BONFIGLIOLI ACTIVE CUBE Series Applications Manual
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BONFIGLIOLI ACTIVE CUBE Series Applications Manual

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ACTIVE CUBE
Application manual - Safe Torque Off

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Summary of Contents for BONFIGLIOLI ACTIVE CUBE Series

  • Page 1 ACTIVE CUBE Application manual - Safe Torque Off...
  • Page 3 General Information about the Documentation This application manual complements the operating instructions and the „Quick Start Guide“ of the ACU frequency inverters (ACTIVE Cube series). It contains all relevant information required for using the safety-oriented function „Safe Torque Off“ (STO).

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Safety Instructions and Information on Use ............ 5 Safety Instructions on Function „Safe Torque Off“ (STO) ......5 Information of Risk Analysis and Risk Assessment ............7 General Description of Safety Function ................. 8 Integrated Safety Function ................. 8 Functional Safety ..................

  • Page 5: General Safety Instructions And Information On Use

    BONFIGLIOLI agent. We would also like to point out that the contents of this documentation do not form part of any previous or existing agreement, assurance or legal relationship.
  • Page 6 Check the safety function at regular intervals according to the results of your risk assessment. BONFIGLIOLI VECTRON recommends that the check is performed after one year, at the latest. The STO function is one fault fail-safe. No single fault or component failure can cause a disabled drive to produce motor shaft torque.

  • Page 7: Information Of Risk Analysis And Risk Assessment

    Information of Risk Analysis and Risk Assessment According to the Directive on Machinery 98/37/EC, the manufacturer of a machine is obliged to carry out a risk analysis in order to identify the hazards related to the ma- chine. The Standard EN 14121-1 – Safety of machinery - Risk assessment – Principles – describes the information required for risk assessment.

  • Page 8: General Description Of Safety Function

    General Description of Safety Function Integrated Safety Function Electronic protection systems are integrated in the drive control system and perform safety functions in order to minimize or eliminate hazards caused by functional errors of machines. The integrated safety functions replace time-consuming and expensive installation of external safety components.

  • Page 9: Description Of Active Cube Safety Function

    Description of ACTIVE Cube Safety Function The frequency inverters of the ACU series of devices feature the integrated safety function „Safe torque off, STO“. In the case of an error or if requested, the power semiconductors of the frequency inverter will be switched off. After this, the frequency inverter does not supply energy to the drive which would cause a revolution or a torque (or a movement or force in the case of a linear drive).

  • Page 10: Two-Channel Monitoring

    Triggering of function “Safe Torque Off” Safe Torque Off can be achieved by: − Intentional triggering during operation in order to stop a drive and safely prevent restarting, e.g. for maintenance work on a machine. − Triggering by actuation of an emergency stop switch or monitoring of protective systems, e.g.
  • Page 11 Stop paths Mains S1IND (STOA) S7IND (STOB) µC Diagnosis and monitoring Control unit Power unit The test required for monitoring is performed by the frequency inverter automatical- ly. If the test results negative, the frequency inverter cannot be switched on any- more.

  • Page 12: Diagnosis Function And Enforced Dynamizing

    Behavior of frequency inverter after start − Initialization − Monitoring for release request (5-second monitoring) − Preparation of release (check of stop paths) − Release of frequency inverter Behavior of frequency inverter in the case of an error − Switch off of IGBT in power output stage by disconnection of optocoupler supply voltage −...

  • Page 13: Diagnosis Indicators

    Sequence of release and monitoring states depending on signals on control inputs STOA and STOB: STOA STOB Diagnosis ok fault fault fault Diagnosis Enable Monitoring (Diagnosis fault) t/ms STOA STOB Diagnosis Diagnosis Enable (5 s monitioring) Monitoring t/ms 5260 5308 Monitoring states 0: Monitoring of Enable Actuation 3: Actuation of STO...

  • Page 14: Requirements To Be Met By Installation

    Requirements to be met by installation Instructions on installation of safety equipment − If work is to be carried out on live components, it must be possible to disconnect the machine from mains supply by means of a main switch. −...

  • Page 15: External Safety Control Equipment

    External Safety Control Equipment Safety control equipment, upon request (e.g. actuation of emergency stop or access to hazard area, must trigger appropriate responses in order to protect people, the machine and the environment. They evaluate sensor signals or safely switch off dan- gerous states.

  • Page 16: Dc 24 V Power Supply By Acu

    DC 24 V Power supply by ACU You can use terminal X210A.1 in order to supply a safety control device. Only use the power supply for the device connected to the frequency inverter. Other safety control devices must not be connected. The maximum output current is 180 mA. The con- nected device must not have higher current requirements.

  • Page 17: Application Examples

    Application Examples The following examples illustrate how the “Safe Torque Off” function works. Accord- ing to EN 60204, stop functions are divided in different categories. By suitable safety control devices, stop categories 0 and 1 can be realized in combination with the fre- quency inverter ACU.

  • Page 18: Direct Stop, Stop Category 0

    Direct Stop, Stop Category 0 The application example shows the minimum circuitry for ACTIVE cube frequency inverters for realization of the safety function STO “Safe Torque Off” with an emer- gency stop device in a common electrical cabinet. If the emergency stop device with two stop channels according to EN ISO 13849-1 PL d, IEC 61508 SIL 2 or EN954-1 Category 3 is actuated, both stop paths STOA and STOB of the ACTIVE Cube frequency inverter are interrupted and the integrated safe- ty function with safe pulse block with SIL 2 according to EN-61800-5-2 is activated.

  • Page 19: Direct Stop With Feedback To Plc, Stop Category 0

    Direct Stop with Feedback to PLC, Stop Category 0 The application circuit shows a drive control system according to EN ISO 13849-1 PL d, IEC 61508 SIL 2 or EN 954-1 category 3 with PLC and safety module. A PLC performs the process control of the frequency inverter and can start the drive profiles via commands.

  • Page 20: Direct Stop, Stop Category 1

    Direct Stop, Stop Category 1 The application example shows the minimum circuitry for ACTIVE cube frequency inverters for realization of the safety function STO “Safe Torque Off” with an emer- gency stop device in a common electrical cabinet. When the emergency stop device is actuated, the travel command “Clockwise” is reset first.

  • Page 21: Direct Stop With Feedback To Plc, Stop Category 1

    Direct Stop with Feedback to PLC, Stop Category 1 The application circuit shows a drive control system according to EN ISO 13849-1 PL d, IEC 61508 SIL 2 or EN 954-1 category 3 with PLC and safety module. A PLC performs the process control of the frequency inverter and can start the drive profiles via commands.

  • Page 22: Internal Dc 24 V Supply, Stop Category 1

    Internal DC 24 V Supply, Stop Category 1 The application example shows the minimum circuitry for ACTIVE cube frequency inverters for realization of the safety function STO “Safe Torque Off” with an emer- gency stop switch in a common electrical cabinet. Supply of the safety control device is effected by the internal DC 24 V supply (max.

  • Page 23: Group Stop, Stop Category 1

    Group Stop, Stop Category 1 The application circuit shows a drive control system according to EN ISO 13849-1 PL d, IEC 61508 SIL 2 or EN 954-1 category 3 with a PLC connected via the field bus and safety module. A PLC performs the process control of the frequency inverter and can start the drive profiles via commands which are communicated through the field bus.

  • Page 24: Error Exclusion "Short Circuit" In The Cabinet

    Error exclusion “short circuit” in the cabinet The application circuit shows a drive control system according to EN ISO 13849 PL d, IEC 61508 SIL 2 or EN 954-1 category 3 with PLC and safety control equipment. Safety control equipment with one enable path and interconnection line is imple- mented instead of safety control equipment with two enable paths.

  • Page 25: Checklist

    Checklist This list provides an overview of the requirements to be met in installation, commis- sioning and operation of the safety function Depending on the application, additional requirements must be met. Complete this list according to your application. Risk analysis: −...

  • Page 26: Safety Function Test Report

    Institut für Arbeitsschutz der Deutschen Gesetzlichen Unfallversi- cherung Test report no. 200622803 Test sample Frequency inverter of ACTIVE Cube series, concept inspection Basis of test DIN EN 61508 Parts 1-7:2002/2005 (as far as applicable) DIN EN ISO 13849-2:2003 (as far as applicable) EN 13849 -1:2006-11...

  • Page 27: Index Of Change

    Index of Change ACU-STOV1-01SV2-03: Clarification of Emergency stop and emergency switch off in chapter 1.1 of the English version. Note for transition period of EN954-1 in chapter 2 updated. ACU-STOV1-01SV2-02: Terminal designation of relay output X10 changed. ACU-STOV1-00SV2-02: New Application example Fault exclusion “Short circuit” in electrical cabinet.
  • Page 29 POLPACK Sp. z o.o. - Ul. Polna 129 - 87100 Torun BRASIL Tel. (+48) 56 6559235 to 37 - Fax (+48) 56 6559238 BONFIGLIOLI REDUTORES DO BRASIL INDÚSTRIA E COMÉRCIO LTDA. www.polpack.com.pl - polpack@polpack.com.pl Travessa Cláudio Armando 171 - Bloco 3 - CEP 09861-730 Bairro Assunção - São Bernardo do Campo - São Paulo (Brasil)
  • Page 30 Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applications since 1956. www.bonfiglioli.com Bonfiglioli Riduttori S.p.A. tel: +39 051 647 3111 VEC 541 R2 / ACU-STOV1-01SV2-03 en fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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