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F6 instruction manual

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COMBIVERT Original Manual Mat.No. Rev. 00F6NES-K000 1B GB Installation Manual COMBIVERT F6 with Safety Function STO Control Circuit
Transcript
Page 1: F6 instruction manual

C O M B I V E R T

Original ManualMat.No. Rev.00F6NES-K000 1B

GB Installation Manual COMBIVERT F6 with Safety Function STOControl Circuit

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Table of Contents

1. Preface ..............................................................................................................51.1 General ................................................................................................................................. 51.2 Safety Instructions .............................................................................................................. 51.3 Validity and liability ............................................................................................................. 51.4 Copyright .............................................................................................................................. 61.5 Specifiedapplication ........................................................................................................... 61.6 Product description ............................................................................................................. 6

2. Control ..............................................................................................................82.1 Features of the control ........................................................................................................ 82.2 Overview ............................................................................................................................... 82.2.1 Control terminal strip X2A ...................................................................................................... 92.2.2 Safety terminal block X2B ...................................................................................................... 92.2.3 CAN terminal block X2C ........................................................................................................ 92.2.4 Analog inputs X2D ................................................................................................................ 92.2.5 Diagnostic interface X4A ........................................................................................................ 92.2.6 Encoder interfaces X3A, X3B ................................................................................................ 92.3 Connection of the control ................................................................................................. 102.3.1 Assembly of the wires .......................................................................................................... 102.4 Assignment of the terminal strip X2A ...............................................................................112.4.1 Connection of the digital inputs ............................................................................................ 122.4.2 Connection of the digital outputs ......................................................................................... 122.5 Assignment of the STO terminal strip X2B ..................................................................... 132.5.1 Inputs ................................................................................................................................... 132.5.1.1 SpecificationoftheSTOinputs ........................................................................................... 132.5.1.2 STOwithOSSDsignals ....................................................................................................... 132.5.2 OutputSTO .......................................................................................................................... 132.6 Assignment of the CAN terminal strip X2C ..................................................................... 142.7 Assignment of the terminal strip for analog inputs X2D ............................................... 142.7.1 Connection of the analog inputs .......................................................................................... 142.7.2 Diagnosis/visualisation ........................................................................................................ 152.7.2.1 Assignment of the interface X4A .......................................................................................... 152.7.2.2 Connection of the RS232 interface ...................................................................................... 152.7.2.3 Connection of the RS485 interface ...................................................................................... 152.7.2.4 Wiring RS485 full duplex ..................................................................................................... 162.7.2.5 Wiring RS485 half duplex .................................................................................................... 162.8 Socket X4C EtherCAT IN and X4B EtherCAT OUT .......................................................... 172.9 Encoder Parameter ............................................................................................................ 172.9.1 Encoder interfaces X3A and X3B ........................................................................................ 18

3. Safety Function STO .....................................................................................193.1 Emergency stop according EN 60204 .............................................................................. 203.2 ClassificationofSTOaccordingIEC61508 ..................................................................... 213.3 ClassificationofSTOaccordingENISO13849 ............................................................... 213.4 Additional instructions ...................................................................................................... 213.5 Functional Description ...................................................................................................... 223.6 Wiring Examples ................................................................................................................ 23

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Table of Contents

3.6.1 Direct switching off with emergency stop switch .................................................................. 233.6.2 Direct switching off with emergency stop switch and monitoring of the wiring .................... 243.6.3 Direct switching off by safety module with test pulses ......................................................... 253.6.4 Wiring SS1 ........................................................................................................................... 26

4. Certification ....................................................................................................284.1 Annex to the declaration of conformity ........................................................................... 28

5. Revision history .............................................................................................30

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Preface

1. Preface1.1 General

First we would like to welcome you as a customer of the company Karl E. Brinkmann GmbH and congratulation to the purchase of this product. You have decided for a product on highest technical level.

Thedescribedhard-andsoftwarearedevelopmentsoftheKarlE.BrinkmannGmbH.Theenclosed documents correspond to conditions valid at printing. Misprint, mistakes and techni-cal changes reserved.

Theinstructionmanualmustbemadeavailabletotheuser.Beforeworkingwiththeunittheusermustbecomefamiliarwithit.Thisespeciallyappliestotheknowledgeandobservanceofthefollowingsafetyandwarningindications.Theusedpictogramshavefollowingsignifi-cance:

Danger Is used, if life or health of the user are endangered or sub-stantial damage to property can occur.Warning

Caution

Attention Is used, if a measure is necessary for safe and trouble-free operation.observe at

all costs

Information Isused,ifameasuresimplifiesthehandlingoroperationofthe unit.Aide

Tip

1.2 Safety Instructions

Observe safety and operating instruc-tions

Condition for all further steps is the knowledge and obser-vance of the safety, EMC and operating instructions (part 1 „GettingStarted“0000NEB-0000).This instruction is provi-ded with the unit or by download of www.keb.de.

Non-observanceofthesafetyinstructionsleadstothelossofanyliabilityclaims.Thesafetyandwarninginstructionsspecifiedinthismanualdonotlayclaimoncompleteness.Thislistis not exhaustive.

1.3 Validity and liabilityThe use of our units in the target products is outside of our control and therefore lies exclusively in the area of responsibility of the machine manufacturer.Theinformationcontainedinthetechnicaldocumentation,aswellasanyuser-specificadvicein spoken and written and through tests, are made to best of our knowledge and information about the application. However, they are considered for information only without responsibil-ity.Thisalsoappliestoanyviolationofindustrialpropertyrightsofathird-party.

Selection of our units in view of their suitability for the intended use must be done generally by the user.

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Preface

Testscanonlybedonewithintheapplicationbythemachinemanufacturer.Theymustberepeated,evenifonlypartsofhardware,softwareortheunitadjustmentaremodified.

Unauthorised opening and tampering may lead to bodily injury and property damage and may entail the loss of warranty rights. Original spare parts and authorized accessories by the manufacturerserveassecurity.Theuseofotherpartsexcludesliabilityfortheconsequencesarising out of.

Thesuspensionofliabilityisespeciallyvalidalsoforoperationinterruptionloss,lossofprofit,datalossorotherdamages.Thisisalsovalid, ifwereferredfirsttothepossibilityofsuchdamages.

If single regulations should be or become void, invalid or impracticable, the effectivity of all other regulations or agreements is not affected.

1.4 CopyrightThecustomermayusetheinstructionmanualaswellasfurtherdocumentsorpartsfromitforinternal purposes. Copyrights are with KEB and remain valid in its entirety.All rights reserved.

KEB®, COMBIVERT®, KEB COMBICONTROL® and COMBIVIS® are registered trademarks of Karl E. Brinkmann GmbH.Other wordmarks or/and logos are trademarks (TM) or registered trademarks (®) of their respective owners and are listed in the footnote on the first occurrence. When creating our documents we pay attention with the utmost care to the rights of third par-ties.Should we have not marked a trademark or breach a copyright, please inform us in order to have the possibility of remedy.

1.5 SpecifiedapplicationTheCOMBIVERTF6servesexclusivelyforthecontrolandregulationofthree-phasemotors.Theoperationofotherelectricconsumersisprohibitedandcanleadtothedestructionoftheunit. Inverter are components designed for inclusion in electrical installations or machinery.

TheusedsemiconductorsandcomponentsofKEBaredevelopedanddimensionedfortheuseinindustrialproducts.IftheKEBCOMBIVERTF6isusedinmachines,whichworkunderexceptional conditions or if essential functions, life-supporting measures or an extraordinary safetystepmustbefulfilled,thenecessaryreliabilityandsecuritymustbeensuredbythemachinebuilder.Theoperationofourproductsoutsidetheindicatedlimitvaluesofthetechni-caldataleadstothelossofanyliabilityclaims.Thesafetyfunctionislimitedtoaservicelifeof 20 years. After this time the unit must be replaced.

1.6 Product descriptionTheproduct familyCOMBIVERTF6withsafety functionSTOhasbeendevelopedfor theuseinsafety-orientedapplications.Thebasicstandardsaswellasapplicationandcountry-specificstandardsmustbeobservedfurthermore.Thestandardsreferredinthismanualmustbe observed supplementary !

ThesafetyfunctionSTOaccordingtoIEC61800-5-2contains:

• Safetorqueoff(SafeTorqueOff-STO)

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Preface

Thesafetyfunctionmeettherequirementsinaccordancewithperformancelevele(ISO13849-1) and SIL 3 (IEC 61508 and IEC 62061). In case of proper project design, installation and operation the safety function protects people against mechanical damages.

ThisaccompanyinginstructionmanualcontainsinformationfortheinstallationandconnectionofthecontroloftheKEBCOMBIVERTF6,aswellasthesafetytechnology.

Numerical code:

ControlwithSTOfunction used in Controller1KF6Kxx-xxxx frequencyinverteruptohousingE

(x=variable y=D, E)xxF6Kxy-xxxx

2KF6Kxx-xxxx frequencyinverteruponhousingG(x=variable y=G…W)

xxF6Kxy-xxxx

Validityofcertificates

The certification of controllers with safety tech-nology is only valid if the material number cor-respondswiththespecifiednumericalcodeund the FS logo is printed on the type plate.

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Control

2. Control2.1 Features of the control

Thecontrolprovidesthefollowinganaloganddigitalfunctions:• Hardware allocation of digital and analog inputs and outputs.• CAN bus interface• Twofieldbusinterfaces• Serial interface for connection to a pc• Twouniversalencoderinterfaces• Hardwareofthecontrolcircuit„safetyseparated“accordingtoEN61800-5-1(baseTN-

C/-S mains)• SafetyfunctionSTO(twochanneltorqueoff)

2.2 OverviewControl 2KF6

X2A

X2B X2C X2D X4A

X3A

X4B X4C

X3B

Control 1KF6

X2A

X2B X2C X2DX4A

X3A

X4B X4CX3B

X2A Control terminal strip X4A Diagnostic interfaceX2B Terminalblocksafetyfunction X4B

Fieldbus interfaceX2C CAN interface X4CX2D Analog inputsX3A Encoder interface channel 1X3B Encoder interface channel 2

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Control

2.2.1 Control terminal strip X2AThecontrolterminalblockX2Aisdesignedasdouble,plug-interminalblockwithspringcageconnection. It contains 28 pole.

2.2.2 Safety terminal block X2BThesafetyterminalblockX2Bisdesignedasdouble,plug-interminalblockwithspringcageconnection. It contains 10 pole.

2.2.3 CAN terminal block X2CThecontrolterminalblockX2Cisdesignedasdouble,plug-interminalblockwithspringcageconnection. It contains 4 pole.

2.2.4 Analog inputs X2DThesafetyterminalblockX2Disdesignedasdouble,plug-interminalblockwithspringcageconnection. It contains 6 pole.

2.2.5 Diagnostic interface X4AThe integratedRS232/485 interfaceservesfor theconnectionofservicetools(e.g.COM-BIVIS)anddisplays.TelegramDIN66019IIisusedascommunicationprotocol.

2.2.6 Encoder interfaces X3A, X3BDerCOMBIVERTcontainstwouniversalencoderinterfaces.Theinterfacescanbeadaptedindependently by parameter to different encoder.

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Control

2.3 Connection of the controlThefollowinginstructionsmustbeobservedatconnection:

Attention Prevent EMC malfunctions• Use shielded / drilled cables• Lay shield on one side of the inverter onto earth potential• Install control cables and power cables separately (approx. 10…20 cm

distance); Kreuzungen im rechten Winkel verlegen• Toavoid interferencesaseparateshieldingmustbeprovided foranalog

and digital control lines. Depending on the use of the relay outputs, an ex-tra shielding is to be used, too.

• In case of inductive load on the relay outputs a protective wiring must be provided (e.g. free-wheeling diode)!

Theterminalsofthecontrolterminalstripandthetransmitterinputsarese-curely isolated in accordance with EN 50178.

2.3.1 Assembly of the wires

1. Strandedwirerigidlyandflexibly max. perm.cross-sec-

tion

stripping length x =

without wire-end ferrule 1,5 mm² 10 mmwith wire-end ferrule without plastic collar

1,5 mm² metal ferrule length

with wire-end ferrule with plastic collar

1 mm² metal ferrule length + 2 mm

X2. Press with screw driver (A) or some-

thing else onto the labelling3. Plug stranded wire (B) into the

squareslot,thatnowirescanbeseen from the outside.

4. Remove screw driver (A) and check iftheline(B)isfixed.Makesurethatthe stranded wire and not the insula-tion is clamped.

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Control

2.4 Assignment of the terminal strip X2A

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

PIN Name Description Specifications1 Out1 Digital output 1 Imax=100 mA2 0V Reference potential for digital output3 Out2 Digital output 2 Imax=100 mA4 0V Reference potential for digital output5 Out3 Digital output 3 Imax=100 mA6 0V Reference potential for digital output7 Out4 Digital output 4 Imax=100 mA8 0V Reference potential for digital output9 I1 Digital input 1

10 24V Voltageoutputforthecontroloftheinputs +24Vdc*11 I2 Digital input 212 24V Voltageoutputforthecontroloftheinputs +24Vdc*13 I3 Digital input 314 24V Voltageoutputforthecontroloftheinputs +24Vdc*15 I4 Digital input 416 24V Voltageoutputforthecontroloftheinputs +24Vdc*17 I5 Digital input 518 24V Voltageoutputforthecontroloftheinputs +24Vdc*19 I6 Digital input 620 24V Voltageoutputforthecontroloftheinputs +24Vdc*21 I7 Digital input 722 24V Voltageoutputforthecontroloftheinputs +24Vdc*23 I8 Digital input 824 24V Voltageoutputforthecontroloftheinputs +24Vdc*25 24Vin Voltageinputforexternalsupply

24Vdc±25%26 0V Referencepotentialfor24Vin27 CRF 10VReferencevoltageforanaloginputs 10Vdc/Imax = 4 mA28 AGND Analogmass(donotconnectto0V)*) Totalcurrentofall24Vdcoutputs:100mA

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Control

2.4.1 Connection of the digital inputsExamples for the connection of the digital inputs

with internal voltage supply with external voltage supply

1817

2019

2221

2423

12141611

109 1315

2423

1012149

26251113

+

2.4.2 Connection of the digital outputsExamples for the connection of the digital outputs

Connection appliance Connection to an external control

34

56

78

12

312 4

56

78

COM DI1 DI3DI2 DI4

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Control

2.5 Assignment of the STO terminal strip X2B

X2B PIN Name I/O

1

2

3 5

6

7

8

9

104

1 STO1+

InputSTOchannel12 STO1+3 STO1-4 STO1-5 STO2+

InputSTOchannel26 STO2+7 STO2-8 STO2-9 STO-OUT

OutputSTO10 STO-OUT

The individual channels are designed potential-free, so 24Vand0Vcanbeconnected.Theinputsaredesignedbywaythatsafety switchgear units with test pulses (OSSD signals) can be connected.Thesignalsarenotevaluated,theyareonlyfiltered.TheOSSDtestintervalislimitedto10ms.ThereferencepotentialforoutputSTO-OUT(terminalsX2B/9and10)isthemassofthecontrol0V(terminalX2A/26).

2.5.1 Inputs

2.5.1.1 SpecificationoftheSTOinputsSTO

InputsStatus 0 Status 1

UL[V] IL[mA] UH[V] IH[mA]max. 5 25 30 25min. -3 notdefined 15 5

Themaximumshort-termstartingcurrentoftheinputislimitedto300mA.

2.5.1.2 STOwithOSSDsignalsThefiltertimedependsontheminimuminputvoltageandcanbespecifiedasfollows:

Inputvoltage[V] OSSDpulsewidth[ms]15 0.118 0.820 1.124 1.530 1.8

2.5.2 Output STOThe short-circuit proof, digital output is specified in accordance with IEC61131-2. The output rated current is 100 mA at 24 Vdc. The output is 24 Vdc if the inputs STO1 and STO2 are set.

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Control

2.6 Assignment of the CAN terminal strip X2C

X2C PIN Name Notes

1

2

3

4

1 CAN highinternally bridged

2 CAN high3 CAN low

internally bridged4 CAN low

2.7 Assignment of the terminal strip for analog inputs X2D

X2D PIN Name Notes Specification

1

2

3

4

5

6

1 AN1- non-floatingdifferential input 1

±10Vdcor4…20 mA2 AN1+

3 AN2- non-floatingdifferential input 2

±10Vdcor4…20 mA4 AN2+

5 AN3- non-floatingdifferential input 3 ±10Vdc

6 AN3+

2.7.1 Connection of the analog inputsExamples for the connection of the analog setpoint input

6285

43

2127

R = 0…3/5/10kΩ 4 63

21 5

2827

+

*

0…±10Vdc

21

43

65

+4…20mA

*) Connectpotentialequalizinglineonlyifapotentialdifferenceof>30Vexistsbetweenthecontrols.Theinternalresistanceisreducedto30kΩ.

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Control

2.7.2 Diagnosis/visualisationThe integratedRS232/485 interfaceservesfor theconnectionofservicetools(e.g.COM-BIVIS)anddisplays.TelegramDIN66019IIisusedascommunicationprotocol.

ThecorrectconfigurationandlanguagefilemustbeloadedfortheoperationwithCOMBIVIS.ThedownladcanbedoneviatheKEBwebsite.

Interface Standard Connecting cableRS485 TIA/EIA-485andISO8482RS232 ANSITIA/EIA-232 0058025-001DRS232/USB 0058060-0020

2.7.2.1 Assignment of the interface X4A5

43

21

98

76

54

32

1

98

76

reserved 1 6 reservedTxD(RS232) 2 7 DGND (reference potential)RxD (RS232) 3 8 TxD-A(RS485)

RxD-A (RS485) 4 9 TxD-B(RS485)RxD-B (RS485) 5

2.7.2.2 Connection of the RS232 interfaceA RS232-cable is needed to connect the interface operator with the PC.

Serial cable to connect the operator with a PC0058025-001D

1

5

6

9 1

5

6

9

2.7.2.3 Connection of the RS485 interface

Thefollowinginstructionsmustbeobservedinordertopreventinterferencesatthe RS485 interface:• useCAT5cable(inpairs,twistedandshieldedcable)• ground at one side (prior at interference-free side)• Connect terminating resistors (120Ω)at bothendsonpair ofwiresof the

communication bus

IfCAT7cableisused(bywayofderogationfromourrecommendation)laytheinterior shield each to the transmitter.

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Control

A biasing can be used if there are still interferences. However, this should be done only once at the communication bus (preferably at the master).

2.7.2.4 Wiring RS485 full duplex

5 4 3 2 1

9 8 7 6

COMBIVERT5 4 3 2 1

9 8 7 6

COMBIVERT

4 5 8 9 4 5 8 9

MasterTxD-ATxD-BRxD-ARxD-B

R R

R

R

R=120Ω

2.7.2.5 Wiring RS485 half duplex

5 4 3 2 1

9 8 7 6

COMBIVERT

4 58 9

5 4 3 2 1

9 8 7 6

COMBIVERT

4 58 9

MasterRXD/TxD-ARXD/TxD-B

R

R

R=120Ω

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Control

2.8 Socket X4C EtherCAT IN and X4B EtherCAT OUT

Description of the LEDs Name Description

Bus speed (yellow)

18X4B EtherCATIN

Link/Activity (green)

Bus speed (yellow)

18X4C EtherCATOUT

Link/Activity (green)

LED bus speed (yellow) Functionoff Transmissionerroron EtherCATreadyforoperationwith100MBit

LED Link/Activity (green) Functionoff Port closed; no data transferon Port opened; no data transfer

flicker Port opened with data transfer

2.9 Encoder ParameterThecontrolcontainstwoencoderinterfaces.Theassignmentofthepinconnectorsisidenti-cal.Thefollowinglimitationsarevalidwhenoperatingwithtwoencoders:• Thevoltagesupplies5Vand8Varegeneratedwithone programmable voltage source.

Onlyencoderswith5Vor8Vsupplyarepossible(e.g.BiSSandHIPERFACEarenotpossible).

• There isonlyoneEndatcoreon theencoder interface, thereforeoperationofadigitalEnDat 2.2 encoder together with a EnDat analog encoder is not possible.

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Control

2.9.1 Encoder interfaces X3A and X3B

Do not plug on/remove en-coder cable during operation

Toavoidundefinedstatesdonotplugon/removethe encoder cable during operation.

Theintegratedencoder interfacesaredesignedfordifferentencoders.Thefollowingtablecontains the possible encoders and the appropriate signal assignment of the plug connector.

Pin assignment according to the adjusted encoder interface (frontview of the control)

2 4 6 8 10 12 14 16 181 3 5 7 9 11 13 15 17

encoderPIN

Inc-TTL Resolver Hiperface SinCos Endat Sin/Cos-SSI

Endat 2.2

BiSS

1 A+ COS+ COS+ COS+ COS+2 A- COS- COS- COS- COS-3 B+ SIN+ SIN+ SIN+ SIN+4 B- SIN- SIN- SIN- SIN-5 N+ Data+ N+ Data+ Data+ Data+ Data+6 N- Data- N- Data- Data- Data- Data-7 COS+ Cos_abs+ Clock- Clock- Clock- Clock-8 COS- Cos_abs-9 SIN+ Sin_abs+ Clock+ Clock+ Clock+ Clock+

10 SIN- Sin_abs-11 Exciter+12 Exciter-13 COM COM COM COM COM COM COM COM

14 COM Internal shielding COM COM COM COM COM COM

15 8V 8V 8V 8V 8V 8V 8V16 5.25V 5.25V 5.25V 5.25V 5.25V 5.25V 5.25V17 24V 24V 24V 24V 24V 24V 24V18 COM COM COM COM COM COM COM

Shielding open with heat-shrink tube and wire-end ferrule

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Safety Function STO

3. Safety Function STO

Only qualified

Staff

Uncontrolled start is possible by improper installation of the safe-tytechnology.Thismaycausedeath,seriousbodilyinjuriesorsubstantial damage to property.Thereforethesafetyfunctionmayonlybeinstalledandputintooperationbyqualifiedpersonnelwhicharetrainedinsafetytech-nology.

Observe all costs

TheCOMBIVERTF6with safety functionmustnotbestarteduntil it is determined that the installation complies with 2006/42/EC (machine directive) as well as the EMC directive (2004/108/EC)(note EN60204).The COMBIVERT F6 with safety function meets the require-ments of the Low-Voltage Directive 2006/95/EC. The harmo-nizedstandardoftheseriesEN61800-5-1(VDE0160)isused.This isaproductof limitedavailability inaccordancewith IEC61800-3.Thisproductmaycauseradiointerferenceinresiden-tial areas. In this case the operator may need to take correspond-ing measures.

With electronic protection devices the safety function is integrated in the drive control in order tominimizeoreliminatedangerbymalfunctionsinmachines.Theintegratedsafetyfunctionreplacethecomplexinstallationofexternalsafetycomponents.Thesafetyfunctioncanberequestedorreleasedbyanerror.

Regular checks

In order to ensure permanent security, the function must be checked in regular intervals according to the results of the risk analysis.

Installation work or troubleshooting can be necessary in hazard areas, whereby protective devicessuchasline-ormotorcontactorsshallnotbeactivated.ThesafetyfunctionSTOcanbe used there. Depending on the application the use of line or motor contactors can be void byusingSTO.Incaseoferrororrequest,thepowersemiconductorofthedrivemoduleareswitchedoffandthedriveisnotsupplied,whichcausesarotationortorque(incaseofalineardrivemove-mentorforce).Theunitcanbesafeswitchedoffand/orremainifanerroroccurs.

Electric Shock ContinuemainsvoltagewithactiveSTOfunction.

Compared to the disconnection by line contactors or motor contactors the integrated safety functionenablesasimpleintegrationofdrivestofunctionalgroupsofasystem.Therebysafetorqueoffcanbelimitedtocertainsystems.Afurtheradvantageisthattherechargeanddis-chargetimeoftheinverterDClinkmustnotbeconsidered.Thustheunitisfasteragainreadyfor operation after an interruption.Regularelectromechanicalequipmentareliabletoabrasion.LossoftheseequipmentoccursbyusingtheSTOfunctionandthemaintenancecostsarereduced.

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Safety Function STO

Characteristicdatafor„Safetorqueoff“• Power supply for the rotation direction of the motor is interrupted (free-wheeling motor)• Used when monitoring of standstill is not necessary• Unintentional starting of the motor is prevented• No galvanic isolation of the motor from the inverter DC link

WhatisrealizedbytheSTOfunctionrelatedtoEN60204?

EmergencystopcanberealizedbytheSTOfunction,sincethemainsvoltagemayremaineffective.Emergency stop can be realized only in connection with a line contactor, which disconnects the mains voltage !

3.1 Emergency stop according EN 60204By using suitable safety switchgear units, stop category 0 and 1 according to EN 60204 can bereachedbytheSTOfunctioninthesystem.Notechapter6forsafetyswitchgearunits.

Stop category 0 „uncontrolled stop“, i.e. stop by immediate removal of power to the actuators.

Stop category 1„controlled stop“, i.e. power to the actuators is retained to apply brakinguntil thestop isachieved.Theenergy isswitchedoffatstandstill.

Emergency stop to EN 60204 must be functional in all operating modes of the drive module. Theresetofemergencystopmaynotleadtoanuncontrolledstartofthedrive.

Restart only after

confirmation

ThedriverestartsiffunctionSTOisnolongerreleased.Inorderto comply with EN 60204, it must be ensured by external meas-uresthatthedriverestartsonlyafterconfirmation.

Without mechanical brake the drive leads to coast; motor is free-wheeling. Additional protec-tive devices must be installed (e.g.locking systems) if damage to persons or property can occur.

Ensure coast of the motor

If danger to persons occur after switching off the motor control bySTO,theentrancetohazardareasmustremaincloseduntilthe drive stops.

Jerks in error case

In case of double malfunction it can lead to unwanted jerk, the rotation angle is depending on the number of poles of the se-lected drive and the gear ratio.

Calculation of the jerk:

Rotation angle of the jerk WR[°]=180°

–––––––––––––––––––––––––––––––––Pole-pairnumberp•gearreductionratiog

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Safety Function STO

Thisbehaviourcanoccureitherbyashortcircuitof theIGBTsorbyinterconnection(alsoshortcircuit)ofthecontroldrivers.Theerrorshouldberegardedascritical,ifthedrivere-mainsinSTOstatus.

3.2 ClassificationofSTOaccordingIEC61508PFH 2.6•10-12 1/hPFD 2.3•10-7 on demandProof-Test-IntervalT 20 years

ForSILclassificationinconnectionwiththeapplicationsconsiderthefailureratesoftheex-ternalswitchdevicesforfinalevaluation.

3.3 ClassificationofSTOaccordingENISO13849Control category 4MTTFD >1000yearsDC high

Fortheclassificationwithinaperformancelevelinconnectionwiththeapplicationsconsiderthefailureratesoftheexternalswitchdevicesforfinalevaluation.

3.4 Additional instructions• Theunitmustbeisolatedfrommainsbymainswitchwhenworkingonpartsundervolt-

age.• Mechanical brakes must be installed additionally if external forces have effect to the drive

axis, e.g. vertical axes (hanging loads) or rotary axes with asymmetrical weight distribu-tion.

• For the protection against pollution (pollution degree 2) the installation of the units must be provided in environment with increased protection (e. g. control cabinet IP 54).

• MakesurethatnosmallpartsfallintotheCOMBIVERTduringassemblyandwiring.Thisalso applies to mechanical components, which can lose small parts during operation.

• Check the safety functions and error responses and generate an acceptance report after installation.

• The start-up can be preventedwith interruption of theSTO signals. STOmay not bereleased in case of danger according to EN 60204-1. Also note the instructions to the external safety switch devices.

• Dimension the safety application by way that the corresponding input current of the safety functions is available for the inputs (see chapter 2.5.1).

Selection of suitable volt-age sources

Use for the connection only suitable voltage sources with safe isolation(SELV/PELV)inaccordancewithVDE0100withnom-inalvoltageof24Vdc±10%.Payattentiononasufficientover-voltage category of the voltage supply.

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Safety Function STO

3.5 Functional DescriptionTheCOMBIVERTwithintegratedsafetyfunctionmeetsthefollowingfunctionaccordingtoIEC 61800-5-2:

• „Safetorqueoff“(SafeTorqueOff–STO)

Thesafety-relateddisconnectionaccordingtoSTOisreachedbyatwo-cannelopto-couplerblockage.Thesupplyoftheopto-couplers,whichareresponsibleforthecommutationoftheconnecteddriveoccursviatransformationcouplingoftheinputvoltage.Thisensuresatinputvoltage loss that no supply of the opto-couplers is possible. If the opto-couplers are not longer supplied,noIGBTcanbecontrolledandthusnoenergycanbesuppliedtothedrive.ThetwochannelsarereachedbywaythatinputSTO1preventsthevoltagesupply(VTRO)of theupperopto-couplersof the inverterbridgeand inputSTO2 the loweropto-couplers(VTRU).TechnicaldataoftheSTOfunctionMaximum ON delay (UIN=15V) 7 msMaximum OFF delay (UIN=30V)at… active modulation 10 ms… inactive modulation until safe state of the driver voltage is reached 50 ms

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Safety Function STO

3.6 Wiring Examples

3.6.1 Direct switching off with emergency stop switch

U V W PE

M

X1A

X4A

1 - STO1+2 - STO1+3 - STO1-4 - STO1-5 - STO2+6 - STO2+7 - STO2-8 - STO2-9 - STO-OUT10 - STO-OUT

Terminal strip X2B

+ -24Vdc

X2A

X2C

X2D

DiagnosisX4B

Field busX4C

Field bus

Power circuit

Control circuit

Safety module

At operation of an emergency stop unit, when both contacts are connected to-gether against a positive supply signal, make sure that there are no crossfaults. Thewiringmustbesuitablearranged.

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Safety Function STO

3.6.2 Direct switching off with emergency stop switch and monitoring of the wiring

U V W PE

M

X1A

Terminal strip X2B

+ -24Vdc

Power circuit

Control circuit

Safety module

1 - STO1+2 - STO1+3 - STO1-4 - STO1-5 - STO2+6 - STO2+7 - STO2-8 - STO2-9 - STO-OUT10 - STO-OUT

X2A

X2C

X2D

X4ADiagnosis

X4BField bus

X4CField bus

Thedisplayedcircuitshowswiringerrorsintheareaoftheemergencystopunitandsupplyline. A possible short circuit on the primary side of the emergency stop switchgear (mass and 24Vdc)andashortcircuitonthesecondarysideoftheunitorwithinthewiringleadseitherdirectly or with closed contacts to a short circuit of the supply, whereby a series-connected 24Vfusetriggers.

Besides the two displayed applications with an emergency stop switchgear, other sensors (like door switches etc.) can be used similarly.

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Safety Function STO

3.6.3 Direct switching off by safety module with test pulses

U V W PE

M

X1A

Terminal strip X2B

Power circuit

Control circuitopenclosed

S1 S2

Safety device

Receipt

Safety module

1 - STO1+2 - STO1+3 - STO1-4 - STO1-5 - STO2+6 - STO2+7 - STO2-8 - STO2-9 - STO-OUT10 - STO-OUT

X2A

X2C

X2D

X4ADiagnosis

X4BField bus

X4CField bus

With operation of the emergency stop unit, e.g. by protection door, the release paths of the safetymodulearedisconnected.ThisleadstothelossoftheSTOsignals(X2B.1and5)andthustoenergydisconnectionofthedrive.Thesafetymodulemakesaconsistencycheckofall signal paths via test signals (OSSD).

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Safety Function STO

3.6.4 Wiring SS1At tripping SS1 (Safe Stop 1) the drive is only disconnected from supply when it has reached astandstill[IEC61800-5-2].Thestopmodeisnotdirectlyrequested,butthemaximumtimeuntilreachingthestandstillisestimated.Thisperiodisloadedinasafetimerelay,whichdis-connectsthedrivefinallyfromsupply.

U V W PE

M

X1A

X4A

Terminal strip X2B

Diagnosis

Power circuit

Control circuitopenclosed

S1 S2

Safety device

Receipt

X2A.13

Safety module

1 - STO1+2 - STO1+3 - STO1-4 - STO1-5 - STO2+6 - STO2+7 - STO2-8 - STO2-9 - STO-OUT10 - STO-OUT

X2A

X2C

X2D

Field busMotion Control

X4B

Field bus

X4C

Field bus

When pressing the emergency stop unit the drive is stopped with a deceleration ramp via input X2A.13 (I3).Simultaneously the expiration of the safe time occurs in the safety module. After expiration of the safe period the control signals STO1+ und STO2+ (X2B.1 and 5) are removed and thus the energy supply of the drive is disconnected.Thefollowingadjustmentsmustbedoneinthedrivemoduleforthefunction„drivestop“:Parameter Adjustmentpn29 „prg. error stop. mode“ (Index 0x2A1D) 1:dec.ramp->Faultpn48-59 (0x2A30-0x2A3C) Adjustment of the deceleration and jerk

values for the adjusted error reactionpn30 „prog. error source“ (Index 0x2A1E) 4: I3 (here in the example)

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Safety Function STO

Function: If the selected input becomes active, the drive decelerates with the adjusted decel-eration ramp and changes then into status 59 „Error prog. input“.

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Annex

4. Certification4.1 Annex to the declaration of conformity

Annex to the declaration of conformity EC for systems with functional safety:Product designation: Inverter - type series xxF6Kxx-xxxx

Dimension 07 - 36Voltageclass 200Vac;400Vac;600Vac

Herewith we declare that the safety module described above corresponds with all relevant regulations of the machinery safety directive 2006/42/EC.

Theabovementionedsafetymodulemeetstherequirementsofthefollowingguidelinesandstandards:• Machinery safety directive 2006/42/EC• EMC directive 2004/108/EC• Low-VoltageDirective 2006/95/EC

EN standards Output Text Reference OutputEN 61800-5-1 09/2003 Electrical power drive systems with ad-

justablespeed:securityrequirementsVDE0160Part 105

09/2003

informative:EN 50178 1997 Installation of high voltage systems with

electronicequipmentVDE0160 04/1998

EN 60664-1 2007 Isolationcoordinatsforelectricalequip-ment in low-voltage systems

VDE0110 01/2008

EN 61800-2 10/1998 Basic determinations for AC inverter VDE0160 Part 102

08/1999

especially for systems with functional safety additionally:EN 61800-5-2 2007 Electrical power drive systems with ad-

justablespeed:functionalsafetyrequire-ments

VDE0160Part 105-2

04/2008

EN 61508-(1…7) Functional safety of electrical/electronic/programmable electronic safety-related systems - Part 1 up to 7

VDE0803 11/2002

EN 60204-1+A1

20062009

Electricalequipmentofmachines; Part1:Generalrequirements

VDE0113-1+A1

200710/2009

EN 62061 Safety of machineryfunctionalsecurityrequirements

VDE0113 Part 50

10/2005

EN 13849-(1, 2) Safety of machinery – 08/2008

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Annex

The conformity was confirmed by the TÜV Rheinland with the EC type examination 01/205/5332/13.

Thenumber/addressoftheindicatedconstitution:NB 0035 TÜVRheinlandIndustrieServiceGmbHAlboinstr. 56, 12103 BerlinGermanyTel.:+49307562-1557Fax: +49 30 7562-1370E-Mail: [email protected]

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Revision history

5. Revision history

Revision Date DescriptionRev.1A 2013-01 First published versionRev.1B 2013-04 Prefacesupplemented;commontypuscorrected;notetopotentialreferenceSTO-Out

inserted;EtherCATINandOUTexchanged(chap.2.8)

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Notices

Page 32: F6 instruction manual

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Rev. 1BDate 06/2013

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