a diagnostics coverage of 90%, that must be achieved by an encoder evaluation unit. For corresponding error presumptions, refer to the EN standard. The encoder evaluation unit must at least meet the requirements for SIL 2. 2) Ambient temperature 40 C Addendum to the Operating Instructions DR , DRN AC Motors 31

32 8 Technical data Characteristic safety values Characteristic safety values for encoders AS7W and AG7W Characteristic safety values according to EN 62061/IEC EN ISO Safety class/underlying standards SIL2 according to EN PL d according to EN ISO System structure HFT = 1 2 channels (corresponds to category 3 according to EN ISO ) Probability of a dangerous failure /h per hour (PFH d value) 1) Mean time to dangerous failure 1566 years (MTTF d value) 2) Mission time/service life 20 years Proof test interval Not required Safe fault coverage (SSF) 95% Motor/encoder connection In the drive with FS logo Exclusion of errors according to EN ISO ) The specified value refers to a diagnostics coverage of 90%, that must be achieved by an encoder evaluation unit. For corresponding error presumptions, refer to the EN standard. The encoder evaluation unit must at least meet the requirements for SIL 2. 2) Ambient temperature 40 C Characteristic safety values for encoders AS7Y and AG7Y Characteristic safety values according to EN 62061/IEC EN ISO Safety class/underlying standards SIL2 according to EN PL d according to EN ISO System structure HFT = 1 2 channels (corresponds to category 3 according to EN ISO ) Probability of a dangerous failure /h per hour (PFH d value) 1) Mean time to dangerous failure 1566 years (MTTF d value) 2) Mission time/service life 20 years Proof test interval Not required Safe fault coverage (SSF) 95% Motor/encoder connection In the drive with FS logo Exclusion of errors according to EN ISO ) The specified value refers to a diagnostics coverage of 90%, that must be achieved by an encoder evaluation unit. For corresponding error presumptions, refer to the EN standard. The encoder evaluation unit must at least meet the requirements for SIL 2. 2) Ambient temperature 40 C 32 Addendum to the Operating Instructions DR , DRN AC Motors

33 Technical data Encoders Encoders ES7S / AG7S / AS7Y / EG7Y / AS7W / AG7W Designation Value Operating ambient temperature for the encoder -30 C to +85 C Ambient temperature of motor -20 C to +40 C Storage temperature -15 C to +70 C Maximum speed 6,000 min -1 Vibration resistance (EN ) 100 m/s 2 10 g (at 10 Hz to 2 khz) Maximum angular acceleration 10 4 rad/s 2 Degree of protection (EN 60529) IP ES7S / EG7S Designation Operating voltage Current consumption without load Resolution Value DC +7 to +30 V 100 ma sin/cos interface 1024 periods/revolution Accuracy (70 angular seconds) 1) Shock resistance (EN ) ES7S: 1,000 m/s g (6 ms) EG7S: 2,000 m/s g (6 ms) 1) Due to the stiffness of the torque arm, you have to take into account an automatically resetting ± 0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft. Addendum to the Operating Instructions DR , DRN AC Motors 33

34 8 Technical data Encoders AS7Y / AG7Y Designation Operating voltage Current consumption without load Resolution of the incremental section Value DC +7 to +30 V 100 ma sin/cos interface 2048 periods/revolution Accuracy of the incremental section (70 angular seconds) 1) Resolution of the absolute section SSI interface, gray-coded 12 bit = 4,096 increments (single-turn) 12 bit = 4,096 increments (multi-turn) Accuracy of the absolute section Clock frequency of the absolute section Shock resistance (EN ) ± 1 LSB (Least Significant Bit) 100 khz to 800 khz AS7Y: 1,000 m/s g (6 ms) AG7Y: 2,000 m/s g (6 ms) 1) Due to the stiffness of the torque arm, you have to take into account an automatically resetting ± 0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft AS7W / AG7W Designation Operating voltage Current consumption without load Resolution of the incremental section Value DC +7 to +30 V 100 ma sin/cos interface 2048 periods/revolution Accuracy of the incremental section (70 angular seconds) 1) Resolution of the absolute section RS-485 interface 13 bit = 8,192 increments (single-turn) 16 bit = 65,536 increments (multi-turn) Accuracy of the absolute section Shock resistance (EN ) ± 1 LSB (Least Significant Bit) AS7W: 1,000 m/s g (6 ms) AG7W: 2,000 m/s g (6 ms) 1) Due to the stiffness of the torque arm, you have to take into account an automatically resetting ± 0.6 twist (depending on the direction of rotation) of the encoder housing compared to the encoder shaft. 34 Addendum to the Operating Instructions DR , DRN AC Motors

35 Technical data Encoders EI7C FS Supply Min. Typ. Max. Unit Operating voltage 1) V B V Max. current consumption (with no load) I max (V B = 24 V, I out = 0) 120 ma 1) The voltage supply must come from SELV/PELV circuits in accordance with DIN EN Designation Value Max. speed n max /min HTL periods per revolution N periods 24 Ambient temperature ϑ A -30 C to +60 C Vibration resistance According to EN : g (98.1 m/s 2 ); Hz Shock resistance According to EN : g (981 m/s 2 ); 6 ms Degree of protection According to EN IP66 Connection M12 (8-pin) Maximum angular acceleration 3000 rad/s 2 Reliable magnetic interference field on the outer contour of the motor B extmax ; H extmax 25 mt; 20 ka/m Signal tracks Min. Typ. Max. Unit Output amplitude per track V high (I out = I out_max ) V B V B V V low (I out = I out_max ) 0 +3 V Max. output current per track I out_max ±30 ma Tolerance signal period (corresponds to the speed tolerance) Track A:B phase offset φ Period.tol (n = constant) φ Phase.A:B (n = constant) % Degrees Pulse duty factor (DIN IEC ) t = t log_1 /(t period ) (n = constant) % Pulse frequency at max. speed (max. speed periods) Output leakage current in deactivated state (= error message) 1) Start-up time (undefined outputs) f max 1.44 khz I Error +250 µa Starting at V B > 9 V 300 ms Error message duration ms (deactivated outputs) 1) 1) The EI7C FS built-in encoder has a self-diagnostics function. If an error is detected, the system reports it by deactivating the output signals to the safety-rated encoder evaluation unit. Addendum to the Operating Instructions DR , DRN AC Motors 35

36 8 Technical data Encoder evaluation unit 8.3 Encoder evaluation unit Designation ES7S, EG7S, AS7W, AS7Y, AG7W, AG7Y encoders: Value Safety requirements SIL 2 (IEC 61508) Error detection rate DC 90% Error presumptions According to EN Signal amplitude monitoring 1) DC 0.7 V to 1.4 V (peak-peak) 1) In the encoder evaluation unit, signals A, A, B, and B must be high-resistance (> 1 kω) to the supply voltage and 0 V. This applies to EI7C FS encoders: The EI7C FS built-in encoder may only be used with safety-rated encoder evaluation units from SEW EURODRIVE. Also observe the manuals for the safety-rated encoder evaluation units. 36 Addendum to the Operating Instructions DR , DRN AC Motors

37 Technical data Work done, working air gap, braking torques of the BE.. brakes Work done, working air gap, braking torques of the BE.. brakes If you use a safety-rated encoder in conjunction with a brake, the maximum working air gaps and the maintenance intervals for the BE.. brakes are reduced according to the table below, replacing the values in the operating instructions. Brake type Braking work done until maintenance Working air gap Brake disk mm mm Braking torque Braking torque settings Type/number of brake springs Purchase order number for brake springs 10 6 J min. 1) Max. Min. Nm Normal blue Normal blue BE X BE X BE BE BE BE Addendum to the Operating Instructions DR , DRN AC Motors 37

38 8 Technical data Work done, working air gap, braking torques of the BE.. brakes Brake type Braking work done until maintenance Working air gap Brake disk mm mm Braking torque Braking torque settings Type/number of brake springs Purchase order number for brake springs 10 6 J min. 1) Max. Min. Nm Normal blue Normal blue BE BE BE BE BE BE ) When checking the working air gap, note: Parallelism tolerances on the brake disk may give rise to deviations of ± 0.15 mm after a test run. 38 Addendum to the Operating Instructions DR , DRN AC Motors

39 Declaration of Conformity 9 9 Declaration of Conformity EC Declaration of Conformity Translation of the original text SEW-EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42, D Bruchsal declares under sole responsibility that the motors of the series DR.. in connection with encoders of the type ES7S / EG7S AS7W / AG7W AS7Y / AG7Y XS7S / XG7S EI7C FS possibly in connection with Gear units of the series R..; RES F.. K..; KES W.. S.. H.. VARIMOT VARIBLOC are in conformity with Machinery Directive 2006/42/EC This includes the fulfillment of the protection targets for "electrical power supply" in accordance with annex I No according to the Low Voltage Directive 73/23/EEC and 2006/95/EC. ErP Directive 2009/125/EC 7) Applied harmonized standards: EN ISO :2008 EN : 2007 EN : 2007 EN : A1:2012 EN ISO 12100:2010 EN ISO 13857: 2008 EN :2010 EN :2007 EN :2007 7) Products that are covered by this Directive meet the requirements of Commission Regulation (EC) No. 640/2009 from July 22, /2009. Bruchsal Johann Soder Place Date Managing Director Technology a) b) a) Authorized representative for issuing this declaration on behalf of the manufacturer b) Authorized representative for compiling the technical documents with same address as manufacturer Addendum to the Operating Instructions DR , DRN AC Motors 39

40 Index Index Icons (Dis)assembling, the encoder (Dis)assembly plates (Dis)assembly, encoder B Brake Braking torques Braking work Working air gap Braking work C Code table Copyright notice... 7 D Designated use Diagnostics, encoder internally E EI7C FS encoder connection EI7C FS visual feedback Electrical connection Electrical installation Embedded safety notes... 6 Encoder evaluation unit... 11, 36 Encoder, safety-related use Exclusion of liability... 7 F FS logo... 9 FS mark, nameplate Functional safety... 9, 14, 22 (Dis)assembly plates Code table Encoder Encoder mounting ID Identification Knowledge... 9 Sealing Functional safety logo... 9 G General safety notes... 8 H Hazard symbols Meaning... 5 I Important information... 4 Inspection Inspection, motor Installation Electrical Interfaces Sine/cosine M Maintenance Measuring wobbling Motor, inspection N Nameplate Notes Designation in the documentation... 5 General... 4 Meaning of the hazard symbols... 5 Safety... 8 P Perform concentricity test Personnel, qualified Position data Product names... 7 R Removing/installing the encoder... 23, 26 AG AS EG ES Right to claim under warranty... 7 S Safety characteristics /EN 04/15 40 Addendum to the Operating Instructions DR , DRN AC Motors

41 Index Safety class Safety function Safety notes... 8 Designated use Designation in the documentation... 5 Electrical connection General... 8 Installation Meaning of the hazard symbols... 5 Operation Structure of embedded... 6 Structure of the section-related... 5 Transport Scope of delivery Section-related safety notes... 5 Service Signal words in the safety notes... 5 Standards... 4 Startup T Target group... 9 Technical data AS7W / AG7W AS7Y / AG7Y EI7C FS ES7S / AG7S / AS7Y / EG7Y / AS7W / AG7W ES7S / EG7S Trademarks... 7 Transport U Unit structure Use, designated V Validity... 4 W /EN 04/15 Working air gap Addendum to the Operating Instructions DR , DRN AC Motors 41

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44 SEW-EURODRIVE Driving the world SEW-EURODRIVE GmbH & Co KG P.O. Box BRUCHSAL GERMANY Phone Fax