Motrona DS230 series, DS240 series Operating Instructions
Safety Manual
DS230 / DS240 series
Safety monitor for SinCos and incremental encoders / sensors
Available devices:
DS230: All inputs and outputs as well as signal splitter function
DS236: All inputs and outputs, but without signal splitter function
DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function
DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter
Product features:
• Monitoring underspeed, overspeed, standstill and direction of rotation
• SIL3 and PLe certification
• Safety functions equivalent to EN61800-5-2 (SS1, SS2, SOS, SLS, SDI, SSM)
• Mounting to 35 mm top hat rail (according to EN 60715)
• USB interface for simple parametrization by the OS 6.0 operator surface
• Optional available 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 signals
• Outputs: 1 Relay Output 5 … 36 VDC (NO), (safety related)
1 Analog Output 4 … 20 mA, (safety related)
4 Control HTL Outputs, (safety related)
• Signal splitter: 1 SinCos Splitter Output, (safety related)
1 RS422 Splitter Output, (safety related)
motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, info@motrona.com, www.motrona.com
Version:
Description:
Ds23001a_oi_e.doc/mb/07/14
First edition pre series
Ds23003a_oi_e.doc/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 publication in other electronic and printed media as well as in the
internet requires prior written authorization by motrona GmbH.
Ds230_03a_oi_e.doc / Jun-15 Page 2 / 100
Table of Contents
1. Safety Instructions and Responsibility ......................................................... 5
1.1. General Safety Instructions .................................................................................. 5
1.2. Use according to the intended purpose ................................................................ 5
1.3. Installation ............................................................................................................ 6
1.4. Cleaning, Maintenance and Service Notes .......................................................... 6
2. Introduction ................................................................................................. 7
3. Available Models ........................................................................................ 8
4. Block Diagrams and Connections ................................................................. 9
4.1. DS230 Block Diagram ........................................................................................... 9
4.2. DS230 Connections ............................................................................................... 9
4.3. DS236 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 ...................................................................................................... 14
5.2. Encoder Supply ................................................................................................... 15
5.3. SinCos-Inputs ...................................................................................................... 19
5.4. RS422-Inputs ....................................................................................................... 20
5.5. HTL / Control Inputs ............................................................................................ 21
5.6. SinCos-Splitter-Output ........................................................................................ 22
5.7. RS422-Splitter-Output......................................................................................... 23
5.8. Analog-Output 4 to 20 mA .................................................................................. 24
5.9. Control-Outputs ................................................................................................... 25
5.10. Relay-Output ....................................................................................................... 26
5.11. DIL switch ........................................................................................................... 27
5.12. Interface for Display Unit BG230 ........................................................................ 28
5.13. USB Interface for the OS6.0 Operator Surface ................................................... 29
5.14. LEDs / Status Indication...................................................................................... 30
Ds230_03a_oi_e.doc / Jun-15 Page 3 / 100
6. Operational Modes .....................................................................................31
6.1. Operational Modes of DS23x types .................................................................... 31
6.2. Operational Mode of DS24x types ...................................................................... 32
6.3. Achievable Safety Levels of DS23x .................................................................... 33
6.4. Achievable Safety Level of DS24x ...................................................................... 34
6.5. „Operational Mode“ = 0 (DS23x) ........................................................................ 35
6.6. „Operational Mode“ = 0 (DS24x) ........................................................................ 36
6.7. „Operational Mode“ = 1...................................................................................... 37
6.8. „Operational Mode“ = 2...................................................................................... 38
6.9. „Operational Mode“ = 3...................................................................................... 39
6.10. „Operational Mode“ = 4...................................................................................... 40
6.11. „Operational Mode“ = 5...................................................................................... 41
6.12. „Operational Mode“ = 6...................................................................................... 42
6.13. „Operational Mode“ = 7...................................................................................... 43
6.14. „Operational 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-Up the Plant .......................................................................................78
8.1. Cabinet installation ............................................................................................. 78
8.2. Parametrization ................................................................................................... 79
8.3. Preparation before first start-up ......................................................................... 84
8.4. Checklist for Parameter Settings ........................................................................ 85
8.5. Definition of the Directions ................................................................................. 85
8.6. Sensor Channel Adaption ................................................................................... 86
8.7. Completion of Commissioning ............................................................................ 88
9. Error Detection ...........................................................................................89
9.1. Error Representation ........................................................................................... 89
9.2. Initial Error .......................................................................................................... 90
9.3. Runtime Error ...................................................................................................... 91
9.4. Error Clearing ...................................................................................................... 93
9.5. Error Detection Time ........................................................................................... 93
10. Parameter List ............................................................................................94
11. Technical Specifications .............................................................................97
11.1. Dimensions ......................................................................................................... 99
12. Certificate ................................................................................................ 100
Ds230_03a_oi_e.doc / Jun-15 Page 4 / 100
1. Safety Instructions and Responsibility
1.1. General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and hints
about the installation, function and usage. Non-observance can result in damage and/or impairment
of the functions to the unit or the machine or even in injury to persons using the equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use these
manual. The unit must be installed, connected and put into operation by a qualified electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property and
for consequential damage, due to incorrect handling, installation and operation. Further claims, due
to errors in the operation manual as well as misinterpretations are excluded from liability.
In addition the manufacturer reserves the 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.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.
1.2. Use according to the intended purpose
The unit is intended exclusively for use in industrial machines, constructions and systems. Nonconforming usage does not correspond to the provisions and lies within the sole responsibility of the
user. The manufacturer is not liable for damages which are arisen through unsuitable and improper
use. Please note that device may only be installed in proper form and used in a technically perfect
condition in accordance to the technical specifications (see chapter 11). The device is not suitable
for operation in explosion-proof areas or areas which are excluded by the EN 61010-1 standard.
Ds230_03a_oi_e.doc / Jun-15 Page 5 / 100
1.3. Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further
it must be ensured that no danger can arise by touching the disconnected voltage-sources.
Devices which are supplied by AC-voltages, must be connected exclusively by switches, respectively
circuit-breakers with the low voltage network. The switch or circuit-breaker must be placed as near
as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated from
dangerous electrical cables (SELV circuits) by using double resp. increased isolation.
All selected wires and isolations must be conforming to the provided voltage- and temperatureranges. Further all country- and application-specific standards, which are relevant for structure, form
and quality of the wires, must be ensured. Indications about the permissible wire 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 screw terminals. All (inclusively unused) terminals must be fastened by turning the relevant
screws clockwise up to the stop.
Overvoltage at the connections must be limited to values in accordance to the overvoltage category
II.
For placement, wiring, environmental conditions as well as shielding and earthing/grounding of the
supply lines the general standards of industrial automation industry and the specific shielding
instructions of the manufacturer are valid. Please find all respective hints and rules on
www.motrona.com/download.html --> [General EMC Rules for Wiring, Screening and Earthing].
1.4. Cleaning, Maintenance and Service Notes
To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff or
assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures or
malfunctions the device must be shipped for back to the manufacturer for checking, adjustment or
reparation. Unauthorized opening and repairing can have negative effects or failures to the
protection-measures of the unit.
Ds230_03a_oi_e.doc / Jun-15 Page 6 / 100
2. Introduction
This series of speed monitors is suitable for safety-related monitor tasks e. g. over-speed, underspeed, standstill and direction of rotation. This SIL3/PLe certified generation of devices was
developed to achieve functional safety by supporting a wide range of sensors and encoders in
different combinations.
Due to its innovative multifunctional inputs these devices are perfectly suitable for the retrofitting of
existing plants and machines which are using “non-safe“ sensors. This offers a great 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 examples are centrifuges, cranes, wind power or hauling plants.
Special features:
Additionally suitable for a "Set-Up Operation",
e. g. for manual settings at plants with open doors and reduced speed
All models are safety-related and dually certified according to
EN 61508, EN 62061 / SIL3 and EN ISO 13849-1 Cat. 3 / Ple,
even when using “non-safety-related” standard sensors or encoders
Wide input frequency range and fast response time
Very versatile range of possible monitoring functions
Easy setup by PC via USB or by the optional programming module BG230
Ds230_03a_oi_e.doc / Jun-15 Page 7 / 100
D S 2 x x
Unit
D =
Speed Monitor
Application
S =
Safety Applications
Housing
2 =
Housing for DIN rail mounting into a control
cabinet (according to EN 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 Inputs for HTL/PNP control signals
Outputs
0 =
1 Relay Output
1 Analog Output
4 Control Outputs
1 SinCos Splitter Output
1 RS422 Splitter Output
6 =
1 Relay Output
1 Analog Output
4 HTL Control Outputs
3. Available Models
Ds230_03a_oi_e.doc / Jun-15 Page 8 / 100
4. Block Diagrams and Connections
4.1. DS230 Block Diagram
4.2. DS230 Connections
Ds230_03a_oi_e.doc / Jun-15 Page 9 / 100
4.3. DS236 Block Diagram
4.4. DS236 Connections
Ds230_03a_oi_e.doc / Jun-15 Page 10 / 100
4.5. DS240 Block Diagram
4.6. DS240 Connections
Ds230_03a_oi_e.doc / Jun-15 Page 11 / 100
4.7. DS246 Block Diagram
4.8. DS246 Connections
Ds230_03a_oi_e.doc / Jun-15 Page 12 / 100
Name
Description see chapter
X1 | RELAY OUT
5.10 Relay-Output
X2 | CONTROL OUT
5.9 Control-Outputs
X3 | 24V IN
5.1 Power Supply
X4 | ANALOG OUT
5.8 Analog-Output 4 to 20 mA
X4 | RS 422 OUT
5.7 RS422-Splitter-Output
X5 | SINCOS OUT
5.6 SinCos-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 Interface for Display Unit BG230
X12
5.13 USB Interface for the OS6.0 Operator Surface
S1
5.11 DIL switch
ERROR - ON
5.14 LEDs / Status Indication
All outputs perform safe. The connection to the outputs is only safe if the sequential
device is able to detect the fault status of each output.
In order to prevent simultaneous damages to the cables by external influences,
the encoder resp. sensor lines must be kept physically separate from one another.
5. Description of Connections
This chapter describes only the electrical connections and their general function. For a detailed
technical information please refer the chapter 11.
Ds230_03a_oi_e.doc / Jun-15 Page 13 / 100
pluggable 2-pin screw terminal [X3]
The input must be protected by an external fuse
(type and value see chapter 11. “Technical Specifications”).
A SIL3 certified power supply can be used without any further external
components or protections.
5.1. Power Supply
If the unit is connected to a DC power supply network, which supplies further devices or systems, it
must be ensured that no voltages ≥ 60 V can occur at the terminals X3:1 and X3:2.
If this cannot be ensured, the unit must be supplied by a separate DC power pack, which may not be
connected to further devices or systems.
The requirements for both kinds of power supply are:
Nominal voltage 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 consumption of the unit is maximum 45 W
The 18 … 30 VDC power supply must be connected by the pluggable 2-pin screw terminal [X3].
The power supply input is protected by an internal reverse polarity protection.
Ds230_03a_oi_e.doc / Jun-15 Page 14 / 100
Encoder supply: SinCos inputs [X6] [X7]
Encoder supply: RS422 inputs [X8] [X9]
HTL encoders or sensors must also be connected to the encoder supply of the RS422 inputs
Supply
SinCos inputs
RS422 inputs
HTL inputs
Sensor1
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
In case of a direct encoder supply it is mandatory to operate the encoders with the
auxiliary voltage from the unit.
An external encoder supply must be done in each case via a relay which is triggered
by the auxiliary voltage of the unit.
5.2. Encoder Supply
The unit offers an auxiliary voltage output to power the used encoder resp. sensors.
The power supply of the encoders must be carried out directly from the safety unit
(see chapter 5.2.1) or in use of an external power supply via a relay (see chapter 5.2.2).
The maximum load of encoder supply is 200 mA each channel (Sensor1 and Sensor2).
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 safety unit can be
exceeded due to different encoders. In this case, the encoder supply will not be enabled and an error
appears (see chapter 9).
In case of such problems or if another voltage level is required, the encoder supply can be switched
via a relay by an external voltage source. The relay activation must essentially be performed by the
encoder supply of safety unit (see chapter 5.2.2).
Ds230_03a_oi_e.doc / Jun-15 Page 15 / 100
Supply
SinCos inputs
RS422 inputs
HTL inputs
Sensor1
[X6:4] [X6:5]
[X8:1] [X8:2]
[X8:1] [X8:2]
Sensor2
[X7:4] [X7:5]
[X9:1] [X9:2]
[X9:1] [X9:2]
Example of a direct encoder supply
In case of a direct encoder supply it is mandatory to supply the encoders with the
auxiliary voltage from the unit.
5.2.1. Direct Encoder Supply
The unit provides an auxiliary encoder supply for each sensor channel
(HTL encoders must be supplied by the encoder supply for the RS422 inputs).
The level of the supply 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).
Ds230_03a_oi_e.doc / Jun-15 Page 16 / 100
Example of an external encoder supply (1 encoder is 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 safety-critical state, in case of
a failure of the relay or a failure of the external encoder voltage (switched by the relay).
5.2.2. External Encoder Supply
An external encoder supply must be done in each case via a relay which is triggered by the auxiliary
voltage of the unit. This is necessary, because the encoder supply will only be activated after the
safety unit has successfully completed its initialization and self-test.
In case of a relay failure or a failure of the external encoder voltage (switched by the relay), the
operator must ensure that the plant cannot reach a safety-critical state.
Explanation / Solution:
In case of an encoder supply failure the encoder would "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 7.4.6). A master controller has to compare these
two states (plant "rotate" and control output "standstill"). If the two states differ the master
controller has to trigger an error and the plant has to go to a safe state.
Ds230_03a_oi_e.doc / Jun-15 Page 17 / 100
Example of an external encoder supply (2 encoders 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 safety-critical state, in case of a
failure of the relay or a failure of the external encoder voltage (switched by the relay).
Continuation “External Encoder Supply”
Ds230_03a_oi_e.doc / Jun-15 Page 18 / 100
male SUB-D connector [X6], [X7]
5.3. SinCos-Inputs
If the operational mode is set for using SinCos encoders (see chapter 7.4.1 / Parameter 000), the unit
will accept SinCos input signals with 1 Vpp and 2.5 V DC-offset at the 9-pin SUB-D connectors [X6]
and [X7].
It is mandatory to connect up 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 evaluation option for any existing reference signals (REF+ and REF-) is not applicable.
All input lines are already terminated by internal 120 Ohm load resistors.
The SinCos encoder must use the corresponding encoder supply at pin 4 and pin 5 of the connector
(see chapter 5.2).
Ds230_03a_oi_e.doc / Jun-15 Page 19 / 100
pluggable 7-pin screw terminal [X8], [X9]
5.4. RS422-Inputs
(Only DS230 and DS236)
If the operational mode (see chapter 7.4.1 / Parameter 000) is set for RS422 encoder use, the unit
will accept differential input signals from an incremental encoder in 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 signal lines (A, /A, B and /B).
An evaluation option for any existing zero pulses (or Z / Z) does not exist.
The RS422 encoder must use the encoder supply at pin 1 and 2 of the respective terminal
(see chapter 5.2).
Ds230_03a_oi_e.doc / Jun-15 Page 20 / 100
Sensor1
[X10 | CONTROL IN]
incremental HTL encoder
[X10:2]
channel A
[X10:3]
channel B
Sensor2
[X10 | CONTROL IN]
incremental HTL encoder
[X10:4]
channel A
[X10:5]
channel B
Sensor1
[X10 | CONTROL IN]
incremental HTL encoder
[X10:2]
channel A
[X10:3]
unconnected / direction signal
Sensor2
[X10 | CONTROL IN]
incremental HTL encoder
[X10:4]
channel A
[X10:5]
unconnected / direction signal
Control1
[X10 | CONTROL IN]
HTL/PNP control signal
[X10:2]
direct control signal
[X10:3]
complementary control signal
Control2
[X10 | CONTROL IN]
HTL/PNP control signal
[X10:4]
direct control signal
[X10:5]
complementary control signal
pluggable 5-pin screw terminal [X10]
It does not make sense to configure the unit for a connection of 2 HTL encoders
simultaneously, because then no more inputs for external commands are available.
With DS24x units, the HTL/PNP inputs can only be used as control-inputs for external
commands.
5.5. HTL / Control Inputs
The screw terminal [X10 | CONTROL IN] has two inputs for signals with HTL level and PNP switching
characteristic. Each of the inputs performs complementary.
Depending on the operational mode (see chapter 7.4.1 / Parameter 000), the control inputs [X10 |
CONTROL IN] can be configured as frequency or as command inputs:
Frequency input for HTL encoders (A / B / 90°):
HTL encoders must be supplied by the encoder supply of the RS422 inputs (chapter 5.2.).
Frequency input for HTL encoders (A) or a proximity switch:
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 signal. HTL encoders must be supplied by the encoder supply of the RS422 inputs (see 5.2).
Control input for HTL commands:
Basically always the complementary signal of the direct input must be applied to the inverted input.
Any other conditions are invalid and are detected as an error by the unit.
For more information about the control inputs see chapter 7.4.7.
Ds230_03a_oi_e.doc / Jun-15 Page 21 / 100
female SUB-D Connector [X5]
The channels SIN+ and SIN- resp. COS+ and COS- must be terminated by
120 Ohm load resistors at the target device.
5.6. SinCos-Splitter-Output
(only DS230 and DS240)
The DS230 respective the DS240 has a safety-related SinCos-Splitter-Output. Depending on the
selected operating mode (0, 1, 2 or 6), the integrated splitter function allows to reproduce the signal
at input terminal [X6 | SINCOS IN 1] to the female 9-pin SUB-D connector [X5 | SINCOS OUT]. Thus the
encoder signal connected to [X6 | SINCOS IN 1] can be processed by 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
the target device.
In case of errors, the DC-offset of the SinCos output is shifted in order to signalize the error
condition to the target device.
The connection to the SinCos splitter output is only safe, if the following device includes a SinCos
monitoring system and can detect the offset error.
Ds230_03a_oi_e.doc / Jun-15 Page 22 / 100
pluggable 7-pin screw terminal [X4]
With DS240 variants only the encoder frequency connected at input terminal
[X6 | SINCOS IN 1] can be exported to the RS422 splitter output.
5.7. RS422-Splitter-Output
(only DS230 and DS240)
The DS230 respective the DS240 has a safety-related RS422-Splitter-Output. Depending on the
selected operating mode, the integrated splitter function allows to reproduce an input frequency to
the output terminal X4 | RS422 OUT. Thereby the RS422 signal can be processed by a further device.
The block diagrams (see chapter 4) give an overview.
The device evaluates two frequency channels. Which input is assigned to which channel is set in the
operating mode (see chapter 7.4.1 / Parameter 000). The splitter output allows to reproduce the
input frequency from one of these channels (see chapter 7.4.9).
Independent from the 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 case of an error, no more incremental signals are available at the RS422 output (Tri-State with
pull-down cut off).
The connection to the RS422 Splitter output is only safe if the following device is capable to detect
the error state of the safety unit.
In DS230 / DS240 versions, the screw terminal [X4] is provided with 7 connections:
[X4 | ANALOG OUT] analog output [X4:1-3]
[X4 | RS422 OUT] RS422 output [X4:4-7]
In DS236 / DS246 versions, the screw terminal [X4] has only 3 connections:
[X4 | ANALOG OUT] analog output [X4:1-3]
[X4 | RS422 OUT] not available!
Ds230_03a_oi_e.doc / Jun-15 Page 23 / 100
pluggable 7-pin screw terminal [X4] at DS230/DS240
pluggable 3-pin screw terminal [X4] at DS236/DS246
In case of an unused analog output [X4:2] and [X4:3] must be linked.
An open analog output (e.g. wire fracture) will release an error status.
5.8. Analog-Output 4 to 20 mA
One safety-related analog output is available at the screw terminal [X4]. The current output is freely
scalable (see chapter 7.4.10). It delivers an output signal, which is proportional to one of the input
frequency (see chapter 7.4.1 / Parameter 003) and independent from the connected sensor types. In
case of an unused analog output [X4:2] and [X4:3] must be linked. An open analog output (e.g. wire
fracture) will release an error status.
During normal operation, the output moves in a proportional range from 4 to 20 mA.
In case of errors, the analog output 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 safety conditions
to all system-parts and -components which are influenced by the analog output.
In DS230 / DS240 versions, the screw terminal [X4] is provided with 7 connections:
[X4 | ANALOG OUT] analog output [X4:1-3]
[X4 | RS422 OUT] RS422 output [X4:4-7]
In DS236 / DS246 versions, the screw terminal [X4] has only 3 connections:
[X4 | ANALOG OUT] analog output [X4:1-3]
[X4 | RS422 OUT] not available!
Ds230_03a_oi_e.doc / Jun-15 Page 24 / 100
pluggable 8-pin screw terminal [X2]
Example: Control-Output with inductive load (Relay)
OUT4 and /OUT4 safety-related wired
Example: Control-Outputs to PLC
OUT4 und /OUT4 safety-related wired
OUT3 not safety-related wired
5.9. Control-Outputs
Four safety-related HTL control outputs are available at the screw terminal [X2 | CONTROL OUT].
Each of the output performs complementary (OUT1, /OUT1 to OUT4, /OUT4).
The switching points and conditions are adjustable by Parameters (see chapter 7.4.5 and 7.4.6)
In normal state (no error, no switching conditions active) the non-inverted outputs offers LOW level
and the inverted outputs offers HIGH level. During HIGH state, 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 external suppression measures
are recommended.
In case of errors all outputs are LOW (no more inversion between Out_ and /Out_).
The connection to the Analog-Output is only safe if the following device is capable to detect the
error state of the safety unit.
Ds230_03a_oi_e.doc / Jun-15 Page 25 / 100
pluggable 2-pin screw terminal [X1]
internal connection [X1]
In case of an open relay-contact, the operator is responsible to ensure
a safe state to all relevant parts and components of the equipment.
The target unit must be able to evaluate edges, in order to determine dynamical
conditions of the relay output too.
At frequencies close to the switching point, relay bouncing may occur through
the variance of the frequency measurement. To prevent this effect, a hysteresis
should be set (see parameter 053).
If short oversteps of the switching point should be detected, a lock output should
be set (see parameter 057)
5.10. Relay-Output
The safety-related relay-output consists of two independent relays with force guided contacts. The
normally open contacts of the two relays (NO) are internally connected in series. At the 2-pin screw
terminal [X1 | RELAY OUT] the series-relay-contact can be tapped for integration into a safety circuit.
The contacts are only closed during normal and disturbance-free operation. They will open to its
safety state in case of errors or when the programmed switching condition (see chapter 7.4.5) is
fulfilled. In a de-energized state of the unit, the contacts are also open.
The switching points and 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 changes to its open and safe condition.
Ds230_03a_oi_e.doc / Jun-15 Page 26 / 100
3-pos DIL switch [S1]
Slider
Condition
Unit-State
1
ON
„Normal Operation“ - Parameter access disabled
OFF
„Factory Settings“ - with next power-on, all Parameters will be reset to default values
2
ON
„Normal Operation“ - Parameter access disabled
OFF
„Self Test Message“ - with next power-on, the unit will transmit a self test protocol
via USB interface
(without “Self 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) only for start-up
Set all DIL switch sliders to „ON“ after start-up
Protect the DIL switch sliders after start-up (e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off
The safety function of the unit cannot be guaranteed before the commissioning
is completed.
DIL Nr. 2
Boot time
ON = Normal Operation
After connecting the supply voltage, the device is ready for operation
after about 2 s
OFF = Self Test Message
After connecting the supply voltage, the device is ready for operation
after about 8 s
5.11. DIL switch
The 3-position DIL switch [S1] is located at the front of the unit
(only accessible, if no display-unit is connected).
The following unit-states can be set by the DIL switch:
5.11.1. Boot time
Ds230_03a_oi_e.doc / Jun-15 Page 27 / 100
8-pin female connector [X11]
5.12. Interface for Display Unit BG230
The serial interface serves for communication between the unit and an optional programming- and
display unit „BG320“, which can be plugged on the front.
The programming and display unit BG230 and the safety unit will be connected by plugging the
BG230 on the female 8-pin connector [X11] at the front.
Ds230_03a_oi_e.doc / Jun-15 Page 28 / 100
USB type B
5.13. USB Interface for the OS6.0 Operator Surface
For communication between the unit and 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 option.
The installation procedure of the USB driver file is described in the following document:
“Installation USB diver”
Ds230_03a_oi_e.doc / Jun-15 Page 29 / 100
Status LEDs
LED (green)
Condition
OFF
Power off - no power supply voltage
ON
Power on - power supply voltage is ok
LED (yellow)
Condition
OFF
Normal operation, self-test successfully completed, no error messages
ON
After power on: the unit 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“
FAST
Error: incorrect self-test or internal error (see chapter 9. Error Detection)
„Programming Mode“ (DIL switch) only for start-up
Set all (DIL switch) sliders to „ON“ after start-up
Protect the (DIL switch) sliders after start-up (e. g. by covering with an adhesive tape)
Normal operation is only permitted when the yellow LED is permanently off
The safety function of the unit cannot be guaranteed before the commissioning is
completed.
5.14. LEDs / Status Indication
Two status LEDs are located at the front of the unit. The green one is marked as [ON] and the yellow
one as [ERROR].
The green status LED uses the following two conditions:
The yellow status LED uses the following four conditions:
OFF = LED if off, ON = LED is lighting
SLOW = slow flashing (approx. 1 Hz), FAST = fast flashing (approx. 2.5 Hz)
Ds230_03a_oi_e.doc / Jun-15 Page 30 / 100
Loading...