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33

Safety functions (only for controls with integrated safety technology)

Safety functions (only for controls with integrated safety technology)

10

Operating manual [27779165/EN] - EMS modular controls

240

_10

0300

05/EN - 0

2/2

022

10

Safety functions (only for controls with integrated safety technology)

10.1

Overview

Basically, two safety functions are possible:
•

STO

: Safe torque shutdown (

S

afe 

T

orque 

O

ff)

•

SLS

: Safety limited speed (

S

afely 

L

imited 

S

peed)

The STO function is implemented differently depending on the communication type:

Communication type rail bus CAN

When using the CAN rail bus communication type, the internal safety relay VSR is used
to safely switch off the torque.

Communication type SMGM

When using the communication type SMGM, the safe torque shutdown is implemented
via PROFIsafe.

The SLS function is only possible in connection with the STO function. The safely limited
speed is implemented by the frequency converter used.

Summary of Contents for EMS

Page 1: ...240_10030005 EN Drive Technology Drive Automation System Integration Services Edition 240 27779165 EN 02 22 Operating manual 27779165 EN Control technology EMS modular controls 02 2022 ...

Page 2: ......

Page 3: ...ng company 15 4 5 Personnel requirements 16 4 5 1 Qualifications 16 4 6 Personal protective equipment 17 4 7 Safety devices 19 4 8 Conduct in case of danger or accident 20 4 9 Signage 21 5 Notes about hazardous substances 22 6 Applicable documents 23 7 Applied guidelines ordinances and standards 24 8 Technical data 26 9 System description 29 9 1 Basic system 29 9 2 Preferred variant 1 Rail bus CAN...

Page 4: ...ule IO 2 57 14 Circuits Power outputs 66 15 Frequency converter 67 16 Communication 68 16 1 Railbus CAN 69 16 1 1 Basics 69 16 1 2 Interface Description 70 16 2 SMGM 72 16 2 1 Basics 72 16 2 2 Interface Description 73 17 Type code 81 18 Type plate 82 19 Order overview scope 83 20 Commissioning 84 20 1 Safety notes 84 20 1 1 Mechanical installation 84 20 1 2 Electrical installation 85 20 1 3 EMC 86...

Page 5: ...nt of malfunction 98 21 3 Error messages 99 21 4 Return repair 100 22 Maintenance 101 22 1 Safety information about repairs 102 23 Transport and storage 103 23 1 Safety instructions for transport and storage 103 23 2 Transport inspection 103 24 Disassembly and disposal 104 24 1 Preparation for disassembly 104 24 1 1 Disassembly 104 24 2 Disposal 105 Index 107 ...

Page 6: ...02 2022 Operating manual 27779165 EN EMS modular controls 1 Document history Part number Version Issue Description changes 27779165 EN 1 01 11 2021 First issue 27779165 EN 1 02 02 2022 Part number of this document added New connector X5 Informa tion added ...

Page 7: ...em EI Field bus Ethernet IP EMC Electromagnetic compatibility ESD Electrostatic discharge FC Frequency converter HF High frequency HW Communication type Half wave IEN Industrial Ethernet PCB Communication type Rail bus PowerCAN PN Field bus PROFINET RS485 Serial interface RS485 standard SMGM Communication type SMGM SSI Serial interface RS422 standard ASL Above sea level XIN Fixed assignment of the...

Page 8: ...accessible to operating and maintenance personnel in the immediate vicinity The basic requirement for safe working is compliance with all specified safety instructions and instructions This documentation does not give instructions for operating the plant machine in which our system is integrated In addition the local accident prevention regulations and general safety regulations for the use of the...

Page 9: ...Measure to avoid it NOTICE Cause of danger Consequence of non compliance Measure to avoid it INFORMATION Cause of danger Consequence of non compliance Measure to avoid it DANGER Residual voltage from charged capacitors Severe injury Do not touch any live product parts or power connections WARNING Residual voltage from charged capacitors Severe injury Do not touch any live product parts or power co...

Page 10: ... controls Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text No tice text Notice text Notice text Notice text Notice text Notice text Notice text Notice text ...

Page 11: ... of knowledge and experience The manufacturer assumes no liability for damage due to Failure to observe the technical documentation Improper use Use of unskilled personnel Unauthorized modifications and technical changes Use of unauthorized spare parts or accessories The actual scope of delivery may deviate from the explanations and illustrations de scribed here in the case of special designs use ...

Page 12: ...NG No liability for changes modifications or accessories Accidents and serious injuries Modifications or changes to the delivered product are only permitted after consulta tion with the manufacturer Original spare parts and accessories approved by the manufacturer ensure safety Use of other parts invalidates any liability on the part of the manufacturer Always consult the manufacturer The guarante...

Page 13: ... This section provides an overview of all important for protecting people as well as safe handling and fault free operation Further task related safety instructions are contained in the sections about individual life phases DANGER Danger if the safety instructions are not observed Death or serious injuries Safety regulations must be strictly observed ...

Page 14: ...on EMS modular controls are only approved for indoor use in industrial environments Control operation in EX areas is not permitted For proper operation all information in this manual must be observed Information requirements for compliance with EMC specifications in these instructions must be fully met The system in which the control is installed must meet all requirements of the Machinery Directi...

Page 15: ...roduct even if it is used as intended In order to reduce the risk of personal injury and property dam age and avoid dangerous situations safety instructions listed in other sections of this manual must be observed The system must not be changed improperly WARNING Danger from incorrect replacement and dismantling Accidents and serious injuries Before starting any dismantling work safety instruction...

Page 16: ...e to the work site at all poles Absence of voltage must be checked with a voltage tester immediately before and after use Grounding and short circuiting Parts on which work will be performed at the work place must first be grounded and then short circuited Grounding and short circuiting must be visible from the workplace De viating from the above it is permitted to ground and short circuit near th...

Page 17: ... form of instructions for operating the system During the entire system service life the provider must check whether the operating instructions he has created correspond to the current status of the regulations and if necessary adapt them The provider must clearly regulate and define who is responsible for installation op eration maintenance and cleaning The provider must ensure that all employees...

Page 18: ...ed electrician see VDE 0105 100 Due to their technical training knowledge and experience as well as knowledge of the relevant standards and regulations the qualified electrician is able to work on electrical systems as well as recognize and avoid possible dangers independently The electrician is specially trained for the work environment in which he works and knows the relevant standards and regul...

Page 19: ...lling parts and slipping on slippery sur faces Protective goggles Goggles are used to protect against flying chips and splashing acids Hard hat Helmets are used to protect against falling and flying parts and materials Gloves To protect the hands from friction abrasions punctures or deep injuries as well as from contact with hot surfaces Protective work clothes Protective work clothing is tight fi...

Page 20: ...instructions 18 Safety instructions 4 240_10030005 EN 02 2022 Operating manual 27779165 EN EMS modular controls Respiratory protection To protect against serious and permanent diseases of the respiratory tract ...

Page 21: ...check whether all safety devices are functional and correctly installed Never disconnect or bypass safety equipment Adherence to the following safety information is required in addition to the safety regu lations of the country valid at the location When working on the system the following accident prevention regulations UVV or newly applicable accident prevention regulations principles of prevent...

Page 22: ...duct in case of danger or accident Preventive measures Keep first aid devices first aid kit blankets etc and a fire extinguisher readily avail able Keep access roads open for rescue vehicles Behavior in case of accidents Secure the accident site and call first aiders for first aid Alert the ambulance service Provide first aid ...

Page 23: ... parts may be touched It must be ensured that components are not live switch off the voltage or if this is not possible cover the parts with insulating material Live parts must be secured against unauthorized approach WARNING Danger from illegible signs Accidents or serious injuries Always keep all safety warning and operating instructions in a legible condition INFORMATION Danger if instructions ...

Page 24: ...y relevant hazardous substances in accordance with the ROHS Directive Information about hazardous substances according to 1907 2006 EC REACH regulation According to the current state of knowledge the module does not contain any relevant hazardous substances according to the REACH regulation Information about hazardous substances according to 2019 1021 EU POP reg ulation According to the current st...

Page 25: ...ctions EPLAN of the corresponding control variant Technical drawing of control Depending on the control communication type the following documents should be used Communication type Rail bus CAN Operating instructions for the stationary rail bus module MAXO RG BSx Operating instructions for the mobile rail bus module MAXO RG BMS Communication type SMGM Operating instructions SMGM system manual modu...

Page 26: ...ater Applied standards DIN EN 60529 2014 09 Amendment 1 2017 02 Amendment 2 2019 06 Protection types by housing IP housing DIN EN IEC 60721 3 1 2018 12 Classification of environmental conditions Part 3 1 Classification of groups of environmental parameters and their severities Storage DIN EN IEC 60721 3 2 2018 12 Classification of environmental conditions Part 3 2 Classes of influ encing variables...

Page 27: ...manual 27779165 EN EMS modular controls 240_10030005 EN 02 2022 Guidelines R delegated guidelines DR and implementing decisions DB DIN EN IEC 63000 2019 05 Technical documentation for providing electrical and electronic equip ment with regard to hazardous substance restrictions Document No Document title ...

Page 28: ...ercurrent at the output Environmental conditions Climatic Storage EN 60721 3 1 1K3 25 70 C 6 months 1K3 25 40 C 6 months Transport EN 60721 3 2 2K3 25 70 C Duty cycle 100 EN 60721 3 3 3K3 0 40 C Duty cycle 70 EN 60721 3 3 3K3 0 50 C 40 50 C reduce the rated output current by 2 5 per 1 C Installation altitude Derating 4000 m above sea level 1000 m above sea level reduce the rated out put current by...

Page 29: ...0 VAC at 45 55 Hz AC 432 528 VAC at 54 66 Hz Number of connections 1 Connection designation X1 Connection type Harting Housing insert HAN Q8 0 agg HAN Q 4 2 M c pin Connections X2 1 X2 4 Motor connection Number of connections Depending on the control type Connection designation X2 x x 1 4 Connection type Harting Housing insert HAN Q 8 0 agg HAN Q8 0 BU C socket Missing connections Unavailable conn...

Page 30: ... type 6x M12 4 pin A coded socket 2x M12 4 pin A coded socket Connection description see section 13 2 Connections Front Module IO 2 optional Type Extension module 2 without display Number of connections 8 Connection types Interface types SAFETY FU1 FU2 Incremental encoder Number type 6x M12 5 pin A coded socket 2x M12 8 pin A coded socket Connection description see section 13 2 Connections Front I...

Page 31: ...lasses and moved to the target position using appropriate sensors In the corresponding versions the control also has safety functions see section 10 Safety functions only for controls with integrated safety technology The control with possible peripherals is shown on the following page Adapted to the different application requirements EMS modular controls are divided into three preferred variants ...

Page 32: ...m control PLC 2 Stationary communication module here MAXO RG BSx rail bus CAN 3 Power and communication rails code tape for positioning 4 Data matrix positioning system PXV 5 Mobile communication module here MAXO RG BMS rail bus CAN 6 Remote control for manual operation maintenance 7 EMS modular control schematic representation of the functional units 8 Motors axles With this preferred variant com...

Page 33: ...m control PLC 2 Stationary communication module here MAXO RG BSx rail bus CAN 3 Power and communication rails code tape for positioning 4 Data matrix positioning system PXV 5 Mobile communication module here MAXO RG BMS rail bus CAN 6 Remote control for manual operation maintenance 7 EMS modular control schematic representation of the functional units 7 1 Safety module for STO function via additio...

Page 34: ...view preferred variant 3 1 System control PLC 2 Stationary communication module here MAXO RG SSS SMGM 3 Power and communication rails code tape for positioning 4 Data matrix positioning system PXV 5 Mobile communication module here MAXO RG SMS SMGM 6 Remote control for manual operation maintenance 7 EMS modular control schematic representation of the functional units 8 Motors axles ...

Page 35: ...que shutdown Safe Torque Off SLS Safety limited speed Safely Limited Speed The STO function is implemented differently depending on the communication type Communication type rail bus CAN When using the CAN rail bus communication type the internal safety relay VSR is used to safely switch off the torque Communication type SMGM When using the communication type SMGM the safe torque shutdown is imple...

Page 36: ...tched off im mediately by deactivating the energy supply When the STO function is active it is not possible for the converter to supply torque generating energy to the drive thus prevent ing the axis from restarting unexpectedly This safety function corresponds to stop category 0 non regulated stop according to EN 60204 1 Fig 10 1 Graphic representation of the STO safety function ITEM Description ...

Page 37: ...roperty damages Shutdown or STO activation always only refers to the selected axis The other axes can still be active depending on the parameterization Note that triggering or activation can be delayed via parameter settings After the STO function switches off the voltage there is a physical delay until the axis finally comes to a standstill This depends on the components used and their mass and f...

Page 38: ...signal SLS status accordingly This safe digital signal is evaluated and processed depending on the application Fig 10 2 Graphic representation of the safety monitoring function SLS ITEM Description SLS activation SLS monitoring activated 1 or HIGH checks whether the respective axis is within the permissible parameterized speed limit value SLS status Status of the respective axis 1 or HIGH Axis mov...

Page 39: ...37 Dimensions Dimensions 11 Operating manual 27779165 EN EMS modular controls 240_10030005 EN 02 2022 11 Dimensions Fig 11 1 EMS control unit dimensions measurements in mm ...

Page 40: ...27779165 EN EMS modular controls 12 Overview 12 1 Complete overview Fig 12 1 Overview EMS modular control figure shows control with three SysBus modules Connection Description A Front with SysBus modules B Bottom with feed and power connections C Back with heat sink ...

Page 41: ...les Fig 12 2 Overview of control front with three SysBus modules Further information about contacts used and assignment Specific information about the control connections can be found in section Connec tions Front 47 You will find the displays in the software description manual Connection Description A SysBus module IM 1 B SysBus module IO 1 C SysBus module IO 2 ...

Page 42: ...es Fig 12 3 Overview of control front with two SysBus modules Further information about contacts used and assignment Specific information about the control connections can be found in section Connec tions Front 47 You will find the displays in the software description manual Connection Description A SysBus module IM 1 B SysBus module IO 1 ...

Page 43: ...with a blind cover Further information about contacts used and assignment Specific information about the connections on the control bottom can be found in section Connections Bottom 42 Connection Description X1 Connection for supply 360 524 VAC X2 1 Axis 1 Motor connection 1 assigned here X2 2 Axis 1 Motor connection 2 assigned here X2 3 Axis 2 Motor connection 1 assigned here X2 4 Axis 2 Motor co...

Page 44: ...If there is no safety relay in the control the contact has no function Specification Description Note Function Mains connection supply voltage 360 524 VAC Designation X1 Connection type HAN Q8 0 agg with HAN Q 4 2 M c pin Harting Contact Function Description 1 L1 Outer conductor L1 2 L2 Outer conductor L2 3 L3 Outer conductor L3 4 Release rail reference L3 Release rail safety relay 5 PE Potential ...

Page 45: ...n Note Function Motor connection Designation X2 1 X2 2 X2 3 X2 4 Number of each control type Connection type HAN Q 8 0 agg with HAN Q 8 0 BU c sock et Harting Contact Function Description 1 U Motor phase U output 2 14 SEW brake connection 14 white 3 W Motor phase output W 4 15 SEW brake connection 15 blue 5 TF TH KTY Motor temperature sen sor 6 13 SEW brake connection 13 red 7 V Motor phase output...

Page 46: ... unconnected contacts n c must remain free There must be no signal at these contacts Specification Description Note Function Connection of external braking re sistor Optional Designation X3 Connection type HAN 3EMV agg QB with HAN Q 5 0 F socket Harting Contact Function Description 1 n c Not connected 2 n c Not connected 3 R Connection external braking re sistor 4 n c Not connected 5 R Connection ...

Page 47: ...nation X4 Connection type HAN 3A agg QB with HAN 12Q SMC BE CRA PE with QL socket Harting Contact Function for handheld control Description 1 l1 signal selection switch FU 1 connection DIO1 2 l1 signal selection switch FU 1 Connection DIO2 3 l1 signal selection switch FU 1 Connection DIO5 4 24 VDC supply HBG 24 VDC Supply voltage 24 VDC 5 l3 signal button FU 1 Connection DIO3 6 l4 signal button FU...

Page 48: ...n X5 Fig 13 5 Contact assignment connector X5 Specification Description Note Function Communication Interface Direct connection EtherCAT Designation X5 Connection type M12 4pole D coded socket Alignment as shown in figure Pin Function Description 1 TX Communication 2 RX Communication 3 TX Communication 4 RX Communication ...

Page 49: ...ol type two to a maximum of three SysBus modules are avail able SysBus module IM 1 is always required as a master module Specification Module IM 1 Module IO 1 Module IO 2 Function Master module CAN internal Yes No Not on CAN bus Slave module CAN internal No Yes Not on CAN bus Interfaces Display Yes No No IR interface Yes No No Service interface 1x USB No No Number of connections M12 4x 8x 8x Digit...

Page 50: ...ing tabs are in the 11 o clock position Angled plugs are recommended for the connection ITEM Function Description A DOT matrix display 6 segments Display of status warning and error messages B IR interface For control by remote control C Service interface USB type C socket X10 Communication interface M12 4 pin D coded socket X11 Communication interface M12 4 pin D coded socket X20 IO interface 1 M...

Page 51: ...1 Fig 13 8 Contact assignment connections X10 X11 Specifica tion Description Note Function Communication interface Fieldbus connection Designation X10 X11 Connection type M12 4 pin D coded socket Coding tab at position 11 o clock Contact Function Description 1 TX Communication 2 RX Communication 3 TX Communication 4 RX Communication ...

Page 52: ...20 Fig 13 9 Contact assignment for connection X20 Specifica tion Description Note Function IO interface Designation X20 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage IO 24 VDC 2 IM 1 XIN1 DIN 1 3 GND Supply ground IO 4 IM 1 XIO1 DIN2 DOUT 1 ...

Page 53: ...ed contacts n c must remain free There must be no signal at these contacts Specifica tion Description Note Function SYSCAN interface VCS SMG SAFE connection Designation X53 Connection type M12 8 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage module 24 VDC 2 n c Not connected 3 GND Supply mass module 4 CAN1 H CAN1 HIGH 5 CAN1 L CAN1 LOW 6 CAN G...

Page 54: ...in the 11 o clock position Angled plugs are recommended for the connection ITEM Function Description X21 IO interface 2 M12 4 pin A coded socket X22 IO interface 3 M12 4 pin A coded socket X23 IO interface 4 M12 4 pin A coded socket X24 IO interface 5 M12 4 pin A coded socket X25 IO interface 6 M12 4 pin A coded socket X26 IO interface 7 M12 4 pin A coded socket X60 STO interface 1 M12 4 pin A cod...

Page 55: ...ion type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage IO 24 VDC 2 IO 1 XIN1 DIN 1 3 GND Supply ground IO 4 IO 1 XIO 1 DIN 2 DOUT 1 Specifica tion Description Note Function IO interface Designation X22 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage IO 24 VDC 2 ...

Page 56: ...O 3 DIN 6 DOUT 3 Specifica tion Description Note Function IO interface Designation X24 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage IO 24 VDC 2 IO 1 XIN 4 DIN 7 3 GND Supply ground IO 4 IO 1 XIO 4 DIN 8 DOUT 4 Specifica tion Description Note Function IO interface Designation X25 Connection type M12 4 pin A coded socket ...

Page 57: ...0005 EN 02 2022 Specifica tion Description Note Function IO interface Designation X26 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub Supply voltage IO 24 VDC 2 IO 1 XIN 6 DIN 11 3 GND Supply ground IO 4 IO 1 XIO 6 DIN 12 DOUT 6 ...

Page 58: ...X60 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 STO1 OUT STO1 output 2 STO1 STO1 input 3 STO1 GND STO1 mass 4 STO1 STO1 input Specifica tion Description Note Function STO2 interface Designation X61 Connection type M12 4 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 STO2 OUT STO output 2 STO2 STO2 in...

Page 59: ...sition Angled plugs are recommended for the connection ITEM Function Description X41 Sensor connection M12 8 pin A coded socket X42 Sensor connection M12 8 pin A coded socket X70 FU1 safety interface M12 5 pin A coded socket X71 FU1 safety interface M12 5 pin A coded socket X72 FU1 safety interface M12 5 pin A coded socket X73 FU2 safety interface M12 5 pin A coded socket X74 FU2 safety interface ...

Page 60: ... Sensor connection incremen tal encoder Incremental encoder 1 Designation X41 Connection type M12 8 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub INC1 Supply voltage 24 VDC 2 GNDINC1 Supply ground 3 A_1 Incremental encoder connection 4 A_1 Incremental encoder connection 5 B_1 Incremental encoder connection 6 B_1 Incremental encoder connection 7 n c Not conn...

Page 61: ...pecifica tion Description Note Function Sensor connection incremen tal encoder Incremental encoder 2 Designation X42 Connection type M12 8 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 Ub INC2 Supply voltage 24 VDC 2 GNDINC2 Supply ground 3 A_2 Incremental encoder connection 4 A_2 Incremental encoder connection 5 B_2 Incremental encoder connection 6 B_2 Increm...

Page 62: ...tact assignment for connection X70 Specifica tion Description Note Function SAFE I0 I1 FU1 interface Designation X70 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Internally routed to FU FU con nection 1 F_SS0 FU1 F_SSO 2 F_DI1 FU1 F_DI1 3 GND FU1 GND 4 F_DI0 FU1 F_DIO 5 F_SS1 FU1 F_SS1 ...

Page 63: ...3 17 Contact assignment for connection X71 Specifica tion Description Note Function SAFE I2 I3 FU1 interface Designation X71 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Internally routed to FU 1 F_SS0 FU1 F_SS0 2 F_DI3 FU1 F_DI3 3 GND FU1 GND 4 F_DI2 FU1 F_DI2 5 F_SS1 FU1 F_SS1 ...

Page 64: ...d contacts Malfunctions Unused or unconnected contacts n c must remain free There must be no signal at these contacts Specifica tion Description Note Function SAFE O0 FU1 interface Designation X72 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Internally routed to FU 1 n c Not connected 2 n c Not connected 3 F_DO0_M FU1 F_DO0_M 4 F_DO0_P FU1 F_DO0_P 5 F...

Page 65: ...3 19 Contact assignment for connection X73 Specifica tion Description Note Function SAFE I0 I1 FU2 interface Designation X73 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Internally routed to FU 1 F_SS0 FU2 F_SS0 2 F_DI1 FU2 F_DI1 3 GND FU2 GND 4 F_DI0 FU2 F_DI0 5 F_SS1 FU2 F_SS1 ...

Page 66: ... Fig 13 20 Contact assignment for connection X74 Specifica tion Description Note Function SAFE I2 I3 FU2 interface Designation X74 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 F_SS0 FU2 F_SS0 2 F_DI3 FU2 F_DI3 3 GND FU2 GND 4 F_DI2 FU2 F_DI2 5 F_SS1 FU2 F_SS1 ...

Page 67: ... unused contacts Malfunctions Unused or unconnected contacts n c must remain free There must be no signal at these contacts Specifica tion Description Note Function SAFE O0 FU2 interface Designation X75 Connection type M12 5 pin A coded socket Coding tab at position 11 o clock Contact Function Description 1 n c Not connected 2 n c Not connected 3 F_DO0_M FU2 F_DO0_M 4 F_DO0_P FU2 F_DO0_P 5 FE FU2 ...

Page 68: ...r outputs 14 240_10030005 EN 02 2022 Operating manual 27779165 EN EMS modular controls 14 Circuits Power outputs The connection of the motor outputs X2 x depends on the respective application of the control Please refer to the control EPLAN ...

Page 69: ...ound in section Safety functions only for controls with integrated safety technology 33 Coding Designation Power Option card Communication 11 MCX91A 0032 5E3 4 S00 000 CSO CMM11A 1 10 kW Without EtherCAT 11 MCX91A 0032 5E3 4 S00 000 DI CSL CMM11A 1 10 kW CSL11A EtherCAT 15 MCX91A 0040 5E3 4 S00 000 CSO CMM11A 1 50 kW Without EtherCAT 15 MCX91A 0040 5E3 4 S00 000 DI CSL CMM11A 1 50 kW CSL11A EtherC...

Page 70: ...tion 68 Communication 16 240_10030005 EN 02 2022 Operating manual 27779165 EN EMS modular controls 16 Communication The following communication options are available for the EMS modular controls Railbus CAN SMGM ...

Page 71: ...g faults quickly and specifically Up to 4 axles can be actuated using the communication variant with MAXO RG BMS Fig 16 1 Schematic representation of railbus communication without additional peripherals 1 Ethernet wire from to the stationary PLC 2 Stationary rail bus module MAXO RG BSx 3 Wire to the main segment 4 Wire to the separating segment 5 Conductor line in the busbar system 6 Line with mob...

Page 72: ...er Enable only axle 1 3 Acceleration bit 0 4 Acceleration bit 1 5 Deceleration bit 0 6 Deceleration bit 1 7 Reserve 3 0 7 Position setting LOW byte 4 0 7 Position setting MIDDLE byte 5 0 7 Position setting HIGH byte 6 0 1 DOUT 4 main flange ON 1 0 forward 1 back 2 1 Fault acknowledgment 3 1 Deactivate stop configuration 4 1 Deactivate BCR fault only axle 1 5 1 DOUT 1 main flange ON 6 1 DOUT 2 main...

Page 73: ... DIN 2 main flange 2 DIN 3 main flange 3 DIN 4 main flange 4 DIN 5 main flange 5 DIN 6 main flange 6 DIN 7 main flange 7 DIN 8 main flange 4 0 Auto manual 1 Standstill 2 Speed reached only axle 1 3 Position reached 4 Bar code zero only axle 1 5 BCR communication active only axle 1 6 Fault number bit 8 value range 0 512 7 ON OFF switch 5 0 7 Fault number bit 0 7 6 0 7 Speed LOW byte 7 0 5 Speed bit...

Page 74: ... possible to continue to use other industrial free communica tion systems without impairments The following shows a schematic design Fig 16 2 Schematic diagram SMGM communication without additional peripherals 1 Ethernet wire from to the stationary PLC 2 Stationary SMGM module MAXO RG SSS 3 Mobile SMGM module MAXO RG SMS 4 Ethernet cable 5 EMS modular control 6 HF wires with mobile couplers 2 piec...

Page 75: ...brake 2 1 Speed controller Enable 3 Acceleration bit 0 4 Acceleration bit 1 5 Deceleration bit 0 6 Deceleration bit 1 7 1 Global vehicle release 3 0 7 Position setting LOW byte 4 0 7 Position setting MIDDLE byte 5 0 7 Position setting HIGH byte 6 0 0 forward 1 back 1 1 Fault acknowledgment 2 1 Deactivate stop configuration 3 1 BCR deactivate fault 4 1 DOUT 1 main flange ON 5 1 DOUT 2 main flange O...

Page 76: ...on bit 1 5 Deceleration bit 0 6 Deceleration bit 1 7 Reserve 3 0 7 Position setting LOW byte 4 0 7 Position setting MIDDLE byte 5 0 7 Position setting HIGH byte 6 0 0 forward 1 back 1 Reserve 2 1 Deactivate stop configuration 3 PwrON PosCom request 4 1 DOUT 1 extension flange ON if available 5 1 DOUT 2 extension flange ON if available 1 DOUT 3 extension flange ON if available 7 1 DOUT 4 extension ...

Page 77: ... 0 1 Emergency stop 1 1 Open brake 2 Reserve 3 Acceleration bit 0 4 Acceleration bit 1 5 Deceleration bit 0 6 Deceleration bit 1 7 Reserve 3 0 7 Position setting LOW byte 4 0 7 Position setting MIDDLE byte 5 0 7 Position setting HIGH byte 6 0 0 forward 1 back 1 Reserve 2 1 Deactivate stop configuration 3 PwrON PosCom request 4 Reserve 5 Reserve Reserve 7 Reserve 7 0 Reserve 1 Reserve 2 Reserve 3 R...

Page 78: ...ion High byte 3 0 DIN 1 main flange 1 DIN 2 main flange 2 DIN 3 main flange 3 DIN 4 main flange 4 DIN 5 main flange 5 DIN 6 main flange 6 DIN 7 main flange 7 DIN 8 main flange 4 0 Auto manual 1 Standstill 2 Speed reached 3 Position reached 4 Bar code 0 5 BCR communication active 6 Fault number bit 8 value range 0 512 7 ON OFF switch 5 0 7 Fault number bit 0 7 6 0 7 Speed LOW byte 7 0 5 Speed bit 8...

Page 79: ...ble 1 DIN 2 extension flange 1 if available 2 DIN 3 extension flange 1 if available 3 DIN 4 extension flange 1 if available 4 DIN 5 extension flange 1 if available 5 DIN 6 extension flange 1 if available 6 DIN 7 extension flange 1 if available 7 DIN 8 extension flange 1 if available 4 0 Reserve 1 Standstill 2 Reserve 3 Position reached 4 Reserve 5 PwrON PosCom request response 7 Reserve 5 0 7 Rese...

Page 80: ...ble 1 DIN 2 extension flange 2 if available 2 DIN 3 extension flange 2 if available 3 DIN 4 extension flange 2 if available 4 DIN 5 extension flange 2 if available 5 DIN 6 extension flange 2 if available 6 DIN 7 extension flange 2 if available 7 DIN 8 extension flange 2 if available 4 0 Reserve 1 Standstill 2 Reserve 3 Position reached 4 Reserve 5 PwrON PosCom request response 7 Reserve 5 0 7 Rese...

Page 81: ...ble 1 DIN 2 extension flange 3 if available 2 DIN 3 extension flange 3 if available 3 DIN 4 extension flange 3 if available 4 DIN 5 extension flange 3 if available 5 DIN 6 extension flange 3 if available 6 DIN 7 extension flange 3 if available 7 DIN 8 extension flange 3 if available 4 0 Reserve 1 Standstill 2 Reserve 3 Position reached 4 Reserve 5 PwrON PosCom request response 7 Reserve 5 0 7 Rese...

Page 82: ... request CAN ID 0x19F EMS modular control data to PLC PM data response CAN ID 0x21F Byte Bit Description 0 0 7 Index query PM data 1 0 7 Reserve 2 0 7 Reserve 3 0 7 Reserve 4 0 7 Reserve 5 0 7 Reserve 6 0 7 Reserve 7 0 7 Reserve Byte Bit Description 0 0 7 Mirroring index query PM data 1 0 7 PM data 2 0 7 3 0 7 4 0 7 5 0 7 6 0 7 Vehicle number LOW byte 7 0 7 Vehicle number HIGH byte ...

Page 83: ...81 Type code Type code 17 Operating manual 27779165 EN EMS modular controls 240_10030005 EN 02 2022 17 Type code ...

Page 84: ...er order number 8 figure D Serial No Module serial number E Input Supply voltage and supply frequency F Brk V Number and height of brake voltage G Power1 Power and duty cycle of the first frequency converter H Power2 Power and duty cycle of the second frequency convert er I Temp Operating temperature range of the module J Production information internal K Data matrix code Machine readable material...

Page 85: ...1575 1 0 0 25740733 Description Axes 2 Communication Railbus CAN SMGM Large services FU1 1 5 kW FU2 7 5 kW Safety technology integrated No Designation Item No MAXO RG CUS SPC ST 2 0 1140 2 1 7 25740741 Description Axes 2 Communication Railbus SMGM Small services FU1 1 1 kW FU2 4 0 kW safety technology integrated Yes STO requires 7th rail relay Designation Item No MAXO RG CUS SPC ST 2 0 1575 2 1 7 ...

Page 86: ...d products Report damages immediately to the transport com pany INFORMATION Danger from connection to incorrect mains voltage Damage or destruction of the control The control may only be installed if the information on the control nameplate corre sponds to the voltage network specifications Information about the installation location It is intended that control system installation location EMS veh...

Page 87: ...of a defec tive insulating distance the contact safety is guaranteed through external measures e g dual insulation The control must be grounded via X1 and the housing PE connection at the bottom DANGER Danger due to residual voltage Death or serious injuries Contacts of power connections motors and external brake resistors on the control bottom X2 x X3 can lead to life threatening voltages even af...

Page 88: ...ation of the sensor cable if the cables are too long Cut the sensor cables to length or place them directly folded and bound together with cable clips in the cable harness to prevent interspersion and inductions Ground the EMS vehicle directly via the grounding contact wire Connect all moving parts with low resistance to the traverse or main girder Use cop per meshwork tape or ground wire with a m...

Page 89: ...sors are active in this operating mode and are queried The manual mode is used for repairing maintaining servicing and moving the control system in case of a fault DANGER Danger of injuries due to inactive limit switches Accidents severe injuries as well as property damage Depending on the configuration of the EMS modular control system in manual mode please ensure that no limit switches are activ...

Page 90: ... on the vehicle Tightening torque 6 4 Nm note the screws strength class ITEM Component Description Position A1 A4 Control attachment points A1 A4 Press in sockets M6 M6 press in socket closed blind hole Position B Screw connection structure recommendation 1 Screw M6 Recommendation M6xL 8 8 Allen or Torx 2 Safety disk S M6 Safety washer with spring action 3 Washers M6 Position C Mounting sockets on...

Page 91: ...g the screw connection Accidents with serious injuries and property damage Controls must be screwed to all four fastening points Screw connection must be carried out so the fastening does not loosen during op eration The screw connection must be checked at regular intervals Specifications for the screw in depth must be observed recommended screw in depth ...

Page 92: ...inst short circuits when water penetrates Make sure the plugs and blind covers have a corresponding IP class EN 60529 Installation Harting connectors control bottom Description applies to all Harting connections on the control Plug in the plug or blind cover to the corresponding connection on the control Lock the plug contact flip the connection lever until it engages Installation M12 connectors c...

Page 93: ...h class DANGER Danger from missing PE connection Death or serious injuries Both PE connections from X1 and housing PE connection must always be connected to the equipotential bonding ITEM Component Description Position A Screw construction for the PE connection recommendation 1 Screw M6 Cylinder head screw M6xL Allen or Torx 2 Safety disk S M6 3 Washers M6 4 Eyelet PE connector M6 5 Washers M6 6 C...

Page 94: ...rectly installed locked or fastened according to the specified torque All unused connections are provided with suitable blind covers locked or fastened according to the specified torque All plug connections or blind covers have the necessary IP protection EN 60529 The control and its connected components show no signs of damage The specified environmental conditions are observed see section Techni...

Page 95: ...tors are connected correctly Whether the control and message rail phases are connected correctly communica tion type rail bus Whether the saved configuration is valid for the application Whether the uploaded parameters are optimally aligned to the motors Information about normal operation handheld control HBG not connected If the handheld control is not plugged in the safety contacts must be bridg...

Page 96: ... failures during commissioning please refer to section Malfunctions 97 Switch the control system on Switch on the mains voltage the control unit is ready for operation after about 1 s The control systems acts in accordance with the parameterized specifications signals at the digital inputs The current operating status or a status message are shown on the display A flashing display means a failure ...

Page 97: ...ntrols 240_10030005 EN 02 2022 20 6 Operation During operation the controls automatically carry out all actions according to the pro gramming This means no actions are necessary during automatic operation In the event of a failure proceed as described in section Malfunctions 97 ...

Page 98: ...t other system parts can lead to tension or automatic processes are running Only take commissioning when the system is switched off or in a seg ment of the system that is switched off Note there may be dangerous stored charges on the terminals Wait five minutes af ter switching off the control system voltage before carrying out any further activities Procedure De energize the system or part of the...

Page 99: ...1 1 Safety notes WARNING Danger of injury due to improper troubleshooting Improper troubleshooting can result in serious personal injury or property damage Ensure that there is sufficient clearance before starting work Switch off the power supply check that no voltage is present and protect it from be ing switched on again ...

Page 100: ...d to persons or property immediately switch on the safety device Identify cause of fault Inform person responsible at site of use Inspection and maintenance work described in this technical documentation must be carried out on a regular basis and documented location spare part work carried out date inspector s name System fault elimination may only be carried out by trained qualified and authorize...

Page 101: ...99 Malfunctions Malfunctions 21 Operating manual 27779165 EN EMS modular controls 240_10030005 EN 02 2022 21 3 Error messages You can find the error messages in the software description manual ...

Page 102: ...in a module then the module must be sent to SEW for repair Please contact the SEW customer service see section Customer service 9 The following information is requiredto guarantee fast repair Customer name address Designation of the system in which the assembly is installed Name of a contact person for poss questions Module designation and serial number Error description which defective pattern wa...

Page 103: ...llowing instructions must be observed DANGER Electric current hazard Death or serious injuries No live parts may be touched It must be ensured that components are not live switch off the voltage or if this is not possible cover the parts with insulating material Live parts must be secured against unauthorized approach Inspection and maintenance work described in this technical documentation must b...

Page 104: ...ious injuries Before starting work ensure there is sufficient space for assembly Pay attention to order and cleanliness in the workplace Follow the procedure according to section Safety instructions 11 before starting work WARNING Danger if persons are inadequately qualified Accidents and serious injuries Have all work performed only by persons qualified for the task Inadequately qualified persons...

Page 105: ...ckaging 23 2 Transport inspection Delivery must be checked for completeness and transport damage upon receipt In case of visible transport damage proceed as follows Do not accept the delivery or only accept it with reservations Note extent of damage on the transport documents or on the transporter s delivery slip INFORMATION Risk of damage in transit Destruction or damage to the assembly loss of w...

Page 106: ... It must be ensured that components are not live switch off the voltage or if this is not possible cover the parts with insulating material Live parts must be secured against unauthorized approach 24 1 1 Disassembly When dismantling it is essential to observe the instructions described in section Safety instructions 11 WARNING Danger from incorrect replacement and dismantling Death or serious inju...

Page 107: ...isposed of must be separated according to their nature Currently valid on site regulations must be observed Overview of parts sub assemblies that must be disposed of separately Electronic scrap circuit boards Batteries and accumulators Plastic Sheet metal Copper Aluminum Information about the WEEE Directive 2021 19 EU The WEEE Directive does not apply to the products described because the products...

Page 108: ...s labels etc Data stored in the assembly device electronically stored data etc Meaning of the symbol crossed out garbage can with black bars Fig 24 1 Symbol Symbol according to WEEE Directive 2012 19 EU or ElektroG Germany The symbol is placed on the nameplate where possible Otherwise the symbol can be found on the product packaging Meaning of the symbol Symbol for the separate collection of elect...

Page 109: ...030005 EN 02 2022 Index C Communication type PCB 69 SMGM 72 Copyright protection 9 E EMC 86 F First commissioning 93 G Grounding 85 I Information about the instructions 6 O Operating modes 87 R Repair 100 S safety aspects 11 Switch on sequence 94 Symbol explanations 7 ...

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