Kostal INVEOR Operating Manual
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Summary of Contents for Kostal INVEOR
- Page 1 Operating manual INVEOR Functional Safety...
- Page 2 This manual may not be reproduced, stored, transmitted or translated in any form or by means of any medium, in whole or in part, without prior written permission. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 3: Table Of Contents
Classification two-channel EN ISO 13849-1 with external diagnosis 29 2.3.9 Classification two-channel EN ISO 13849-1 with dynamic testing ... 29 2.3.10 Classification one-channel (reduced SIL and PL) ......30 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 4 Carrying out external diagnosis ............52 8.1.3 External dynamic test ..............53 Terminal assignment ............55 INVEOR connection diagram ............56 Terminal assignment X310 .............. 57 Terminal assignment X5 ..............58 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
- Page 5 14.2 List of figures ................... 80 14.3 Appendix: Commissioning ............... 81 14.3.1 Quick-start guide for asynchronous motors ........81 14.3.2 Quick-start guide for synchronous motors ........82 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 6: General Information
Labels on the drive controller ............13 Qualified staff ................... 14 Proper use..................14 Responsibility .................. 15 CE marking ..................15 Abbreviations................... 16 1.10 Certificate ..................18 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 7: Information About Documentation
This manual is a part of the product and should be stored in a safe place. It applies exclusively to the INVEOR from KOSTAL Industrial Electronics GmbH. Provide the operator of the system with this manual so it is available when needed. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 8: Other Applicable Documents
Operating manual for INVEOR drive controller Table 1: Other applicable documents 1.1.2 Storing the documentation Store this manual and all other applicable documents safely so they are available when needed. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 9: Notes In This Manual
De-energise the device and secure it from being switched on again before opening it. Fig.: 1 Structure of warnings Warning symbol Signal word Type of danger Corrective actions 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 10 CAUTION Indicates a hazard with a low level of risk, which, if not avoided, will result in minor or slight injury or property damage. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
- Page 11 S y mb ol s w i t h i n t h e i n f o r ma t i o n n o t e s Important information Damage to property possible O t h e r n ot es Additional information Enlarged representation 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 12: Symbols Used In This Manual
Fig.: 3 Symbols and icons used A b b r ev i at i on s u s ed Abbreviation Explanation Tab. Table Fig. Figure Item Chapter 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 13: Labels On The Drive Controller
Danger due to electrical shock and discharge Danger due to electrical shock and discharge. Wait two minutes (discharge time of the capacitors) after shut-down Additional earth connection Observe and read operating manual 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 14: Qualified Staff
Using drive units in equipment that is not fixed is considered as an exceptional environmental condition and is only permitted if allowed by the standards and guidelines applicable on site. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 15: Responsibility
• Directive on Electromagnetic Compatibility (Directive 2004/108/EC of the Council) You can download the Declaration of Conformity from www.kostal-industrie-elektrik.com. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 16: Abbreviations
(AOPD) that is connected to the machinery control system and switched to OFF status when the sensor part is activated during correct operation. Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 17 Mean Time to Failure (also β value) Common Cause Failure Safety Requirement Specification PELV Protected Extra Low Voltage SELV Safety Extra Low Voltage Table 2: Abbreviations and terms 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 18: Certificate
G e n e r a l i n f o r m a t i o n 1.10 Certificate 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 19: Safety
Classification two-channel EN ISO 13849-1 with external diagnosis 29 2.3.9 Classification two-channel EN ISO 13849-1 with dynamic testing ... 29 2.3.10 Classification one-channel (reduced SIL and PL) ......30 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 20: General Safety Instructions
PTC terminals T1/ T2 2.2.2 Protection from contamination IMPORTANT INFORMATION With open housing, contamination degree 2 must be observed in order to ensure the safety function. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 21: Elimination Of Errors
All cables are to be inspected for correct wiring prior to commissioning. 2.2.6 Loss of the safety function IMPORTANT INFORMATION Permanent 24 V voltage to the STO inputs results in the loss of the safety function. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 22: Safety Classification / Characteristic Values
(normally reversible) and/or short in certain conditions duration serious injury, (normally frequently to hardly possible irreversible) including death continuously and/or long in duration 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 23: Classification Iec 60204-1
S a f e t y 2.3.2 Classification IEC 60204-1 Three stop functions are named in the standard that are designated as categories 0 to 2. Categories 0 and 1 can be realised with INVEOR platform drive controllers with a pulse block. Stop category-0 An uncontrolled shut-down through immediate interruption of the power supply to the machine drive elements (safety-related activation of the pulse block). -
Page 24: Classification Iec 61800-5-2
In the STO status, the drive is not separated from the energy supply, as only the activation of the IGBTs is securely switched off. Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 25: Classification Two-Channel En 62061 Without External Diagnosis
60 [%] Diagnosis coverage 99.24 % Proportion of safe failures 20 years Duration of usage Table 3: Classification two-channel EN 62061, without external testing 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 26: Classification Two-Channel En 62061 With External Diagnosis
90 [%] Diagnosis coverage 99.92 % Proportion of safe failures 20 years Duration of usage Table 4: Classification two-channel EN 62061 with external diagnosis 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 27: Classification Two-Channel En 62061, Without Dynamic Testing
99 [%] Diagnosis coverage 99.99 % Proportion of safe failures 20 years Duration of usage Table 5: Classification two-channel EN 62061, with enhanced external testing 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 28: Classification Two-Channel En Iso 13849-1 Without External Diagnosis
Cat.3 with DC = 60% actually limits the performance level to d. However, the increased failure-safety present in this case and documented in the context of the FMEA is of equal value, and PL e is thus achieved. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 29: Classification Two-Channel En Iso 13849-1 With External Diagnosis
167 [a] Mean time to failure (dangerous) 99 [%] Diagnosis coverage 20 years Duration of usage Table 8: Classification two-channel EN ISO 13849-1 with enhanced external testing 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 30: Classification One-Channel (Reduced Sil And Pl)
When an external control system carries out a test of the connection in the application 100 times more often than a "sharp" requirement of the STO function, SIL 2 and PL d are achieved. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 31: Type Key/Scope Of Application
– Safety application printed circuit board A03- – No fieldbus A031 – Profibus A032 – CANopen A033 – EtherCAT A034 – ProfiNet A036 – Sercos III Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 32: Future Type Key
PW12 (11 kW); PW13 (15 kW); PW14 (18.5 kW); PW15 (22 kW) High-performance printed circuit board: Equipment generation: 1 – current version LP01 – Standard LP02 – With brake chopper 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 33: Technical Data
Technical data Technical data, general ..............34 Technical data STO ................. 34 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 34: Technical Data, General
Table 10: Technical data STO The STO response team is the time between the deactivation of the STO input signal to the definite fail-safe pulse block. Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 35 T e c h n i c a l d a t a Continuation Fig.: 7 OSSD test pulses, in this case 2 test pulses Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
- Page 36 T e c h n i c a l d a t a Continuation Fig.: 8 STO input IMPORTANT INFORMATION The maximum STO response time of 50 ms is to be taken into account when using the machine. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 37: Safety Functions
STO without external diagnosis ............40 5.2.2 STO with external diagnosis ............41 5.2.3 STO with dynamic test ..............42 SS1 function (Safe Stop 1)............... 43 5.3.1 SS1 ....................44 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 38: Control Modes
"reaction time" will be described and explained. 5.1 Control modes The STO function is effective at a higher level in all drive controller operating modes. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 39: Sto Function (Safe Torque Off)
After the STO function is triggered, the drive is switched off (impulse block) and the drive control runs down without braking (when no brake has been activated). IMPORTANT INFORMATION The shut-down time must be considered in this application. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 40: Sto Without External Diagnosis
(1) Emergency stop switch (S1): Request for a free-running stop and activation of the safety function "safe torque off". (2) Push button (S2): Resetting the OSSD switching device. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 41: Sto With External Diagnosis
(1) Emergency stop switch (S1): Request for a free-running stop and activation of the safety function "safe torque off". (2) Push button (S2): Resetting the OSSD switching device. (3) Response of safety branch of external control. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 42: Sto With Dynamic Test
"safe torque off". (2) Push button (S2): Resetting the OSSD switching device. (3) Response of safety branch of external control. See also chapter 8.1.3 "External dynamic test" 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 43: Ss1 Function (Safe Stop 1)
The STO status is assumed after expiration of the parameterisable SS1 time. The brake ramp is not monitored in the process. Fig.: 13 Safety function SS1 without monitoring with brake ramp 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 44: Ss1
(4) The emergency stop starts the fast delay ramp (rapid stop) by way of the input Dig In5. Following expiration of the time stored in the OSSD switching device, the secure stop is triggered. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 45: Application Instructions - Safety
Application instructions - Safety Restarting protection ............... 46 External STO input voltage .............. 47 Digital input (not safety-related) ............48 Internal auxiliary voltage ..............48 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 46: Restarting Protection
A p p l i c a t i o n i n s t r u c t i o n s - S a f e t y In order to clearly explain the wiring of the INVEOR frequency converter, the fundamental connection examples will be presented in the following chapters. -
Page 47: External Sto Input Voltage
PELV or SELV provisions in accordance with EN 60204-1. The 24 V power supply used for the STO supply must be adequate for the grid- side voltage interruption defined in EN 60204-1. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 48: Digital Input (Not Safety-Related)
SELV/PELV requirement on terminal X5 and can be used as supply voltage for the STO channels. In this application case, a max. of 30 mA is available for additional external components. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 49: Parameterization
0 Hz from the max. speed (1.021). If the set rapid stop time cannot be achieved, the fastest possible deceleration time is implemented. Table 11: SS1 parameter rapid stop (not safety-related) 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 50: Diagnosis
Diagnosis Diagnosis safety function ..............51 8.1.1 Carrying out an internal diagnosis ............ 52 8.1.2 Carrying out external diagnosis ............52 8.1.3 External dynamic test ..............53 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 51: Diagnosis Safety Function
50 ms. IMPORTANT INFORMATION This reaction time is to be observed when using the machine and configured in accordance with the external fault diagnosis. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 52: Carrying Out An Internal Diagnosis
STO channels are supplied with 24 V, the relay falls and the contacts C1 and C2 are interrupted. Carry out a diagnosis prior to every start-up of the motor. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 53: External Dynamic Test
4. Only supply STO2 with 24 V => Relay remains open (otherwise fault in channel 1) 5. STO1 and STO2 supplied with 24 V => Motor can be activated Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 54 Delay of the diagnosis relay max. 50 ms Activation of the fault "STO implausible" 2 seconds IMPORTANT INFORMATION The maximum test interval is 1 year. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 55: Terminal Assignment
Terminal assignment INVEOR connection diagram ............56 Terminal assignment X310 .............. 57 Terminal assignment X5 ..............58 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 56: Inveor Connection Diagram
RS485 programming interface (M12 plug) Internal potentiometer Motor protection switch or load break switch (optional) Mains terminals Digital/analogue inputs and outputs X310 Digital inputs and outputs for functional safety (option) 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 57: Terminal Assignment X310
Normally open contact for response of STO to external control system (diagnosis) Normally open contact for response of STO to external control system (diagnosis) Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 58: Terminal Assignment X5
Dig. In 4 Error reset (parameter 1.180) Dig. In 5 Rapid stop Dig. Out 1 Fault message (parameter 4.150) Dig. Out 2 Free (not assigned) Continues on next page 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 59 Ground A. In 1 PID actual value (parameter 3.060) A GND (Ground 10 V) Ground A. In 2 Free (not assigned) A GND (ground 10 V) Ground 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 60: Installation/Disassembly/Commissioning
Connections size D "EtherCAT" ............67 10.7 STO connection cable ..............68 10.8 Disassembly ..................68 10.9 Commissioning ................69 10.9.1 STO validation ................. 69 10.9.2 SS1 Validation ................. 69 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 61: Installation
See chapter 1 "General information" of the operating manual "INVEOR drive controller". IMPORTANT INFORMATION With open housing, contamination degree 2 must be observed in order to ensure the safety function. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 62: Connections Size A "Canopen" / "Profibus
Potentiometer Grid connection Blind plug STO ( install EMC screw connection supplied in the package Blind plug STO ( install EMC screw connection supplied in the package 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 63: Connections Size A "Ethercat
Potentiometer Grid connection Blind plug STO ( install EMC screw connection supplied in the package Blind plug STO ( install EMC screw connection supplied in the package 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 64: Connections Sizes B - C "Canopen" / "Profibus
Potentiometer Blind plug STO ( install EMC screw connection supplied in the package Blind plug STO ( install EMC screw connection supplied in the package Grid connection 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 65: Connections Sizes B - C "Ethercat
Potentiometer Blind plug STO ( install EMC screw connection supplied in the package Blind plug STO ( install EMC screw connection supplied in the package Grid connection 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 66: Connections Size D "Canopen" / "Profibus
Potentiometer Blind plug STO ( install EMC screw connection supplied in the package Blind plug STO ( install EMC screw connection supplied in the package Grid connection 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 67: Connections Size D "Ethercat
Blind plug; for the insertion of the STO connection cable, install EMC screw connection in the accompanying package Grid connection 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 68: Sto Connection Cable
(core end sleeves with and without plastic collars) Length of stripped 9 to 10 mm insulation: 10.8 Disassembly See chapter 1 "General information" of the operating manual "INVEOR drive controller". 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 69: Commissioning
The SS1 validation thus contains the check of the STO safety function (see 10.4.1) of the drive controller and the check of the external safety switching device, which requests the STO function upon expiration of the set time. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 70: Dealing With Malfunctions
11. Dealing with malfunctions 11.1 Error detection and troubleshooting ..........71 11.2 Malfunction overview ............... 72 11.3 Fault display ..................73 11.4 Fault-finding and troubleshooting ............ 74 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 71: Error Detection And Troubleshooting
If damaged parts or components need replacing, only ever replace with original parts. Danger due to electrical shock and discharge. Wait two minutes (discharge time of the capacitors) after shut-down 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 72: Malfunction Overview
(CANOpen, Profibus DP, EtherCAT) A list of possible fault messages can be found in chapter 6.2 of the operating manual for the INVEOR drive controller. 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 73: Fault Display
Identification of motor data Initialisation Firmware update Bus error operation Bus error ready for operation Tab. 1: LED flash codes LED off LED on LED flashes LED flashes quickly 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 74: Fault-Finding And Troubleshooting
D e a l i n g w i t h m a l f u n c t i o n s 11.4 Fault-finding and troubleshooting Utilise the operating manual of the INVEOR sizes A - D for assistance in fault- finding and troubleshooting. -
Page 75: Maintenance
12.2 Checklist for maintenance See chapter 1 "General information" of the operating manual "INVEOR drive controller". 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 76: Index
Connections sizes B - C EtherCAT ..................... 65 Dealing with malfunctions......................70 Diagnosis safety function ......................51 Digital input ..........................58 Digital input (not safety-related) ....................48 Digital output ........................... 58 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 77 Legal notice ..........................2 Maintenance ..........................75 Malfunction overview ......................72 Parameterisation ........................8 Parameterization ........................49 Principle of STO without external diagnosis ................40 Restarting protection ....................... 46 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
- Page 78 Terminal assignment ........................ 55 Terminal assignment X310 ....................... 57 Terminal assignment X5 ......................58 Type key/scope of application ....................31 Warning symbols ........................10 Warnings ............................ 9 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
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Page 79: Overview: Tables / Figures
Table 8: Classification two-channel EN ISO 13849-1 with enhanced external testing ..................29 Table 9: Classification one-channel IEC 61508 and EN ISO 13849 .... 30 Table 10: Technical data STO ..............34 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 80: List Of Figures
Fig.: 25 Connections size D "EtherCAT" ............67 Fig.: 26 Block diagram for quick start for ASM ..........81 Fig.: 27 Block diagram for quick start for SM..........82 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 81: Appendix: Commissioning
O v e r v i e w : T a b l e s / F i g u r e s 14.3 Appendix: Commissioning 14.3.1 Quick-start guide for asynchronous motors Fig.: 26 Block diagram for quick start for ASM 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... -
Page 82: Quick-Start Guide For Synchronous Motors
O v e r v i e w : T a b l e s / F i g u r e s 14.3.2 Quick-start guide for synchronous motors Fig.: 27 Block diagram for quick start for SM 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN... - Page 83 N ot e s 2015-12 | DOC01546896 - 0001 | Operating manual INVEOR STO | V1.2 EN...
- Page 84 KOSTAL Industrie Elektrik GmbH Lange Eck 11 58099 Hagen Germany Service-Hotline: +49 2331 8040-848 Phone: +49 2331 8040-800 Fax: +49 2331 8040-602 www.kostal-industrie-elektrik.com...
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