Upgrading from 8BVIxxx-1 and 8BVIxxx-3 SafeMOTION ACOPOSmulti modules to 8BVIxxx-4 modules

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When upgrading the ACOPOSmulti SafeMOTION hardware in a machine from 8BVIxxx-1 or 8BVIxxx-3 SafeMOTION ACOPOSmulti modules to 8BVIxxx-4 modules it is important to note that the hardware upgrade in Automation Studio needs to be replaced as well. Using 8BVIxxx-4 SafeMOTION ACOPOSmulti modules with the wrong hardware upgrades will result in non-functional modules.

Additionally, the Automation Studio project and the SafeDESIGNER project need to be compiled and downloaded.

The required device upgrades to be used are the following:

  • V4.6/V6.0 HW (8BVIxxxxxxSS.xxx-4) (EnDat 2.2 single axis)

  • V4.6/V6.0 HW (8BVIxxxxxxSA.xxx-4) (SinCos single axis)

  • V4.6/V6.0 HW (8BVIxxxxxxDS.xxx-4) (EnDat 2.2 double axis)

Also, the 8BVSV2SAFE1-1 SafeMOTION encoder module needs to be replaced by the following module:

  • V4.6/V6.0 HW Upgrade (8BSMC9173)

These upgrades are available on the B&R website or through Automation Studio → Tools → Upgrades.

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Hardwareaustausch SafeMotionUmrichter
Problem with a changed 8BVI0330HWSS.00-1
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Legacy Safety

When upgrading from 8BVIxxx-1 or 8BVIxxx-3 SafeMOTION ACOPOSmulti modules to 8BVIxxx-4 in an Automation Studio project that uses Legacy Safety, there are a few different requirements and additional steps that need to be taken to ensure a successful replacement.

The following Safety Release version must be used:

  • Safety Release 1.10

While the hardware upgrades for the 8BVIxxx-4 modules are the same as for mapp Safety (see above), the hardware upgrade for the 8BSMC9173 required is different:

  • V4.0 (8BSMC9173) - 1.10.4.1

This upgrade is available on the B&R website ( V4.0 HW Upgrade (8BSMC9173) | B&R Industrial Automation ) or through Automation Studio → Tools → Upgrades.

Since Automation Studio will automatically try to use the newest installed hardware upgrade version when doing a hardware “Replace”, it is not possible to directly replace the 8BVSV2SAFE1-1 on the 8BVIxxx-4 with the 8BSMC9173 v1.10.4.1 - if you try to do this by adding the module to the hardware tree and then dragging it in, you will see the following error: “Hardware module type 8BSMC9173 requires Safety Release 5.4 or higher. Current Safety Release is 1.10.”

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This is because it is by default using the hardware upgrade version 2.6.0.0 and finding that it is incompatible with Legacy Safety.

To work around this, you need to do the following after replacing the 8BVIxxx-1 or 8BVIxxx-3 with the 8BVIxxx-4:

  1. Delete the old 8BVSV2SAFE1-1 encoder module.
  2. Add the 8BSMC9173 to the bottom of the hardware tree as an “Unconnected Hardware Module”.
  3. Manually set the hardware upgrade version of the 8BSMC9173 to 1.10.4.1.
  4. Drag it into SS1 of the 8BVIxxx-4.

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If you have multiple SafeMOTION ACOPOSmulti’s that you are replacing, for subsequent replacements to the first one you can simply:

  1. Replace the 8BVIxxx-1 or 8BVIxxx-3 with the 8BVIxxx-4.
  2. Delete the old 8BVSV2SAFE1-1 encoder module.
  3. Copy and paste the 8BSMC9173 with hardware upgrade version 1.10.4.1 from the first 8BVIxxx-4 to SS1 of the newly replaced 8BVIxxx-4.

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After making these changes, the Automation Studio project and the SafeDESIGNER project need to be compiled and downloaded, and the Safety application must be fully tested and verified.

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