Lenze L-force 9400 Bedienungsanleitung

EDS94AYAD

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Ä.,4zä

Manual

L-force | 9400



E94AYAD - SM300

Safety module

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Please read these instructions and the documentation of the standard device before you

start working!

Observe the safety instructions given therein!

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Safety engineering

Contents

1-1

EDS94AYAD EN 2.2

1 Safety engineering

Contents

1.1 Basics 1.1-1.......................................................

1.1.1 Introduction 1.1-1..........................................

1.1.2 Drive-based safety with L-force | 9400 1.1-1....................

1.1.3 Terms and abbreviations of the safety engineering 1.1-2..........

1.1.4 Important notes 1.1-3.......................................

1.1.5 Safety instructions 1.1-4.....................................

1.1.6 Application as directed 1.1-4.................................

1.1.7 Hazard and risk analysis 1.1-5................................

1.1.8 Standards 1.1-5............................................

1.1.9 Overview of sensors 1.1-5....................................

1.2 Device modules 1.2-1...............................................

1.2.1 Slot 1.2-1..................................................

1.2.2 Function mode of the safety modules 1.2-2.....................

1.2.3 Safety module SM300 1.2-3..................................

1.2.4 Connection of safety sensors 1.2-8............................

1.3 Safety functions 1.3-1...............................................

1.3.1 Integration into the application of the controller 1.3-1...........

1.3.2 Error states 1.3-3...........................................

1.3.3 Safe torque off 1.3-5........................................

1.3.4 Safe stop 1 1.3-7...........................................

1.3.5 Safe PROFIsafe connection 1.3-9..............................

1.4 Acceptance 1.4-1...................................................

1.4.1 Description 1.4-1...........................................

1.4.2 Periodic inspections 1.4-1....................................

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Safety engineering

Basics

Introduction

1.1

1.1.1

1.1-1

EDS94AYAD EN 2.2

1.1 Basics

1.1.1 Introduction

With increasing automation, protection of persons against hazardous

movements is becoming more important. Functional safety describes the

measures needed by means of electrical or electronic equipment to reduce

or remove danger caused by failures.

During normal operation, safety equipment prevents people accessing

hazardous areas. In certain operating modes, e.g. set-up mode, work needs

to be carried out in hazardous areas. In these situations the machine

operator must be protected by integrated drive and control measures.

Drive-based safety provides the conditions in the controls and drives to

optimise the safety functions. Planning and installation expenditure is

reduced. In comparison to the use of standard safety engineering,

drive-based safety increases machine functionality and availability.

1.1.2 Drive-based safety with L-force | 9400

The controllers of the L-force|9400 range can be equipped with a safety

module. The functional range of the safety module types varies in order to

optimally implement different applications.

”Drive-based safety” stands for applied safety functions, which can be used

for the protection of persons working on machines.

The motion functions are continued to be executed by the controller. The

safety modules monitor the safe compliance with the limit values and

provide the safe inputs and outputs. When the limit values are exceeded the

safety modules start the control functions according to EN 60204-1 directly

in the controller.

The safety functions are suitable for applications according to IEC 61508

SIL 3 and meet, depending on the module, the requirements of EN 954,

part 1 up to control category 4.

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Safety engineering

Basics

Terms and abbreviations of the safety engineering

1.1

1.1.3



1.1-2 EDS94AYAD EN 2.2

1.1.3 Terms and abbreviations of the safety engineering

Abbreviation Meaning

9400 Lenze servo controller

EC_S0 Error-Class Stop 0

EC_S1 Error-Class Stop 1

EC_S2 Error-Class Stop 2

EC_FS Error-Class Fail-Safe

Cat. Category according to EN 954-1

OSSD Output Signal Switching Device, tested signal output

PS PROFIsafe

PWM Pulse width modulation

S-DI Safe input (Safe Digital Input)

S-DO Safe output (Safe Digital Output)

SIL Safety Integrity Level according to IEC 61508

SM Safety module

Optocoupler

supply Supply of optocouplers to control the driver

OFF state Signal state of the sensors when they are activated or respond

ON state Signal state of the sensors in normal operation

Abbreviation Safety function

SDI Safe direction

SLI Safely limited increment

SLS Safely limited speed

SOS Safe operating stop

SS1 Safe stop 1

SS2 Safe stop 2

SSM Safe speed monitor

STO Safetorqueoff

Formerly: safe standstill

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Safety engineering

Basics

Important notes

1.1

1.1.4

1.1-3

EDS94AYAD EN 2.2

1.1.4 Important notes

The following pictographs and signal words are used in this documentation

to indicate dangers and important information:

Structure of safety instructions:

Danger!

(characterises the type and severity of danger)

Note

(describes the danger and gives information about how to

prevent dangerous situations)

Pictograph and signal word Meaning

Danger!

Danger of personal injury through dangerous electrical

voltage.

Reference to an imminent danger that may result in death or

serious personal injury if the corresponding measures are

not taken.

Danger!

Danger of personal injury through a general source of

danger.

Reference to an imminent danger that may result in death or

serious personal injury if the corresponding measures are

not taken.

Stop!

Danger of property damage.

Reference to a possible danger that may result in property

damage if the corresponding measures are not taken.

Pictograph and signal word Meaning

Note! Important note to ensure troublefree operation

Tip! Useful tip for simple handling

Reference to another documentation

Pictograph and signal word Meaning

Warnings!

Safety or application note for the operation of a

UL-approved device in UL-approved systems.

Possibly the drive system is not operated in compliance with

UL if the corresponding measures are not taken.

Warnings!

Safety or application note for the operation of a

UR-approved device in UL-approved systems.

Possibly the drive system is not operated in compliance with

UL if the corresponding measures are not taken.

Safety instructions

Application notes

Special safety instructions

and application notes for UL

and UR

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Safety engineering

Basics

Safety instructions

1.1

1.1.5



1.1-4 EDS94AYAD EN 2.2

1.1.5 Safety instructions

1.1.6 Application as directed

The safety modules SMx (E94AYAx) may only be used together with Lenze

drive controllers of the L-force | 9400 (E94A...) series.

Any other use shall be deemed inappropriate!

ƒ Only skilled personnel are permitted to install and commission the

safety functions.

ƒ All control components must comply with the demands of the hazard

and risk analysis.

ƒ Install the controllers in control cabinets with IP54 protection.

ƒ Wiring with insulated wire end ferrules or rigid cable is vital.

ƒ For modules without integrated short-circuit monitoring:

– All safety-relevant external cables (e.g. control cables for safety

functions, feedback contacts) outside the control cabinet must be

protected, e.g. by a cable duct.

– In this connection, make sure that short circuits cannot occur!

– For further measures see ISO 13849-2.

ƒ If external forces act on the drive axes, additional brakes are necessary.

The effect of the gravitational force on hanging loads must be

especially observed!

Danger!

If the request for the safety function is cancelled, the drive will

restart automatically.

You must provide external measures which ensure that the drive

only restarts after a confirmation (EN 60204).

Danger!

When the “safe torque off” (STO) function is used, an

”emergency-off” according to EN 60204 is not possible without

additional measures. There is no electrical isolation, no service

switch or repair switch between motor and controller!

“Emergency-off” requires an electrical isolation, e.g. by a central

mains contactor!

After the installation is completed, the operator must check the wiring of the

safety function.

The functional test must be repeated at regular intervals. The time intervals

to be selected depend on the application, the entire system and the

corresponding risk analysis. The inspection interval should not exceed one

year.

Installation/commissioning

During operation

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Safety engineering

Basics

Hazard and risk analysis

1.1

1.1.7

1.1-5

EDS94AYAD EN 2.2

In case of a short-circuit of two power transistorsa residual movement of the

motorofupto180°/numberofpolepairsmayoccur!(Example:4-pole

motor ⇒residual movement max. 180 °/2 = 90 °)

This residual movement must be considered in the risk analysis, e.g. safe

torque off for main spindle drives.

1.1.7 Hazard and risk analysis

This documentation can only accentuate the need for a hazard analysis. The

user of drive-based safety must concentrate on dealing with the standards

and legal position.

Before putting a machine into circulation, the manufacturer of the machine

must carry out a hazard analysis according to the Machinery Directive

89/392/EEC to find out the hazards related to the application of the

machine. To achieve a level of safety as high as possible the Machinery

Directive contains three principles:

ƒ Removing or minimising the hazards by the construction itself.

ƒ Taking the protective measures required against hazards that cannot

be removed.

ƒ Documentation of the existing residual risks and training of the user

regarding these risks.

The execution of the hazard analysis is specified in EN 1050, guidelines for

risk assessment. The result of the hazard analysis determines the category

of safety-based control modes according to EN 954-1 which the

safety-oriented parts of the machine control must comply with.

1.1.8 Standards

Safety regulations are confirmed by laws and other governmental

guidelines and measures and the prevailing opinion among experts, e.g. by

technical regulations.

The regulations and rules to be applied must be observed in accordance with

the application.

1.1.9 Overview of sensors

Passive sensors are two-channel switching elements with contacts. The

connecting cables and the sensor function must be monitored.

The contacts must switch simultaneously. Nevertheless, safety functions

will be activated as soon as at least one channel is switched.

The switches must be wired according to the closed-circuit principle.

Examples of passive sensors:

ƒ Door contact switch

ƒ Emergency-off control units

Residual hazards

Passive sensors

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Safety engineering

Basics

Overview of sensors

1.1

1.1.9



1.1-6 EDS94AYAD EN 2.2

Active sensors are units with two-channel semiconductor outputs (OSSD

outputs). Drive-based safety integrated in this device series allows for test

pulses < 1 ms to monitor the outputs and cables.

P/N-switching sensors switch the positive and negative cable or signal and

earth cable of a sensor signal.

Theoutputs mustswitch simultaneously.Nevertheless,safety functionswill

be activated as soon as at least one channel is switched.

Examples of active sensors:

ƒ Lightgrid

ƒ Laser scanner

ƒ Control

For sensor inputs that are not used ”no sensor” must be parameterised. It is

monitored that no sensor signal is applied.

Connected deactivated sensors can create the false impression of safety

technology being provided. For this reason, a deactivation of sensors by

parameter setting only is not permissible and not possible.

Active sensors

Sensor inputs

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