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6.3.

Achievable Safety Levels of DS23x

To achieve a maximum of SIL3/PLe on system-level, no certificated sensors are required to fulfil the
integrity of the device. When using standard sensors, only the required safety level (by complying the
safety-related characteristics SFF, HFT, Type A/B, PFH, PFD resp. category, DCavg and MTTFd) and
systematic safety integrity must be ensured for the entire protection circuit. Software programs (like
SISTEMA) are very helpful for creating such evaluations of safety-related machine control systems
according to the EN ISO 13849 norm.

Mode Sensor1

Sensor2

Function

Achievable
Safety Level

0

SinCos encoder at
[X6 | SINCOS IN 1]

SinCos encoder at
[X7 | SINCOS IN 2]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

1

SinCos encoder at
[X6 | SINCOS IN 1]

HTL encoder (A, B, 90°)
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

2

SinCos encoder at
[X6 | SINCOS IN 1]

HTL encoder (A) at
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****

3

HTL encoder (A, B, 90°)
[X10 | CONTROL IN]

HTL encoder (A, B, 90°)
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

4

HTL encoder (A, B, 90°)
[X10 | CONTROL IN]

HTL encoder (A) at
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****

5

HTL encoder (A) at
[X10 | CONTROL IN]

HTL encoder (A) at
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****

6

SinCos encoder at
[X6 | SINCOS IN 1]

RS422 encoder at
[X9 | RS422 IN 2]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

7

RS422 encoder at
[X8 | RS422 IN 1]

RS422 encoder at
[X9 | RS422 IN 2]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

8

RS422 encoder at
[X8 | RS422 IN 1]

HTL encoder (A, B, 90°)
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe
SIL3 / PLe

9

RS422 encoder at
[X8 | RS422 IN 1]

HTL encoder (A) at
[X10 | CONTROL IN]

Speed
Direction
Standstill

SIL3 / PLe
SIL3 / PLe ****
SIL3 / PLe ****

**** A safety level can only be achieved in these cases, if it is physically ensured that there only
can be only one direction of rotary and linear movement. This can be realized for example by
using a self-locking gearbox.

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Содержание DS230 Series

Страница 1: ...able display and programming unit BG230 for parametrization and indication Inputs for 2 SinCos encoders 2 RS422 incremental encoders 2 HTL PNP incremental encoders proximity switches or control signal...

Страница 2: ...c sn ag 06 15 First edition series Rechtliche Hinweise All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH Any reproduction modification usage or publ...

Страница 3: ...236 Block Diagram 10 4 4 DS236 Connections 10 4 5 DS240 Block Diagram 11 4 6 DS240 Connections 11 4 7 DS246 Block Diagram 12 4 8 DS246 Connections 12 5 Description of Connections 13 5 1 Power Supply 1...

Страница 4: ...tional Mode 8 44 6 15 Operational Mode 9 45 7 Start Up the Unit 46 7 1 Setup by PC 47 7 2 Setup by the Programming Module BG230 48 7 3 Parameter Menu Overview 49 7 4 Parameter Description 51 8 Start U...

Страница 5: ...he right to modify the hardware software or operation manual at any time and without prior notice Therefore there might be minor differences between the unit and the descriptions in operation manual T...

Страница 6: ...cross sections for wiring are described in the technical specifications see chapter 11 Before first start up it must be ensured that all connections and wires are firmly seated and secured in the scr...

Страница 7: ...at opportunity to save costs for expensive and certified sensors Also the costs for new installations and adjustments can be reduced significantly by using the existing components and wiring Typical e...

Страница 8: ...N 60715 Inputs 3 2 Inputs for SinCos encoders 2 Inputs for incremental RS422 encoders 2 Inputs for HTL PNP incremental encoders or HTL PNP control signals 4 1 Input for SinCos encoder with SIL3 PLe 2...

Страница 9: ...Ds230_03a_oi_e doc Jun 15 Page 9 100 4 Block Diagrams and Connections 4 1 DS230 Block Diagram 4 2 DS230 Connections...

Страница 10: ...Ds230_03a_oi_e doc Jun 15 Page 10 100 4 3 DS236 Block Diagram 4 4 DS236 Connections...

Страница 11: ...Ds230_03a_oi_e doc Jun 15 Page 11 100 4 5 DS240 Block Diagram 4 6 DS240 Connections...

Страница 12: ...Ds230_03a_oi_e doc Jun 15 Page 12 100 4 7 DS246 Block Diagram 4 8 DS246 Connections...

Страница 13: ...nCos Splitter Output X6 SINCOS IN 1 5 3 SinCos Inputs X7 SINCOS IN 2 5 3 SinCos Inputs X8 RS422 IN 1 5 4 RS422 Inputs X9 RS422 IN 2 5 4 RS422 Inputs X10 CONTROL IN 5 5 HTL Control Inputs X11 5 12 Inte...

Страница 14: ...e range from 18 30 VDC Ripple 10 24 V External fuse 2 5 A medium time lag required A separate power pack must cover the following requirements The switch on current of the unit is maximum 2 5 A The co...

Страница 15: ...2 Sensor2 X7 4 X7 5 X9 1 X9 2 X9 1 X9 2 Examples for the connection of encoders and the encoder supply can be found in chapter 6 When powering up the encoder supply the maximum input current of the s...

Страница 16: ...pply voltage is approximate 2 V below the 18 30 VDC power supply at terminal X3 The maximum load of encoder supply is 200 mA each channel Sensor1 and Sensor2 Supply SinCos inputs RS422 inputs HTL inpu...

Страница 17: ...ould rotate but the unit is incapable to detect speed or speed differences In order to detect this error the operator can use e g a control output of the unit which indicates standstill see Section 7...

Страница 18: ...are switched via 1 relay An external encoder supply must be done in each case via a relay which is triggered by the auxiliary voltage of the unit The operator must ensure that the plant cannot reach a...

Страница 19: ...always all existing signal lines SIN SIN COS and COS The internal SinCos encoder signal monitor verifies the Common Mode range of each signal line and is capable to detect cable fractures An evaluatio...

Страница 20: ...RS422 format at the terminal strips X8 and X9 The RS422 input channels A and A resp B and B are internally terminated by a dynamic terminating circuit 220 pF 120 ohm It is mandatory to connect up all...

Страница 21: ...X10 5 unconnected direction signal e g to evaluate a gear wheel by connecting a proximity switch The inputs X10 3 resp X10 5 may be unconnected internal pull down or can be used for a static direction...

Страница 22: ...y a further target device The signal delay time between SinCos input and SinCos output is approximately 200 ns The channels SIN and SIN resp COS and COS must be terminated by 120 Ohm load resistors at...

Страница 23: ...input signal SinCos resp HTL always incremental RS422 square wave pulses are generated at X4 RS422 OUT The signal delay time between the RS422 input and the RS422 output is approximately 600 ns In ca...

Страница 24: ...utput is 0 mA The connection to the Analog Output is only safe if the following device is capable to detect the error state of the safety unit In case of errors the operator is responsible to ensure s...

Страница 25: ...the output level is about 2 V below the supply voltage connected to terminal X3 24V IN Each output has a push pull output stage and short circuit protection When switching inductive loads additional e...

Страница 26: ...conditions of the relay output are freely programmable by parameters see chapter 7 4 5 and 7 4 6 Further the opener is also integrated within all monitoring functions In case of an error the contact c...

Страница 27: ...lf Test Message booting of the start up is faster 3 ON Normal Operation Parameter access disabled OFF Programming Mode allows access to the Parameters by display unit or PC Programming Mode DIL switch...

Страница 28: ...erves for communication between the unit and an optional programming and display unit BG320 which can be plugged on the front 8 pin female connector X11 The programming and display unit BG230 and the...

Страница 29: ...a PC or a super ordinate controller a serial interface simulation is accessible at the USB port For connection a standard USB cable with a Type B connector is used The USB cable is available as an opt...

Страница 30: ...is running up self test in progress During normal operation error released by the process divergence of frequencies etc SLOW DIL1 OFF unit state Factory Settings DIL3 OFF unit state Programming Mode F...

Страница 31: ...ailable 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Not available Not available 4 HTL encoder A B 90 X10 CONTROL IN HTL encoder A at X10 CONTROL IN Not available Not availabl...

Страница 32: ...s In Case of DS24x only operational mode 0 see chapter 8 4 1 Parameter 000 has to be used Mode Sensor1 Sensor2 Control1 Control2 0 SIL3 PLe SinCos encoder X6 SINCOS IN 1 Sensor1 and Sensor2 are intern...

Страница 33: ...coder A at X10 CONTROL IN Speed Direction Standstill SIL3 PLe SIL3 PLe SIL3 PLe 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Speed Direction Standstill SIL3 PLe SIL3 PLe SIL3...

Страница 34: ...F HFT Type A B PFH PFD resp category DCavg and MTTFd and systematic safety integrity must be ensured for the entire protection circuit Software programs like SISTEMA are very helpful for creating such...

Страница 35: ...This mode only DS23x is used to evaluate a dual channel system equipped with two SinCos sensors resp Encoders which must be performed in accordance to chapter 5 3 In this operational mode a DS230 var...

Страница 36: ...plementary Achievable Safety Level Speed SIL3 PLe Direction SIL3 PLe Standstill SIL3 PLe This mode only DS24x is exclusively used to connect a SIL3 resp PLe certificated SinCos sensor encoder which mu...

Страница 37: ...r a combination of a SinCos encoder and an incremental dual channel HTL encoder is used The SinCos encoder must be performed in accordance to chapter 5 3 and the incremental encoder to chapter 5 5 In...

Страница 38: ...his mode only DS23x allows to evaluate a dual channel system equipped with two different encoder types Therefor a combination of a SinCos encoder and an incremental single channel HTL encoder is used...

Страница 39: ...e This mode only DS23x allows to evaluate a dual channel system equipped with two incremental dual channel HTL encoders The encoder must be performed in accordance to chapter 5 5 A DS230 variant repro...

Страница 40: ...be realized for example by using a self locking gearbox This mode only DS23x allows to evaluate a dual channel system equipped with two different encoder types Therefor a combination of an incremental...

Страница 41: ...inear movement This can be realized for example by using a self locking gearbox This mode only DS23x allows to evaluate a dual channel system equipped with two identical encoder types Therefor a combi...

Страница 42: ...el system equipped with two different encoder types Therefor a combination of a SinCos and a RS422 TTL encoder is used The SinCos encoder must be performed in accordance to chapter 5 3 and the RS422 T...

Страница 43: ...vel Speed SIL3 PLe Direction SIL3 PLe Standstill SIL3 PLe This mode only DS23x allows to evaluate a dual channel system equipped with two identical RS422 TTL incremental encoders The encoder must be p...

Страница 44: ...dual channel system equipped by two different incremental encoder resp sensor types Therefore an incremental RS422 TTL and a dual channel HTL encoder are used The RS422 TTL encoder must be performed i...

Страница 45: ...This can be realized for example by using a self locking gearbox This mode only DS23x is used to evaluate a dual channel system equipped by two different incremental encoder resp sensor types Therefor...

Страница 46: ...the DIL switch slider 3 to its OFF position unit state Programming Mode Connect the unit to the OS6 0 operator surface or alternatively to a BG230 programming and display unit Programming Mode DIL sw...

Страница 47: ...is also available for download on www motrona com After a successful installation of the operator software OS6 0 and the USB driver see document installation USB driver the PC can be connected via a...

Страница 48: ...done by the programming module BG230 The optional display and programming module BG230 is used for Parameter settings and diagnosis without a PC It is easily connectable by plugging onto the front of...

Страница 49: ...029 Preselect OUT2 H 003 F1 F2 Selection 030 Preselect OUT2 L 004 Div Switch f 031 Preselect OUT3 H 005 Div Value 032 Preselect OUT3 L 006 Div f Value 033 Preselect OUT4 H 007 Div Calculation 034 Pre...

Страница 50: ...me OUT2 Serial Menu 046 Pulse Time OUT3 068 Serial Unit No 047 Pulse Time OUT4 069 Serial Baud Rate 048 Pulse Time REL1 070 Serial Format 049 Hysteresis OUT1 071 Serial Page 050 Hysteresis OUT2 072 Se...

Страница 51: ...setting must be 1 016 Position Drift1 Position Drift1 and Position Drift2 must be equal 017 Phase Err Count1 Phase Err Count1 and Phase Err Count2 must be equal 020 Direction2 Direction1 and Direction...

Страница 52: ...X10 CONTROL IN available for control signals Not available 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Not available Not available 4 HTL encoder A B 90 X10 CONTROL IN HTL enc...

Страница 53: ...e unit The setting is valid for both inputs channels 0 001 9 999 sec 0 001 002 Wait Time Defines the period time of the lowest frequency resp the waiting time between 2 rising edges which is detected...

Страница 54: ...rameter 000 is monitored and processed as basic frequency The basic frequency selection affects the following outputs Analog Output Control Outputs Relay Outputs And thus the following menus preselect...

Страница 55: ...05 Div Value maximum Divergence Defines the maximum allowed percentage divergence between the frequencies of sensor1 and sensor2 If this value is exceeded the unit switches to an error status see para...

Страница 56: ...nit reacts immediately to each frequency deviation 10 Medium filter The unit tolerates temporary deviations and fluctuations e g caused from torsion or mechanical vibrations and reacts delayed to devi...

Страница 57: ...rror status 1 Normal state Before exiting the Programming Mode the Parameter always must be set to 1 2 Error clearing All errors reported by the unit will be reset A direct changeover between 0 and 2...

Страница 58: ...tputs Relay Outputs And thus the following menus preselected thresholds in the Preselect Menu see chapter 7 4 5 switching behaviors in the Switching Menu see chapter 7 4 6 analog output in the Analog...

Страница 59: ...00 0 017 Phase Err Count1 faulty pulse counting limit Important notes for DS240 DS246 see chapter 7 4 1 The DS unit is able to detect incorrect pulse sequences as well as faulty phase positions The er...

Страница 60: ...specified by the Operation Mode 0 1 0 020 Multiplier2 1 10 000 1 021 Divisor2 1 10 000 1 022 Position Drift2 0 100 000 0 023 Phase Err Count2 1 1 000 10 024 Set Frequency2 500 000 0 500 000 0 Hz 0 025...

Страница 61: ...mit values for the set up mode and production mode A switchover between the switching points High and Low can only be released by an external command resp by using one of the both control inputs at te...

Страница 62: ...6 50 000 032 Preselect OUT3 L Lower switching point of output OUT3 X2 5 6 60 000 033 Preselect OUT4 H Upper switching point of output OUT4 X2 7 8 70 000 034 Preselect OUT4 L Lower switching point of o...

Страница 63: ...ameter 027 ff Additional features which can be assigned to the output S self locking function see parameter 057 Lock Output H switching hysteresis see parameter 049 ff Hysteresis A start up delay see...

Страница 64: ...ection values S H A 6 f Preselection Output switches in event of leaving the frequency band Preselection Hysteresis Only used with positive preselection values S H A 7 f 0 Output switches if a positiv...

Страница 65: ...ion Hysteresis Only used with positive preselection values S H A 7 f 0 Output switches if a positive frequency e g clockwise direction is detected The directional information will be deleted immediate...

Страница 66: ...044 ff no self locking function Parameter 057 can be assigned to the respective output 049 Hysteresis OUT1 Percental hysteresis of the adjusted switching point see parameter 027 and 028 0 100 0 0 050...

Страница 67: ...nds 7 start up delay 64 seconds 8 start up delay 128 seconds 9 automatically until the value has been exceeded for the first time see chapter 7 4 5 0 9 0 The defined delay time window is valid for all...

Страница 68: ...ts 1 to 5 are used to assign the lock function to the respective outputs The highest valued bit 6 determines if a locked output can be released exclusively by an external input signal bit 6 0 see chap...

Страница 69: ...o assign the desired switching conditions to the selected outputs The outputs are selectable by using a 5 bit binary code Output RELAY OUT4 OUT3 OUT2 OUT1 Bit 5 4 3 2 1 Binary 10000 01000 00100 00010...

Страница 70: ...eration both tracks generally must have opposite conditions but in the test mode arbitrary output conditions can be simulated The output conditions are assignable by a 9 bit binary code 0 511 0 OUT RE...

Страница 71: ...asons both control inputs are complementary The switching conditions active HIGH or active LOW can be defined by parameter 063 Basically always the complementary signal of the direct input must be app...

Страница 72: ...RG 10 Freeze Frequency1 Freezes the actual encoder frequency of Sensor1 stat PRG 11 Freeze Frequency2 Freezes the actual encoder frequency of Sensor2 stat PRG 12 Freeze Frequency12 Freezes the encoder...

Страница 73: ...moving from LOW to HIGH X10 3 3 dynamic function active when moving from HIGH to LOW X10 2 and simultaneously moving from LOW to HIGH X10 3 0 3 0 064 Input 2 Function assigns a control function to inp...

Страница 74: ...d 5 19 200 Baud 6 38 400 Baud 7 56 000 Baud 8 57 200 Baud 9 76 800 Baud 10 115 200 Baud 0 10 0 070 Serial Format format of the serial data 0 9 0 0 7 data bits parity even 1 stop bit 1 7 data bits pari...

Страница 75: ...or the transmission of the initialization values to the operator surface OS6 0 respectively to the BG230 programming and display unit 0 The initialization values will be transmitted with 9600 baud Aft...

Страница 76: ...t frequency sensor1 or sensor2 is exported at terminal X4 RS422 OUT Which input is assigned to which channel sensor1 or sensor2 is set in the operating mode see chapter 7 4 2 parameter 000 0 Sensor1 A...

Страница 77: ...the conversion range in Hz Defines the final frequency at which the analog output should set its final value of 20 mA 100 000 080 Analog Gain gain of the D A converter in With a setting of 100 the fr...

Страница 78: ...The unit must be in a mechanically and technically perfect condition The unit must be snapped onto a 35 mm DIN rail according to EN 60715 by using the clip at the rear It must be ensured that the per...

Страница 79: ...the device function and the error detection time No Parameter Notice 000 Operational Mode 001 Sampling Time 002 Wait Time 003 F1 F2 Selection 010 Power up Delay 016 Position Drift1 017 Phase Err Coun...

Страница 80: ...be used only if the RS422 output is used The RS422 output essentially depends on the following parameters No Parameter Notice 000 Operational Mode 074 RS Selector 8 2 5 Analog Output Settings These pa...

Страница 81: ...39 Switch Mode OUT1 044 Pulse Time OUT1 049 Hysteresis OUT1 054 Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 Input2 Configuratio...

Страница 82: ...Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 Input2 Configuration OUT4 No Parameter Notice 000 Operational Mode 003 F1 F2 Select...

Страница 83: ...Preselect REL1 L 043 Switch Mode REL1 048 Pulse Time REL1 053 Hysteresis REL1 054 Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 I...

Страница 84: ...ively to an optional BG320 programming and display unit the operator surface OS6 0 must be installed correctly and running on the PC all Parameters must be set to correct values Commissioning may only...

Страница 85: ...he switching characteristics and command assignments for the HTL inputs defined 2 Is the source input for the RS422 splitter output selected see parameter 074 3 Is the analog output scaled with a star...

Страница 86: ...reduction between both encoders then the higher frequency must be adjusted to the lower one For this calculation the scaling factors see chapter 7 4 3 are used In the example above the frequency 2 is...

Страница 87: ...Ds230_03a_oi_e doc Jun 15 Page 87 100 By scaling the frequency 1 both internally calculated frequencies are approximately equal and the calculated ratio is close to 0...

Страница 88: ...It is imperative to test the function of the relay and the evaluation in the target device finally The user of the equipment is responsible for ensuring all relevant parts of the system to a safe sta...

Страница 89: ...no more current range 4 20 mA is given All digital outputs are set to LOW no more inversion between Out X and Out X No more incremental signals are available at the RS422 output Tri State with pulldo...

Страница 90: ...de H 0000 2000 H 0000 0020 GPI Error Error of the control inputs See runtime error error code H 0000 2000 H 0000 0040 CAP Error Internal error Switch off and switch on the unit If the error repeats co...

Страница 91: ...0010 External Supply BG Error Error of the supply of the BG230 Remove the BG230 Switch off and switch on the unit If error code is off external error e g short circuit in the BG230 If error code is s...

Страница 92: ...r Error of the phase of Sensor1 Check parameter 017 Switch off and switch on the unit H 0002 0000 Phase Channel 2 Error Error of the phase of Sensor2 Check parameter 024 Switch off and switch on the u...

Страница 93: ...9 5 Error Detection Time Basically it is not possible to specify an exact error detection time because the error detection depends on many factors Reaction time The error detection time depends among...

Страница 94: ...nt1 1 1000 10 4 0 B7 018 Set Frequency1 5000000 5000000 0 87 1 B8 019 Reserved 0 10000 1000 5 0 B9 020 Direction2 0 1 0 1 0 C0 021 Multiplier2 1 10000 1 5 0 C1 022 Divisor2 1 10000 1 5 0 C2 023 Positi...

Страница 95: ...1000 0 4 1 F2 053 Hysteresis REL1 0 1000 0 4 1 F3 054 Startup Mode 0 10 0 1 0 F4 055 Startup Output 0 31 0 2 0 F5 056 Standstill Time 0 9999 0 4 3 F6 057 Lock Output 0 31 0 2 0 F7 058 Action Output 0...

Страница 96: ...Parameter Min Value Max Value Default Characters Decimal Places Serial Code 078 Analog Start 5000000 5000000 0 87 1 H5 079 Analog End 5000000 5000000 100000 87 1 H6 080 Analog Gain 1 1000 100 4 0 H7...

Страница 97: ...HTL encoders proximity switches or control commands HTL PNP 10 30 V max 15 mA max 1 kHz max 250 kHz X10 screw terminal 5 pin 1 5 mm SinCos output safety related Splitter output Signal tracks Amplitude...

Страница 98: ...characteristic data Classification Approved Safety Function System structure System architecture DCavg SFF MTTFD PFH SD SU DD DU Safety functions SIL3 PLe depends on the used encoder input signals Cer...

Страница 99: ...Ds230_03a_oi_e doc Jun 15 Page 99 100 11 1 Dimensions inclusive BG230 at front Front Rear DS230 BG230 option...

Страница 100: ...Ds230_03a_oi_e doc Jun 15 Page 100 100 12 Certificate...

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