brake test diagnostics function with movisafe® cs

*29125855_0719*Drive Technology \ Drive Automation \ System Integration \ Services

Manual

MOVIDRIVE® modular/system/technologyBrake Test Diagnostics Function with MOVISAFE® CS..A

Edition 07/2019 29125855/EN

SEW-EURODRIVE—Driving the world

Table of contents

Manual – Brake Test Diagnostics Function with MOVISAFE® CS..A 3

Table of contents1 General information.................................................................................................................. 5

1.1 About this documentation ............................................................................................... 51.2 Structure of the safety notes ........................................................................................... 5

1.2.1 Meaning of signal words ................................................................................ 51.2.2 Structure of section-related safety notes........................................................ 51.2.3 Structure of embedded safety notes .............................................................. 6

1.3 Rights to claim under limited warranty ............................................................................ 61.4 Content of the documentation......................................................................................... 61.5 Applicable documentation............................................................................................... 61.6 Decimal separator in numerical values ........................................................................... 61.7 Copyright notice .............................................................................................................. 61.8 Product names and trademarks...................................................................................... 7

2 Safety notes .............................................................................................................................. 82.1 Preliminary information ................................................................................................... 82.2 Duties of the user............................................................................................................ 82.3 Target group ................................................................................................................... 82.4 Designated use ............................................................................................................... 92.5 Startup/operation ............................................................................................................ 92.6 Definitions ..................................................................................................................... 10

3 System description ................................................................................................................ 113.1 Test rate in safe braking systems ................................................................................. 12

3.1.1 Regular call-up of the brake test .................................................................. 123.1.2 One-off call-up of the brake test ................................................................... 12

3.2 Diagnostic coverage (DC)............................................................................................. 13

4 Functional description of the static brake test .................................................................... 144.1 Direction of movement/test direction............................................................................. 14

4.1.1 Load torque > 0 (5 test steps) ...................................................................... 154.1.2 Load torque = 0 (3 test steps) ...................................................................... 17

4.2 Step-by-step brake test procedure................................................................................ 184.2.1 Step 1: Clearing ........................................................................................... 184.2.2 Step 2: Load torque test (optional) ............................................................... 194.2.3 Step 3: Active testing of the brake ............................................................... 194.2.4 Step 4: Passive brake testing (optional)....................................................... 204.2.5 Step 5: End of test........................................................................................ 20

5 Project planning notes........................................................................................................... 215.1 MOVISUITE® permission level ..................................................................................... 215.2 MOVIDRIVE® modular/system/technology .................................................................. 215.3 MOVIDRIVE® modular/system with CiA402 device profile .......................................... 215.4 MOVISAFE® CS..A safety card .................................................................................... 215.5 Drive safety functions.................................................................................................... 225.6 Motors ........................................................................................................................... 225.7 User units...................................................................................................................... 225.8 Direction of rotation reversal ......................................................................................... 22

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Table of contents

Manual – Brake Test Diagnostics Function with MOVISAFE® CS..A4

5.9 Encoder/safety encoder ................................................................................................ 235.10 Systems with mechanical backlash .............................................................................. 235.11 Brake control/safe brake control ................................................................................... 235.12 Number of testable brakes............................................................................................ 24

6 Startup ..................................................................................................................................... 256.1 Configuring the brake test............................................................................................. 25

6.1.1 Pre-selection for control ............................................................................... 256.1.2 Starting the "Assist CS.." parameterization tool ........................................... 266.1.3 "Checksum overview" menu......................................................................... 266.1.4 "Basic settings" menu................................................................................... 266.1.5 "Safe inputs" menu....................................................................................... 276.1.6 "Safe outputs" menu..................................................................................... 286.1.7 "Encoder" menu ........................................................................................... 296.1.8 "F communication" menu ............................................................................. 306.1.9 "User units" menu......................................................................................... 306.1.10 "STO/SBC" menu......................................................................................... 306.1.11 Menus "SSx" to "SLA" .................................................................................. 316.1.12 "Brake test" menu......................................................................................... 316.1.13 "Function assignment" menu........................................................................ 35

6.2 Control brake test.......................................................................................................... 366.2.1 Starting conditions........................................................................................ 366.2.2 Starting the brake test .................................................................................. 376.2.3 Test result and ending the test..................................................................... 37

7 Operation................................................................................................................................. 387.1 Process and actual values ............................................................................................ 387.2 Status message SBT active.......................................................................................... 387.3 Aborting the brake test.................................................................................................. 387.4 Error messages............................................................................................................. 40

7.4.1 Display of error messages ........................................................................... 407.4.2 List of error messages.................................................................................. 407.4.3 Acknowledging the error messages ............................................................. 44

8 Acceptance ............................................................................................................................. 45

9 Appendix ................................................................................................................................. 469.1 FCB concept ................................................................................................................. 46

Index ........................................................................................................................................ 47

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1General informationAbout this documentation


1 General information1.1 About this documentation

This documentation is an integral part of the product. The documentation is intendedfor all employees who perform work on the product.Make sure this documentation is accessible and legible. Ensure that persons respon-sible for the systems and their operation as well as persons who work with the productindependently have read through the documentation carefully and understood it. If youare unclear about any of the information in this documentation, or if you require furtherinformation, contact SEW‑EURODRIVE.

1.2 Structure of the safety notes1.2.1 Meaning of signal words

The following table shows the grading and meaning of the signal words for safetynotes.

Signal word Meaning Consequences if disregarded

DANGER Imminent hazard Severe or fatal injuries

WARNING Possible dangerous situation Severe or fatal injuries

CAUTION Possible dangerous situation Minor injuries

NOTICE Possible damage to property Damage to the product or its envi-ronment

INFORMATION Useful information or tip: Simplifieshandling of the product.

1.2.2 Structure of section-related safety notesSection-related safety notes do not apply to a specific action but to several actionspertaining to one subject. The hazard symbols used either indicate a general hazardor a specific hazard.This is the formal structure of a safety note for a specific section:

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

Meaning of the hazard symbolsThe hazard symbols in the safety notes have the following meaning:

Hazard symbol MeaningGeneral hazard

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1 General informationRights to claim under limited warranty


1.2.3 Structure of embedded safety notesEmbedded safety notes are directly integrated into the instructions just before the de-scription of the dangerous action.This is the formal structure of an embedded safety note:

SIGNAL WORD Type and source of hazard. Possible consequence(s) if disregar-ded. Measure(s) to prevent the hazard.

1.3 Rights to claim under limited warrantyRead the information in this documentation. This is essential for fault-free operationand fulfillment of any rights to claim under limited warranty. Read the documentationbefore you start working with the product.

1.4 Content of the documentationThis documentation contains additional safety-related information and conditions foroperation in safety-related applications.

1.5 Applicable documentationThis documentation supplements the operating instructions and restricts the usage in-structions in accordance with the following information. This documentation must beused only in conjunction with the operating instructions:• Operating instructions "MOVIDRIVE® modular/system/technology" and

"MOVIDRIVE® modular/system with CiA402 device profile".• Manual "MOVIDRIVE® modular, MOVIDRIVE® system - safety card MOVISAFE®

CS..A (Version 1)".• Manual "MOVIDRIVE® modular/system/technology - safety card MOVISAFE®

CS..A (Version 2)".Always use the latest edition of the documentation and the software.The SEW‑EURODRIVE website (www.sew‑eurodrive.com) provides a wide selectionof documents for download in various languages. If required, you can also order prin-ted and bound copies of the documentation from SEW‑EURODRIVE.

1.6 Decimal separator in numerical values

In this document, a period is used to indicate the decimal separator.Example: 30.5 kg

1.7 Copyright notice

© 2019 SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-tion, distribution or any other use of the whole or any part of this documentation isstrictly prohibited. 29

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1General informationProduct names and trademarks


1.8 Product names and trademarks

The brands and product names in this documentation are trademarks or registeredtrademarks of their respective titleholders.

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2 Safety notesPreliminary information


2 Safety notes2.1 Preliminary information

The following general safety notes serve the purpose of preventing injury to personsand damage to property. They primarily apply to the use of products described in thisdocumentation. If you use additional components, also observe the relevant warningand safety notes.

2.2 Duties of the userAs the user, you must ensure that the basic safety notes are observed and compliedwith. Make sure that persons responsible for the machinery and its operation as wellas persons who work on the device independently have read through the documenta-tion carefully and understood it.As the user, you must ensure that all of the work listed in the following is carried outonly by qualified specialists:• Setup and installation• Installation and connection• Startup• Maintenance and repairs• Shutdown• DisassemblyEnsure that the persons who work on the product pay attention to the following regula-tions, conditions, documentation, and information:• National and regional safety and accident prevention regulations• Warning and safety signs on the product• All other relevant project planning documents, installation and startup instructions,

and wiring diagrams• Do not assemble, install or operate damaged products• All system-specific specifications and conditionsEnsure that systems in which the product is installed are equipped with additional mo-nitoring and protection devices. Observe the applicable safety regulations and legisla-tion governing technical work equipment and accident prevention regulations.

2.3 Target group

Specialist for me-chanical work

Any mechanical work may be performed only by adequately qualified specialists. Spe-cialists in the context of this documentation are persons who are familiar with thedesign, mechanical installation, troubleshooting, and maintenance of the product whopossess the following qualifications:• Qualification in the mechanical area in accordance with the national regulations• Familiarity with this documentation

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2Safety notesDesignated use


Specialist for elec-trotechnical work

Any electrotechnical work may be performed only by electrically skilled persons with asuitable education. Electrically skilled persons in the context of this documentation arepersons who are familiar with electrical installation, startup, troubleshooting, and main-tenance of the product who possess the following qualifications:• Qualification in the electrotechnical area in accordance with the national regula-

tions• Familiarity with this documentation

Additional qualifi-cation

In addition to that, these persons must be familiar with the valid safety regulations andlaws, as well as with the requirements of the standards, directives, and laws specifiedin this documentation.The persons must have the express authorization of the company to operate, pro-gram, parameterize, label, and ground devices, systems, and circuits in accordancewith the standards of safety technology.

Instructed persons All work in the areas of transportation, storage, operation and waste disposal must becarried out by persons who are trained appropriately. The purpose of the instruction isto give persons the ability to perform the required tasks and work steps in a safe andcorrect manner.

2.4 Designated useThe "Brake test diagnostics function (SBT)" is implemented as a firmware function forMOVISAFE® CS.A safety cards. The product is intended for use:• In commercial systems.• As diagnostic software for testing the functionality. and performance capability of

brakes.• For brakes which close in the de-energized state.• In horizontal or vertical applications.The SBT brake test diagnostics software is not an independent safety function butsupplements a higher-level safety system with brake diagnostics that is required bythe standards.The diagnostic software provides the degree of diagnostics coverage that is requiredby the standards (DC value). You can use this to evaluate the safety integrity that hasbeen achieved by the higher-level safety system.There is a difference between the physical characteristics between dynamic brakingand static stopping. The braking distance at the machine may therefore be slightlylonger in spite of successfully passing the braking tests.When installed in machines, startup (i.e. start of designated operation) is prohibiteduntil it is determined that the machine complies with the local laws and directives.Unintended or improper use of the product may result in severe injury to persons anddamage to property.

2.5 Startup/operation

Observe the safety notes in the chapters "Startup" (→ 2 25) and "Opera-tion" (→ 2 38) in the documentation.Depending on the degree of protection, products may have live, uninsulated, andsometimes moving or rotating parts, as well as hot surfaces during operation.29

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2 Safety notesDefinitions


Mechanical blocking or internal protective functions of the product can cause a motorstandstill. Eliminating the cause of the problem or performing a reset may result in thedrive restarting automatically. If, for safety reasons, this is not permitted for the drive-controlled machine, first disconnect the product from the supply system and then starttroubleshooting.The fact that the operation LED and other display elements are no longer illuminateddoes not indicate that the product has been disconnected from the supply system andno longer carries any voltage.In the event of deviations from normal operation, switch the product off. Possible devi-ations are increased temperatures, noise, or vibration, for example. Determine thecause. Contact SEW‑EURODRIVE if necessary.Do not deactivate monitoring and protection devices of the machine or system, evenfor a test run.Additional preventive measures may be required for applications with increased haz-ard potential. Be sure to check the effectiveness of the protection devices after everymodification.

2.6 Definitions• The designation "F-DI." represents a safe digital input.• The designation "F-DO." represents a safe digital output.• The designation "CS..A" is used as a generic term for all derivatives of the

MOVISAFE® CS product series. If a particular derivative is referred to in themanual, then the complete designation is used.

• The term "safe" used in this manual refers to the classification as a safe functionaccording to EN ISO 13849-1.

• The "Assist CS.." parameterization tool is the parameterization interface inMOVISUITE® for the MOVISAFE® CS..A safety card.

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3System description


3 System descriptionThe "brake test" diagnostic function supplements a safe braking system that consistsof several system components and sets requirements for the interfaces between therespective components.The following figures show an extremely simplified system structure of a safe brakesystem with one brake [A] and two brakes [B] and an integrated brake test.

[A] [B]

BST1

DB

00

SB

C

CS.A

F-DO. F-PLC

Uz

MOVIDRIVE®

EURODRIVE

V1 V2

[1]

[2] [3] [4]

29317708043

BST1 BST2S

BC

1

DB

00

SB

C 2

CS.A

F-DO.

F-DO.F-PLC

Uz

MOVIDRIVE®

EURODRIVE

V1 V2

EURODRIVE

V1 V2

[2] [3] [3] [4]

[1]

29317711627

MOVIDRIVE® MOVIDRIVE® modular/system/technology frequency inverter

F-PLC Higher-level safety controller

CS.A MOVISAFE® CS..A safety card

[1] F-communication

[2] Motor

[3] Brake(s) attached to motor

[4] Encoder, attached to motor

BST1/2 BST safe brake module

UZ DC link voltage

DB00 Control signal for functional control of the brake

SBC, SBC 1, 2 Control signal(s) for safe control of the brake(s) and for controllingthe brake(s) during an active brake test

F-DO. Safe digital output

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3 System descriptionTest rate in safe braking systems


3.1 Test rate in safe braking systemsThe frequency of execution of a brake test is defined using the test rate. The braketest is called up via a higher-level controller and must be ensured by the user.SEW‑EURODRIVE recommends calling up the brake diagnostics using a safe control-ler.The test rate must be defined by the user in a machine-specific way. Applicative andstandards requirements must be taken into consideration when doing so.

3.1.1 Regular call-up of the brake testIn IFA report 04/2018 "Safe drive controllers with frequency inverters", the Institute forOccupational Safety recommends regularly performing a brake test after approx. 8hours or one shift. The same applies to system structures in category 2 and 3.

Special feature for machines with access regulationIn machines where access to the danger zone is safely prevented, e.g. via securitydoors with an active guard locking device, the brake test can be performed immedi-ately before accessing the hazard zone. Access to the hazard zone may be grantedonly after a positive diagnostics result.

3.1.2 One-off call-up of the brake testIn addition to regular call-ups, it is advisable to execute the brake test after the follow-ing events:• Initial startup of a system• After emergency stop braking• After voltage failure• After the system is switched on• After inspection, maintenance or repair of the brake

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3System descriptionDiagnostic coverage (DC)


3.2 Diagnostic coverage (DC)The diagnostic coverage (DC) measures the effectiveness of the diagnostics in accor-dance with EN ISO 13849-1. The diagnostic coverage is specified as the ratio of thefailure rate of discovered dangerous failures to the failure rate of overall dangerousfailures. Diagnostics is required from a system architecture of category 2 and higher.The functional and performance capability of a brake can be adversely affected by amultitude of potential faults. The potential faults are summarized in one of the follow-ing fault patterns, which are discovered by the brake test.

Fault pattern Effect of fault Discovery of faultBrake remains applied Safe state Fault is discovered

Brake remains open Dangerous state Fault is discovered

Insufficient braking torque Dangerous state Fault is discovered

In order to determine the Performance Level (PL) that has been achieved in safebrake systems, a DC value of DC = 90% can be assumed for the brake test.

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4 Functional description of the static brake testDirection of movement/test direction


4 Functional description of the static brake test

WARNINGPerforming the brake test on a damaged brake or machine can lead to undesiredmovement of the machine.This can result in severe or fatal injuries.• No person may be present in the hazard zone during an active brake test.• The mechanics of a hoist must be designed for a possible fall using buffers, for

example.• The brake test must be performed with the machine in a suitable test position.

The Safe Brake Test (SBT) function is a static brake test for horizontal and vertical ap-plications. The static brake test diagnoses whether the brake that is being tested canmaintain a static test torque. The driving motor therefore generates a configurable testtorque that is applied to the active brake.The brake test takes place in several stages. This makes it possible to clearly detectthe numerous potential errors and minimize the effects of the system on the result ofthe brake test. To begin with, the drive carries out a parameterizable movement. Thestatic brake test must be called up from a suitable test position that allows the ma-chine to make this movement.The required test torque must be parameterized when the drive is started up. A staticload torque acting upon the drive due to the own weight of the system, for example,must be taken into consideration. Before calling up the brake test and during the braketest, it must be ensured that the load conditions are steady during startup in accor-dance with the settings so that the brake is tested correctly.The brake test records torques via the inverter and specifies torques to the inverter assetpoints. The torques are not evaluated from a safety technology point of view. Theaccuracy of the torque recording corresponds to the accuracy of the inverter.When executing the brake test, movements are safely monitored for adherence to thelimit values that have been set by the MOVISAFE® CS..A safety card.In safe brake systems with more than one brake, the static brake test must be carriedout separately for each brake. The brake test described here can test one or 2 brakes.With 2 brakes, the brakes are tested separately using the same test torque. One brakeis applied for testing, whereas the second brake remains open.

4.1 Direction of movement/test directionThe static brake test can be performed in the positive or negative direction of move-ment/test direction. The positive or negative specification relates to the counting direc-tion of the encoder values, e.g. increasing encoder values (positive) or decreasing en-coder values (negative) for a movement in the set direction of movement.

INFORMATION• The following figures are examples and can vary depending on the actual load

situation and the respective setting.• More information about the individual test steps can be found in chapter "Step-by-

step brake test procedure".

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4Functional description of the static brake testDirection of movement/test direction


4.1.1 Load torque > 0 (5 test steps)The following example figures apply to applications with a load torque of M > 0 (5 teststeps), e.g. hoist.• Positive direction of movement / positive test direction

t0

-M

+M[3][2][1] [4] [5]

29156898187

• Positive direction of movement / negative test direction

t

0

+M

-M[3]

[2][1]

[4] [5]

29156903691

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4 Functional description of the static brake testDirection of movement/test direction


• Negative direction of movement / positive test direction

t

0

-M

+M[3][2][1] [4] [5]

29156907275

• Negative direction of movement / negative test direction

t

0

-M

+M

[3]

[2][1]

[4] [5]

2916126285929

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4Functional description of the static brake testDirection of movement/test direction


4.1.2 Load torque = 0 (3 test steps)The following example figures apply to applications with a load torque of M = 0 (3 teststeps), e.g. powertrain.• Positive direction of movement / positive test direction

t

0

-M

+M531

29161267595

• Positive direction of movement / negative test direction

t

0

-M

+M

53

1

29161271179

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4 Functional description of the static brake testStep-by-step brake test procedure


• Negative direction of movement / positive test direction

t

0

-M

+M531

29161300363

• Negative direction of movement / negative test direction

t

0

-M

+M

53

1

29161303947

4.2 Step-by-step brake test procedureThe static brake test goes through the following steps. Parameter names are shown initalics.

4.2.1 Step 1: ClearingIn step 1, the system availability for a brake test and the correct starting conditions arechecked, e.g. the load torque setting. Errors in the overall system can be detected,e.g. a blocked mechanism or a brake that fails to open. Effects on the result of thebrake test are reduced.A jerk time set in the inverter is not taken into consideration when clearing. Clearingtakes place without jerk limitation.

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4Functional description of the static brake testStep-by-step brake test procedure


Clearing takes place in the following sub-steps:• The drive moves to the set target position. The movement takes place in the set di-

rection of movement. The target position is specified via the clearing distance.• The brake test calculates the duration that is required for this and checks the ac-

tual movement.• After reaching the target position, the brake test waits for the duration of the set

waiting time. If position control is in operation, the drive remains in the target posi-tion. This position is monitored using the Permitted movement during idle state tol-erance. Then the next step is performed.

• The drive moves back in the opposite direction to 50% of the set target position.The movement takes place against the set direction of movement. The target posi-tion is specified via the clearing distance.

• The brake test calculates the duration that is required for this and checks the ac-tual movement.

• After reaching the target position, the brake test waits for the duration of the setwaiting time. If position control is in operation, the drive remains in the target posi-tion. Then the next step is performed.

All brakes are opened via the inverter during clearance.

4.2.2 Step 2: Load torque test (optional)In step 2, a check is performed to verify if the static load torque determined in the cur-rent test situation is within the set limits.This step cannot be used in machines without static load torque. In these cases, theload torque must be set to "0". The brake test then skips this step.The load torque test takes place in the following sub-steps:• The drive remains at the target position for the Duration of individual test steps if

position control is active. This position is monitored using the Permitted movementduring idle state tolerance.

• The actual torques are determined via the inverter via the Duration of individualtest steps and the current load torque is calculated from this (arithmetic meanvalue).

• The set Load torque is checked against the calculated load torque. This must bewithin the range of the set load torque, taking the load torque tolerance into con-sideration.

All brakes are opened via the inverter during the load torque test.

4.2.3 Step 3: Active testing of the brakeIn step 3, the brake is tested to verify if it can maintain the set Test torque.The brake is loaded with the Test torque for the set Individual test step duration. Pos-sible movement of the machine is monitored during brake loading. The movementmust be within the range of the Permitted movement during idle state.The magnitude and direction of the actual torque supplied by the inverter is monitored.The recorded actual torque (arithmetic mean value) must be greater than the Testtorque minus the Permitted deviation from test torque.If 2 brakes are to be tested, this test step is first carried out with one brake, and thesecond brake remains open. This test step is then repeated for the second brake, andthe first brake remains open.

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4 Functional description of the static brake testStep-by-step brake test procedure


INFORMATION• Depending on the direction of the test and load torque, the torque acting upon the

brake can be increased or reduced. The Load torque configured in the brake testmust be adhered to whenever the brake test is performed.

• All torques relate to the motor shaft.

4.2.4 Step 4: Passive brake testing (optional)In step 4, the brake is tested to verify if it can maintain the present load torque.This step cannot be used in machines without a load torque. In these cases, the loadtorque must be set to a value of "0". The brake test then skips this step.The brake is exclusively loaded with the load torque of the machine without additionaltorque from the drive. In order to do so, the drive safety function STO is activated atthe inverter via the Duration of individual test steps. The drive cannot generate anytorque. Possible movement of the machine is monitored whilst the "STO" state is ac-tive. The movement must be within the range of the Permitted movement during idlestate.If 2 brakes are to be tested, this step is first carried out with one brake, and the secondbrake remains open. This step is then repeated for the second brake, and the firstbrake remains open.

4.2.5 Step 5: End of testIn order to complete the brake test, the existing brakes are applied and the STO drivesafety function is activated at the inverter. Afterwards, brake test control can be deacti-vated.

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5Project planning notesMOVISUITE® permission level


5 Project planning notes5.1 MOVISUITE® permission level

MOVISUITE®permissionlevel

The CS..A safety cards, including the "Brake test" diagnostic function, are certified.The functional features can be an operational constituent of the application-side safetyconcept.Startup and diagnostics in the MOVISUITE® engineering software requires a permis-sion level of "Internal". Contact SEW‑EURODRIVE if required.

5.2 MOVIDRIVE® modular/system/technologyMOVIDRIVE® modular/system/technology

• The brake test can be used in combination with the MOVIDRIVE® modular/system/technology inverters.

• The MOVIDRVE® modular/system/technology inverters must be started up in CFCor VFCPLUS control mode (with encoder).

• The brake test is exclusively compatible with drive train 1 (AS1).• The required test torque for testing the brakes must be taken into consideration

during the configuration of the MOVIDRVE® modular/system/technology inverter.• The setting of the Current limit and Torque limit parameters in the inverter must al-

low the test torque to be built up.• Select the parameter settings of the "FCB 01 output stage inhibit" drive function as

follows:– 0: Release brake/DynaStop® with FCB 01 – enable

– 1: Apply brake/DynaStop® in STO state

This corresponds to the default setting in the delivery state.

5.3 MOVIDRIVE® modular/system with CiA402 device profileMOVIDRIVE® modular/systemwith CiA402deviceprofile

The "Brake test" diagnosis function for the MOVIDRIVE® modular/system inverter withCiA402 device profile and firmware version ≥ 5.00 is in preparation. Application solu-tions that are currently needed can be requested from SEW‑EURODRIVE.

5.4 MOVISAFE® CS..A safety cardMOVISAFE® CS..Asafety card

The "Brake test" diagnostic function is available for the MOVISAFE® CSS21A andCSS31A safety cards. The safety cards require series firmware version ≥ V1.05.

INFORMATIONPay attention to the compatibility of the CS..A safety card for the respective inverter.More information can be found in the manual of the MOVISAFE® CS..A safety card.

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5 Project planning notesDrive safety functions


5.5 Drive safety functionsWhen the "Brake test" diagnostic function is being used, pay attention to compatibilitywith the drive safety functions of the CS..A safety card.• Activating one of the following drive safety functions during an active brake test

aborts the brake test:– STO/SBC– SSx– SOS– SSR– SDI– SLI

• The SLS/SSM and SLA drive safety functions can be used at the same time as thebrake test. A limit violation at one of these drive safety functions aborts the braketest, even if the limit violation is exclusively signaled via the F communication.

The functionality of a drive safety function is always guaranteed and has a higher pri-ority than the brake test.

5.6 MotorsThe brake test is compatible with motors that can be operated on MOVIDRIVE® modu-lar/system/technology.The existing requirements for the motors with regard to the CFC or VFCPLUS controlmodes must be observed.

5.7 User unitsThe brake test uses the user units which are set in the inverter, e.g. min-1, mm/s.If the user units in the inverter are changed at a later date, check that the safety cardsettings are correct. After changing the user units in the inverter, restart the "AssistCS.." parameterization tool. Check the settings and correct them, if necessary.

5.8 Direction of rotation reversalIf the direction of rotation reversal has been deactivated for the inverter, set the count-ing direction for the encoder to "Normal" in the "Assist CS.." parameterization tool.This is the default setting.If the direction of rotation reversal has been activated for the inverter, set the countingdirection for the encoder to "Inverted" in the "Assist CS.." parameterization tool.

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5Project planning notesEncoder/safety encoder


5.9 Encoder/safety encoderThe brake test requires a motor encoder as encoder feedback to the inverter. If thebrake test is evaluated in a safety-related system, e.g. in accordance with the Per-formance Level (PL), the encoder must be designed as a safety encoder. The follow-ing SEW‑EURODRIVE encoders can be selected in the "Assist CS.." parameterizationtool:• ES7S/EG7S• AS7W/AG7W• AK0H/AK1HThe EK8S and AK8W encoders/safety encoders cannot yet be selected in the "AssistCS.." parametrization tool. Since the encoder interface of encoders E.8S and A.8W iscompatible with encoders E.7S and A.7W, proceed as follows in "Assist CS.." duringstartup:• If encoder/safety encoder EK8S is used, select setting "ES7S/EG7S".• If encoder/safety encoder AK8W is used, select setting "AS7W/AG7W".Encoders/safety encoders A.7W, AK8W and AK.H are combi encoders. In addition tothe incremental Sin/Cos signals, they also provide Multiturn absolute value signals(RS485 or HIPERFACE®). The CS..A safety card uses the Sin/Cos signals of the re-spective encoder for the brake test.

5.10 Systems with mechanical backlashIf a brake test is to be implemented in a system, only a small amount of mechanicalbacklash may build up between the brake and the encoder when the brake test is ac-tive.The brake test setting, e.g. limit values, may not be used to compensate for mechani-cal backlash.

5.11 Brake control/safe brake control

WARNINGA faulty brake control connection and defective brake switching times can lead toundesired movement of the drive. An axis that is loaded with gravitational force(such as a hoist) may fall down.This can result in severe or fatal injuries.• Output DB00 at the basic unit is not safety-related. Connect the safe brake con-

trol only to the safe digital output F-DO, to which the SBC drive safety function isassigned.

• The brake release and application time that is set in the inverter must correspondto the brake that is used.

The brake test requires control of the brake via a brake rectifier. During the startup ofthe MOVIDRIVE® modular/system/technology inverter in drive train 1 (AS1) with brakecontrol, select Brake rectifier. Selecting Direct connection (DC24V) is not compatiblewith the brake test.

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5 Project planning notesNumber of testable brakes


To start up the brake test, activate the SBC safety function in parameterization tool"Assist CS..A". When SBC is activated, the inverter also forwards the functional con-trol (DB00) via the CS..A safety card to the assigned safe digital output F-DO withinthe device..The brake can be controlled via:• F-DO (CSS..A) + DB00 (basic unit)

Application: BST safe brake module. Connect F-DO.. to safe control input USAFE.Connect DB00 to functional control input UIN.

• F-DO (CSS..A)Application: BST safe brake module. Connect F-DO.. to safe control input USAFE

and functional control input UIN. With this connection, DB00 is not occupied on thebasic unit.

Use safe brake module BST in the safe brake system for interrupting the energy sup-ply to the brake so that the brake is switched off in a safety-related way (for more in-formation, see chapter "System description").The available brake controls with a 24 V DC control input from SEW‑EURODRIVE canbe used in a brake system without safety technology relevance that has been exten-ded with a brake test. Brake control then takes place exclusively via the assigned F-DO. The functionality of the functional actuation (DB00) remains unchanged.If other brakes or drives are present in a multiple-axis system and are mechanicallycoupled to the drive to be tested, these brakes must be open and torque-free for theduration of the brake test.

5.12 Number of testable brakesA maximum of 2 brakes can be tested for each CS..A safety card. They are assignedvia the functional assignment of the F-DO safety digital outputs.

F-DO F-DO function Meaning for SBTF-DO 00 None

STOSBC

SBT not availableSBT not availableSBT can be configured for a brake

F-DO 01 NoneSTOSBC

SBT not availableSBT not availableSBT can be configured for a brake

If F-DO 00 and F-DO 01 are set to "SBC", the brake test is carried out for 2 brakes.The brake test first tests brake 1 (F-DO 00) and automatically repeats test steps 3 to 5for brake 2 (F-DO 01). With 2 brakes, both brakes are tested with identical brake testsettings.

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6StartupConfiguring the brake test


6 Startup

6.1 Configuring the brake test

INFORMATIONParameter names are shown in italics in this chapter.

6.1.1 Pre-selection for controlThe brake test can optionally be called up via a safe signal or in combination with astandard signal and a safe signal.The required actuation is selected in the parameterization tool "Assist CS..". To do so,call up parameter Activation via SBT clearance in the "Brake test" menu.You have the following configuration options:1. Activation by SBT clearance = 1

The brake test is started via safe signal SBT Clearance. This can optionally besent via a safe digital input (F-DI) at the safety card or via a bit in the safe processoutput data (F-PO) of the F communication.No additional signal is required to start the brake test.

2. Activation by SBT clearance = 0The brake test starts with the two signals "SBT Clearance" and "Activate SBT".The "SBT Clearance" signal can optionally be sent via a safe digital input (F-DI) atthe safety card or via a bit in the safe process output data (F-PO) of the F commu-nication.The "Activate SBT" signal is also required at the start of the brake test. The "Acti-vate SBT" signal can optionally be emitted via a digital input (DI) at the inverter orvia a bit in the process output data (PO) of the communication.

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6 StartupConfiguring the brake test


6.1.2 Starting the "Assist CS.." parameterization tool

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1. Start the "Assist CS.." parameterization tool and log in with your password. Ensurethat you are connected to the desired device by entering or reading the safety keyID.

2. Confirm your entries with the [Log in and continue] button. The "Parameterize"window opens. The processing of the individual menu items is described in the fol-lowing chapters.

6.1.3 "Checksum overview" menuThe checksums are needed after completing the configuration for accepting the re-spective functions.

6.1.4 "Basic settings" menuThe menu is not needed to configure the brake test. The system limit settings are notrelevant for the brake test.

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6.1.5 "Safe inputs" menu

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If the brake test is to be started via a safe digital input (F-DI), select the relevant F-DIin accordance with its connection (single/dual channel, etc.).

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6.1.6 "Safe outputs" menu

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In order to actuate the brake, assign the "SBC" function to the desired safe digital out-put (F-DO) during function assignment. Select the connection type for the relevantsafe digital output (F-DO) in accordance with its connection (single/dual channel, etc.).

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6.1.7 "Encoder" menu

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Select the safety encoder that is used from the "Encoder type" list. Adjust the otherencoder settings such as counting direction (see chapter "Direction of rotation re-versal" (→ 2 22)).The EK8S and AK8W encoders/safety encoders cannot yet be selected in the "AssistCS.." parametrization tool. Since the encoder interface of encoders E.8S and A.8W iscompatible with encoders E.7S and A.7W, proceed as follows in "Assist CS.." duringstartup:• If encoder/safety encoder EK8S is used, select setting "ES7S/EG7S".• If encoder/safety encoder AK8W is used, select setting "AS7W/AG7W".

INFORMATIONSafety encoder EI7C FS is unsuitable for carrying out brake tests.

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6.1.8 "F communication" menu

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During operation with F communication, select the F protocol type that is being usedfrom the list. In the event of operation without F communication, select "No protocol".

6.1.9 "User units" menuThe brake test uses the user units that are set in the inverter. More information aboutthis can be found in chapter "User units" (→ 2 22).

6.1.10 "STO/SBC" menu

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Safe brake control must be activated to configure the brake test. Set "SBC enable" to"1" for this purpose.

6.1.11 Menus "SSx" to "SLA"Menus "SSx" to "SLA" are not required to configure the brake test.

6.1.12 "Brake test" menu

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Menu item DescriptionEnable • "1"

The brake test is enabled on the safety card and can beused.

• "0"The brake test is not enabled on the safety card.

Activation by SBTclearance

• "1"The brake test starts solely with the "SBT Clearance" sig-nal (F-DI or F-PO).

• "0"Starting the safe brake test requires that two signals beset, "SBT Clearance" (F‑DI or F‑PO) and "ActivateSBT" (DI or PO).

Direction of move-ment/test direction

• Positive direction of movement / positive test direction:– Clearance in the positive direction of movement takes

place in step 1.– The build-up of the test torque in the positive direction

of movement takes place in step 3.• Positive direction of movement / negative test direction:

– Clearance in the positive direction of movement takesplace in step 1.

– The build-up of the test torque in the negative direc-tion of movement takes place in step 3.

• Negative direction of movement / positive test direction– Clearance in the negative direction of movement

takes place in step 1.– The build-up of the test torque in the positive direction

of movement takes place in step 3.• Negative direction of movement / negative test direction

– Clearance in the negative direction of movementtakes place in step 1.

– The build-up of the test torque in the negative direc-tion of movement takes place in step 3.

Maximum travel sec-tion in the direction ofmovement

• The set value defines a limit value for the set direction ofmovement. The required movement for clearance is per-mitted up to this limit value.

• The set value must be greater than the set Clearing dis-tance.

Maximum travel sec-tion in the against thedirection of movement

• The set value defines a limit value against the set direc-tion of movement. The required movement for clearanceis permitted up to this limit value.

• The set value must be greater than the set Clearing dis-tance.

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Menu item DescriptionRetraction distance • The machine moves in the required direction of move-

ment with the set track length in step 1. Then the ma-chine moves against the required direction of movementwith half the track length.

• The value must be smaller than the value set for Maxi-mum travel section in the direction of movement.

• The value must be greater than 20 times the value ofPermitted movement in idle state.

• The Clearing distance must be selected in such a waythat clearing takes at least as long as the Duration of indi-vidual test steps.

Information:After clearing the machine in step 1, the position differs fromthe start position. If the identical start/end position is requiredin a machine-specific manner, positioning to the desired posi-tion must be carried out by the machine control after thebrake test is complete.

Positional tolerancefor retraction distance

Maximum permitted difference between the actual clearingdistance and the setpoint entered in the Clearing distance.

Acceleration duringclearing

• Setpoint for accelerating the machine to the set Maximumspeed during clearance.

• With machines with Load torque= 0, the acceleration ofthe inverter must be set.

Maximum speed dur-ing clearance

Maximum permitted speed of machine during clearance.The actual speed during clearance varies together with theRetraction distance. With long travel sections, the machinemoves at the set maximum speed. With short clearing dis-tances, the actual speed will be less in order to move to thetarget position correctly.

Tolerance for clear-ance duration

Maximum permitted deviation of actual clearance duration incomparison to the calculated duration.The duration that is expected is calculated from the followingparameter settings:• Retraction distance• Maximum speed during clearance• Maximum acceleration during clearance• Encoder filter time

Waiting time Time for which the drive stops (waits) after a movement orpossible movement before the next sub-step starts. The wait-ing time allows possible vibration/fluctuation in the machineto die away.

Permitted movementin idle state

During the brake test, the position is monitored several timesduring idle state. The setting value tolerates the maximummovement during idle state.

Load torque • Entry of load torque that is present at the drive at the testposition.

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Menu item DescriptionLoad torque tolerance • The set load torque is tested during the test procedure.

This parameter defines the permitted deviation from theparameterized load torque.

• Possible load torque fluctuations over the planned ser-vice life of the machine such as friction, wear etc. mustbe taken into consideration.

• The tolerance may not be used to compensate for differ-ent load conditions.

Duration of individualtest steps

• Duration of individual test steps until next test step, e.g.stopping the test torque in step 3.

• The duration must make it possible to determine the ac-tual torques. SEW‑EURODRIVE recommends durationsgreater than 0.5 s. With a high level of device utilization,the minimum duration can also be greater.

Test torque Setting for the desired test torque with which the brake istested. The level and direction of an existing load torquemust be taken into consideration.Examples:• Hoist: Base load "pushes" in the direction of movement.

– Required test torque: 100 Nm, base load: +30 Nm– Test torque setting: 70 Nm

• Hoist: Base load "pulls" in the direction of movement.– Required test torque: 100 Nm, base load: -30 Nm– Test torque setting: 130 Nm

• Trolley: No base load present– Required test torque: 100 Nm, base load: 0 Nm– Test torque setting: 100 Nm

Permitted deviationfrom test torque

The setting tolerates a deviation of the actual test torque inrelation to the set test torque.

Brake release time Duration until brake opens. The value is taken from the start-up of drive train 1 (AS1) of the inverter and displayed here forinformation.

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6.1.13 "Function assignment" menu

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The required function is assigned to the safe digital inputs F-DI and the safe digitaloutputs F-DO in the "Function assignment" menu.

Function assignment of safe digital outputs F-DOIf 2 brakes are to be tested in the safe brake system, both F-DOs must be selectedwith the "SBC" function. Afterwards, the two F-DOs function as follows:• With functional actuation, the two F-DOs control both brakes simultaneously within

the device via the inverter (DB00).• With safe control using the SBC function via the MOVISAFE® CS..A safety card,

both brakes are safely switched off at the same time.• When the brake test is carried out, both brakes are controlled separately. First, the

brake test is carried out with the brake controlled at F-DO 00, then the brake test isautomatically repeated with the brake controlled at F-DO 01.

Menu item DescriptionF-DO 00 • "None"

The output has no function.• "STO"

The output switches to a status of STO when activation/deactivation take place.

• "SBC"The output takes over the function of the safe brake con-trol SBC and the functional actuation DB00 from the in-verter. The SBT brake test tests the brake that is con-trolled with this output.

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6 StartupControl brake test


Menu item DescriptionF-DO 01 • "None"

The output has no function.• "STO"

The output switches to a status of STO when activation/deactivation take place.

• "SBC"The output takes over the function of the safe brake con-trol SBC and the functional actuation DB00 from the in-verter. The SBT brake test tests the brake that is con-trolled with this output.

Function assignment of safe digital inputs F-DI

Menu item DescriptionF-DI 00 to F-DI 03 • "None"

The input has no function.• "SBT-Clearance"

Depending on the setting of menu item "Activation bySBT clearance", the signal triggers the enable for carry-ing out the brake test or for starting the brake test.

• Other settable functionality has no bearing on the braketest.

6.2 Control brake test

6.2.1 Starting conditionsPay attention to the following starting conditions before activating the brake test.• The machine must be in a suitable test position that makes a movement possible

during the active brake test. Executing the brake test must not put persons at risk.• Activate a suitable function block (e.g. FCB 26) at the inverter, which allows the

brake test to be executed.The brake test is aborted if a function block with a higher priority is activated. Youwill find the current function blocks in the inverter in chapter "FCB concept". Moreinformation about the FCB concept is described in the inverter product manual.

• Pay attention to compatibility with the drive safety functions. Refer to chapter"Drive safety functions".

• If F-communication is being used, deactivate non-enabled drive safety functions inthe F-PO with a logical "1" for the duration of the active brake test.

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6StartupControl brake test


6.2.2 Starting the brake test• Start the brake test via safe signal "SBT Clearance". In accordance with the para-

meterization, the brake test starts immediately or must be additionally started us-ing the "Activate SBT" signal.Function block FCB 23 is active in the inverter when executing the safe brake test.FCB 23 is exclusively used in combination with the safe brake test. Bit "SBT-Ac-tive" is set to a logical status of "1" in the process data (PI and F-PI).

• If a safe digital output F-DO is parameterized to the safe brake control functionSBC, the brake that is controlled by this F-DO is tested. If both F-DOs of the safetycard are parameterized to SBC, the brake test is performed twice. The brake at F-DO 00 is tested first. If this test is error-free, the test of the second brake is auto-matically tested at F-DO 01. Steps 3 – 5 are repeated to test the second brake.

6.2.3 Test result and ending the testThe brake test can be completed with or without an error message.1. Brake test finishes without an error message.

The brake has successfully passed the brake test. Completion of the brake test isindicated by bit "SBT-Active" being set to logical "0". At the same time, the inverteris set to status "STO". The "STO" bit is set to logical "1". The 7-segment display atthe inverter flashes in status "C2".Brake test control can be deactivated (signals "SBT-Clearance" and, if necessary,"SBT activate"). The inverter switches to FCB 02.

2. Brake test finishes with an error message.The brake has not passed the brake test. Completion of the brake test is indicatedby bit "SBT-Active" being set to logical "0". At the same time, the inverter is set tostatus "STO". The "STO" and "Diagnosis ASF" bits are set to logical "1". The 7-segment display at the inverter flashes with error message E‑46.50 (Safety carderror). The safety card signals an error detected by SBT E-70.xx (safe brake sys-tem). The error numbers of positions "xx" provide detailed information about theerror that has been detected. A list of error numbers can be found in chapter "Listof error messages".To acknowledge an error, first deactivate the safe brake test control (signals "SBTClearance" and, if necessary, "Activate SBT"). You can then reset the pendingerror by acknowledging the error at the safety card. After successful acknowledg-ment, the inverter switches to FCB 02.

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7 OperationProcess and actual values


7 Operation

7.1 Process and actual valuesIn MOVISUITE® diagnosis, the process and actual values for the brake test are dis-played under [MOVISAFE® CS..A] > [Brake test].

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7.2 Status message SBT activeThe status of the brake test is transmitted in the F communication (F-PI) in bit "SBTActive".• SBT-Active = 0: Brake test is inactive• SBT-Active = 1: Brake test is activeThe SBT active status is inactive if the brake test shows the following states:• Brake test has not been activated• Brake test has ended• Brake test was aborted. The "Diagnosis ASF" bit is also set to logical "1" as an

error message.The status is transferred to the inverter internally. It can continue to be used in the in-verter, e.g. as a digital output or for transferring to the process data (PI).

7.3 Aborting the brake testIf an active brake test is aborted, the STO drive safety function is activated at the in-verter. The inverter cannot build up any more torque. At the same time, the F-DOs thatare assigned with SBCs are switched off. The brakes are applied. The drive can stillmove for the duration of the brake application time.An active brake test is aborted if the following events occur:• In step 1, a section is detected that is bigger than the section set under Maximum

travel section in the direction of movement or Maximum travel section against thedirection of movement.

• In step 1, the target position is not reached on time when clearance is performed.In order to do so, the brake test calculates the anticipated position duration fromthe settings of the following parameters:

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7OperationAborting the brake test


– Retraction distance

– Maximum speed during clearance

– Maximum acceleration during clearance

– Encoder filter time

After the calculated position duration, including the set tolerance, the drive musthave undershot the minimum speed of the speed functions..

• In step 1, an actual position is detected during clearance, which differs more thanthe permitted value under Clearance distance, taking into consideration the Posi-tional tolerance for the clearance distance.

• In step 1, a movement is detected during the wait time, which is greater than thevalue set under Permitted movement during idle state.

• In steps 2 and 3 (load torque test and "Active" brake testing), it is detected that thedifference between the determined load torque and the Load torque settings whenconsidering the Load torque tolerance is unacceptably high.

• In steps 2 and 3 (load torque test and "Active" brake testing), the number of recor-ded actual torques is too low.

• In step 3, a movement is detected during "active" brake testing that is greater thanthe value set under Permitted movement during idle state.

• In step 3 during "active" brake testing, it is detected that the difference betweenthe determined actual torque and the Test torque settings when considering thePermitted deviation from test torque is unacceptably high.

• In step 3 during "active" brake testing, it is detected that the inverter is generatingthe required test torque in the wrong direction of movement.

• In step 4, a movement is detected during "passive" brake testing that is greaterthan the value set under Permitted movement during idle state.

• Activation of one of the following drive safety functions: STO/SBC, SSx, SOS,SSR, SDI, SLI.

• Limit violation at one of the SLS/SSM or SLA drive safety functions, even if thelimit violation is signaled solely by the F communication.

• Activation of a drive function (FCB) with a higher priority in the inverter.• Control of the "Activate SBT" or "SBT Clearance" signals is deactivated (logical

"0").• The brake is applied by the inverter.• Error status at safety card CS..A.• Safety card CS..A is parameterized, the report is generated or the parameteriza-

tion is confirmed.• Error status at inverter.

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7 OperationError messages


7.4 Error messages7.4.1 Display of error messages

Error messages for the brake test function are displayed as follows:• On the inverter with:

– E-46.50 safety card: Warning (with fault class "Warning")– E-46.52 safety card: Critical error (with fault class "System error")

• On the safety card CS..A with E-70.xx safe brake systemPositions "xx" represent placeholders for a detailed error number in accordancewith chapter "List of error messages".

• In the process data (F-PI and PI)

7.4.2 List of error messages

Fault 70 Safe brake system

Subfault: 70.1Description: Safe brake test aborted. Enable signal fault.

Fault class: Warning

Cause Measure

The enable signal has been deactivated when ex-ecuting the safe brake test.

Make sure that the enable signal remains activeduring the safe brake test.

Subfault: 70.2Description: Safe brake test aborted. Brake request error.


Cause Measure

Basic unit requested brake application duringsafe brake test.

Make sure that no drive function is controlled orthat the basic unit is not in fault status.

Subfault: 70.3Description: Safe brake test aborted. Drive safety function fault.


Cause Measure

Instance of drive safety functions STO/SBC,SOS, SSx, SSR, SDI or SLI activated during thesafe brake test.

Make sure that no drive safety function is activa-ted while the brake test is active (only SLS/SSMor SLA are permitted).

Subfault: 70.4Description: Safe brake test aborted. Load torque fault.


Cause Measure

Measured load torque outside configured toler-ance.

Make sure that the load torque matches the set-tings during the brake test.

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7OperationError messages


Subfault: 70.5Description: Safe brake test aborted. Test torque not reached.


Cause Measure

Basic unit does not deliver parameterized testtorque.

– Check the settings of the basic unit and adjust,if necessary.– Make sure that the basic unit can deliverenough power.

Subfault: 70.6Description: Safe brake test aborted. Error, maximum travel section in the direction of movement.


Cause Measure

Maximum travel section exceeded in the directionof movement.

– Choose a sufficiently long maximum travel sec-tion (travel section > retraction distance + posi-tional tolerance).– Check the direction of movement and correct, ifnecessary.– Check the settings for direction of rotation re-versal and adjust, if necessary.– Make sure that the movement can be per-formed and that the drive does not slip.

Subfault: 70.7Description: Safe brake test aborted. Error, maximum travel distance against the direction of move-ment.


Cause Measure

Maximum travel distance exceeded against thedirection of movement.

– Choose a sufficiently long maximum travel sec-tion (travel section > retraction distance + posi-tional tolerance).– Check the direction of movement and correct, ifnecessary.– Check the settings for direction of rotation re-versal and adjust, if necessary.– Make sure that the movement can be per-formed and that the drive does not slip.

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Subfault: 70.9Description: Safe brake test aborted. Error, clearing distance exceeded.


Cause Measure

The deviation of the actual clearing distance isgreater than permitted in the setting Positional tol-erance for clearing distance.

– Check the settings of the basic unit and adjust,if necessary.– Check the encoder setting in parameterizationtool "Assist CS.." and correct, if necessary.– Check the value of the parameter Positional tol-erance for clearing distance, and increase, if ne-cessary.– Make sure that the basic unit can deliverenough power.

Subfault: 70.10Description: Safe brake test aborted. Error FCB 23.


Cause Measure

FCB with higher priority than FCB 23 activated inthe basic unit.

Do not activate an FCB in the basic unit with ahigher priority than FCB 23 while the safe braketest is running.

Subfault: 70.11Description: Safe brake test aborted. Error, communication with the basic unit.


Cause Measure

Timeout error in communication with basic unit. – Repeat the brake test.– If the fault occurs repeatedly, replace the safetycard and send it together with the fault number toSEW‑EURODRIVE. For further support, contactSEW‑EURODRIVE Service.

Subfault: 70.12Description: Safe brake test aborted. Error, assignment of drive safety function SBC.


Cause Measure

SBC drive safety function not assigned to safe di-gital output F‑DO.

– Check the parameter setting of the safety card.– Assign the SBC drive safety function to one ofthe safe digital outputs F‑DO and connect thebrake control (e.g. BST) to it.

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7OperationError messages


Subfault: 70.13Description: Safe brake test aborted. Error, movement during idle state.


Cause Measure

Maximum movement permitted at idle state ex-ceeded.Brake or basic unit cannot hold the load torque.

– Check Permitted movement during idle stateparameter and correct, if necessary.– Make sure that the brake control is correct.– Make sure that the basic unit provides the re-quired power.– Make sure that the brake can hold the loadtorque and the test torque.

Subfault: 70.14Description: Safe brake test aborted. Minimum speed fault.


Cause Measure

Speed greater than parameterized minimumspeed detected at end of retraction distance.

– Check the settings of the safety card, and ad-just, if necessary.– Check the settings of the basic unit and adjust,if necessary.– Make sure that the basic unit is not subject tooverload.

Subfault: 70.15Description: Safe brake test aborted. Minimum speed fault.


Cause Measure

Speed greater than parameterized minimumspeed detected when activating brake test.

Check the minimum speed and adjust, if neces-sary.

Subfault: 70.16Description: Safe brake test aborted. Fault in effective direction of test torque.


Cause Measure

The torque specified by the basic unit has thewrong effective direction.

– Check the settings of the basic unit and adjust,if necessary.– Check the settings for direction of rotation re-versal and adjust, if necessary.

Subfault: 70.18Description: Safe brake test aborted. Error, error acknowledgment.

Fault class: System error

Cause Measure

Fault acknowledged during safe brake test. Deactivate the safe brake test before acknowled-ging the fault.

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Subfault: 70.19Description: Safe brake test aborted. Drive safety function signals limit violation.


Cause Measure

Limit violation signaled by drive safety functionactive at the same time (e.g. SLS) during safebrake test.

– Check which drive safety function signaled thelimit violation.– Refer to the measures in the fault description toeliminate the fault.

Subfault: 70.20Description: Safe brake test aborted. Safety card fault.


Cause Measure

Fault detected by safety card during safe braketest.

– Check which fault has occurred.– Refer to the measures in the fault description toeliminate the fault.

Subfault: 70.22Description: Safe brake test aborted. Fault while checking load torque.


Cause Measure

Failed to check load torque while executing safebrake test. Cannot determine load torque.

– Extend the duration of the individual test steps.– Deactivate load torque checking (loadtorque = 0).

Subfault: 70.23Description: Safe brake test aborted. Error, measured values.


Cause Measure

Failed to determine test torque while safe braketest is running.

– Extend the duration of the individual test steps.– If the fault occurs repeatedly, replace the deviceand send it together with the fault number toSEW‑EURODRIVE. For further support, contactSEW‑EURODRIVE Service.

7.4.3 Acknowledging the error messagesObserve the information in chapter "Test result and ending the test" (→ 2 37).

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8Acceptance


8 AcceptanceTo complete the startup, proper functionality of the brake test must be checked via anacceptance procedure. A report can be generated using the "Assist CS.." parameteri-zation tool. More information can be found in the manual of the MOVISAFE® CS..Asafety card.

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9 AppendixFCB concept


9 Appendix

9.1 FCB conceptThe FCB concept (FCB - Functional Control Block) term describes the modular firm-ware design of MOVI-C® inverters, which ensures that a wide range of drive functionscan be selected or deselected flexibly and easily using control words.All primary functions, i.e. functions that move or control the motors, are designed asindividual FCBs that only have to be selected to perform a specific task, e.g. position-ing.You can switch between different FCBs at any time. Switching to another FCB takesplace with a maximum delay of 0.5 ms.Different priorities are assigned to the FCBs. If a FCB with a higher priority than thecurrently active FCB is selected, the FCB with the higher priority is activated.The FCBs are sorted in descending order of their priority in the following list:• FCB 01 Output stage inhibit• FCB 14 Emergency stop• FCB 13 Stop at application limits• FCB 18 Rotor position identification• FCB 25 Motor parameter measurement• FCB 12 Reference travel• FCB 04 Manual mode• FCB 20 Jog mode• FCB 19 Position hold control• FCB 21 Brake test• FCB 23 Brake test, safety card CS..A• FCB 10 Interpolated positioning control• FCB 09 Positioning control• FCB 06 Interpolated speed control• FCB 05 Speed control• FCB 08 Interpolated torque control• FCB 07 Torque control• FCB 26 Stop at user limits• FCB 02 Default stop

INFORMATION• The FCB concept and the functionality of the respective FCBs are described in the

inverter product manual.• The FCB 23 is exclusively used in combination with the brake test of safety card

CS..A described herein.

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Index

IndexA

Appendix ............................................................. 46FCB concept................................................... 46

B

Brake testDirection of movement/test direction .............. 14Functional description .................................... 14Step-by-step procedure.................................. 18

Brake test system description ............................. 11Diagnostics coverage (DC) ............................ 13Test rate in safe braking systems................... 12

Brake test, step by step procedureEnd of test ...................................................... 20Step 1: Clearing.............................................. 18Step 2: Load torque test (optional) ................. 19Step 3: Active testing of the brake.................. 19Step 4: Passive brake testing (optional)......... 20

C

Configuring the brake test"Basic settings" menu..................................... 26"Brake test" menu........................................... 31"Checksum overview" menu........................... 26"Encoder" menu ............................................. 29"F communication" menu ............................... 30"Function assignment" menu.......................... 35"Safe inputs" menu......................................... 27"Safe outputs" menu....................................... 28"STO/SBC" menu ........................................... 31"User units" menu........................................... 30Menus "SSx" to "SLA" .................................... 31Pre-selection for control ................................. 25Starting the "Assist CS.." parameterization tool....................................................................... 26

Control brake testStarting conditions.......................................... 36Starting the brake test .................................... 37Test result and ending the test ....................... 37

Copyright notice .................................................... 6

D

Decimal separator ................................................. 6Definitions............................................................ 10

Designated use ..................................................... 9Diagnostics coverage (DC) ................................. 13Direction of movement/test direction

Load torque = 0 (3 test steps) ........................ 17Load torque > 0 (5 test steps) ........................ 15

Documents, applicable .......................................... 6

E

Embedded safety notes......................................... 6Error messages

Acknowledgment ............................................ 44Display............................................................ 40List.................................................................. 40

F

Functional description of the brake test............... 14

H

Hazard symbolsMeaning............................................................ 5

N

NotesDesignation in the documentation .................... 5Meaning of the hazard symbols ....................... 5

O

Operation............................................................. 38Aborting the brake test ................................... 38Error messages .............................................. 40Process and actual values ............................. 38Safety notes ..................................................... 9SBT active status message............................ 38

Other applicable documentation............................ 6

P

Product names ...................................................... 7Project planning notes

Brake control/safe brake control..................... 23Direction of rotation reversal .......................... 22Drive safety functions ..................................... 22Encoder/safety encoder ................................. 23Motors ............................................................ 22MOVIDRIVE® modular/system/technology..... 21MOVIDRIVE® modular/system with CiA402device profile .................................................. 21

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Index

MOVISAFE® CS..A safety card ...................... 21MOVISUITE® permission level ....................... 21Number of testable brakes ............................. 24Systems with mechanical backlash................ 23User units ....................................................... 22

R

Rights to claim under limited warranty .................. 6

S

Safety notesDesignation in the documentation .................... 5Meaning of the hazard symbols ....................... 5Preliminary information..................................... 8Structure of embedded..................................... 6Structure of section-related .............................. 5

Section-related safety notes.................................. 5Signal words in safety notes.................................. 5Startup................................................................. 25

Control brake test ........................................... 36Safety notes ..................................................... 9

T

Target group.......................................................... 8Test rate in safe braking systems........................ 12

One-off call-up of the brake test ..................... 12Regular call-up of the brake test .................... 12Special feature for machines with access regula-tion.................................................................. 12

Trademarks ........................................................... 7

U

Use, designated .................................................... 9

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SEW-EURODRIVE—Driving the world

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