BONFIGLIOLI Agile Applications Manual
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BONFIGLIOLI Agile Applications Manual

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Summary of Contents for BONFIGLIOLI Agile

  • Page 1 Agile Application manual Functional Safety...

  • Page 3: Table Of Contents

    CONTENT General information about the documentation ............. 5 Instruction manuals..................5 This document .................... 5 Warranty and liability ................. 6 Obligation ....................6 Copyright ....................6 Storage ......................6 General safety instructions and information on use ............7 Terminology ....................7 Designated use ...................
  • Page 4 Definitions of the AGL Safety functions ............ 18 Specification of the Safety Function 1 (SF1): STO ........18 Specification of the Safety Function 2 (SF2): SS1 ........19 Description of Safety Function ..............20 Two-Channel Monitoring ................21 Diagnosis function and enforced dynamizing ........... 23 Requirements to be met by installation ...............

  • Page 5: General Information About The Documentation

    If you require further information or if you meet with specific problems which are not dealt with in sufficient detail in the documentation, contact your local 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: Warranty And Liability

    1.3 Warranty and liability BONFIGLIOLI VECTRON GmbH would like to point out that the contents of this user manual do not form part of any previous or existing agreement, assurance or legal relationship. Neither are they intended to supplement or replace such agreements, assurances or legal relationships.

  • Page 7: General Safety Instructions And Information On Use

    2 General safety instructions and information on use This chapter contains general safety instructions for the Operator and the Operating Staff. At the be- ginning of certain main chapters, some safety instructions are included which apply to all work described in the relevant chapter.

  • Page 8: Residual Risks

    For, example, the machine/plant must not be operated  by uninstructed staff,  while it is not in perfect condition,  without protection enclosure (e.g. covers),  without safety equipment or with safety equipment deactivated,  when general requirements, such as operating conditions and technical data, are not met. The manufacturer shall not be held liable for any damage resulting from such misuse.

  • Page 9: Warning Information And Symbols Used In The Operating Instructions

    2.6 Warning information and symbols used in the Operating Instruc- tions 2.6.1 Hazard classes The following hazard identifications and symbols are used to mark particularly important information: DANGER Identification of immediate threat holding a high risk of death or serious injury if not avoided.

  • Page 10: Esd Symbol

    2.6.7 ESD symbol Symbol Meaning ESD: Electrostatic Sensitive Devices, i.e. components and assemblies sensi- tive to electrostatic energy 2.6.8 Information signs Symbol Meaning Tips and information making using the frequency inverter easier. 2.6.9 Font style in documentation Example Font style bold Representation of parameter numbers 1234...

  • Page 11: Ear Protectors

    2.9.2 Use in combination with third-party products  Please note that Bonfiglioli Vectron GmbH will not accept any responsibility for compatibility with third-party products (e.g. motors, cables or filters).  In order to enable optimum system compatibility Bonfiglioli Vectron GmbH offers components fa- cilitating commissioning and providing optimum synchronization of the machine/plant parts in op- eration.

  • Page 12: Safe Operation

    carry out earthing and short-circuiting cover or shield neighboring live parts 2.9.5 Safe operation  During operation of the frequency inverter, always comply with the applicable national and inter- national regulations/laws on work on electrical equipment/plants.  Before commissioning and the start of the operation, make sure to fix all covers and check the terminals.
  • Page 13 Electric scrap, electronic components, lubricants and other utility materials must be treated as special waste and may only be disposed of by specialized companies. In any case, comply with any applicable national disposal regulations as regards envi- ronmentally compatible disposal of the frequency inverter. For more details, contact the competent local authorities.

  • Page 14: Safety Instructions On Function "Safe Torque Off" (Sto)

     Check the safety function at regular intervals according to the results of your risk analysis. Bonfiglioli Vectron MDS GmbH recommends that the check be performed after one year, at the latest. The STO function is fail-safe for one fault. However, on rare occasions, the occurrence of component defects may cause jerking of the motor shaft (max.

  • Page 15: Approved Devices

    3.1 Approved Devices The following device variants of the Agile device series are approved for applications with functional safety. Additional to the below mentioned Type codes, the name plate of these devices contains a “STO certified” logo. 3.1.1 Connection 3x AC 400/480 V...

  • Page 16: Information Of Risk Analysis And Risk Assessment

    4 Information of Risk Analysis and Risk Assessment According to the Machinery Directive 2006/42/EC, the manufacturer of a machine is obliged to carry out a risk analysis in order to identify the hazards related to the machine. The Standard EN 12100 – Safety of machinery - General principles for design - Risk assessment and risk reduction describes the information required for risk assessment.

  • Page 17: General Description Of Safety Function

    5 General Description of Safety Function 5.1 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 18: Description Of Active Cube Safety Function

    6 Description of ACTIVE Cube Safety Function The frequency inverters of the AGL devices series feature the integrated safety function „Safe torque off, STO“. With a suitable external safety control device the function „Safe Stopp 1 (SS1 c)“ according to EN 61800- 5-2 can be realized together with the AGL.

  • Page 19: Specification Of The Safety Function 2 (Sf2): Ss1

    Redundancy On two channels (2) Performance Level (EN ISO 13849-1) Kategorie (EN ISO 13849-1) Amount of Processs interfaces Two (2) Design of Processs interface Two yellow marked spring terminals X11.3 and X13.3 (inputs STOA und STOB) Type of Processs interfaces SPS-Type 1 compatible according to IEC61131-2 Operation modes with limited functiona- None...

  • Page 20: Description Of Safety Function

    Speed axis Time axis Time frame, when braking ramp is triggered (non safe path) Time frame, when STO is triggered Time between activation of braking ramp and triggering STO Are of maximum braking Time, Set up on external safety control device. Area of discontinuation 6.4 Description of Safety Function In the case of an error or if requested, the power semiconductors of the frequency inverter will be...

  • Page 21: Two-Channel Monitoring

     Contactors on motor side not required, reduced installation requirements, less components, more space in electrical cabinet  Simple realization with external safety control device for Stop-Category 0  With a suitable external safety control a functional safety according to Stop Category 1 can be achieved ...
  • Page 22 If the function STO is triggered, the high level controller (PLC) has no more influence on the inverter release in the frequency inverter. To restart, the inverter release is enabled by the release by the user or by the superior PLC. An error inside the STO self-monitoring is identified and can then be repaired (e.g.

  • Page 23: Diagnosis Function And Enforced Dynamizing

     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 24: Requirements To Be Met By Installation

    Select the dimensions of the safety application such that the input current according to the operating instructions is available for each of the inputs STOA and STOB (typical: 10 mA). If more than one Agile frequency inverters are connected to one safety control device, the safety control device must provide sufficient power for all of them.

  • Page 25: External Dc 24 V Power Supply

    Examples of contact sensors:  Emergency stop control device for stop in dangerous situations  Position switch, e.g. for monitoring slide doors, safety grids or moving machine parts Examples of no-contact sensors: Light barriers, e.g. for monitoring areas with dangerous movements ...

  • Page 26: Requirements To Be Met By Acceptance Inspection

    9 Requirements to be met by acceptance inspection The acceptance inspection of the safety function is ordered by the manufacturer of the machine. The inspection (acceptance, validation) shall be performed by a properly qualified person. The result of the inspection is to be documented and must be signed by the inspector. Each safety function must be documented in detail in this report.

  • Page 27: Application Examples

    When operating the emergency stop device with two stop channels both release paths paths STOA and STOB of the Agile frequency inverter are interrupted and the integrated safety function is triggered by interrupting the inverter release. A (non-safe) feedback to a process control can be done via a connected field bus.

  • Page 28: Sto Direct Stop With Error Exclusion "Short Circuit" In The Cabinet

    10.1.2 STO Direct Stop with error exclusion “short circuit” in the cabinet The application circuit shows a drive control system with safety module according to EN ISO 13849-1 PL d and Category 3 or IEC 61508 SIL 2. Safety control equipment with one enable path and intercon- nection line is implemented instead of safety control equipment with two enable paths.

  • Page 29: Sto Direct Stop With Feedback To Plc

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

  • Page 30: Sto Direct Stop W/ Feedback To Plc W/ Error Exclusion "Short Circuit" In Cabinet

    10.1.4 STO Direct Stop w/ Feedback to PLC w/ error exclusion “short circuit” in cabinet The application circuit shows a drive control system with PLC and safety module according to EN ISO 13849-1 PL d and Category 3 or IEC 61508 SIL 2. Safety control equipment with one enable path and interconnection line is implemented instead of safety control equipment with two enable paths.

  • Page 31: Ss1 According To Stop Category 1

    When the emergency stop device is actuated, the travel command “Clockwise” is reset first. After a delay t , the contacts on the safety switch interrupt the two enable paths STOA and STOB of the Agile frequency inverter and the integrated safety function is triggered. The delay time is set on the safety control device and must be selected according to the application.

  • Page 32: Ss1 Direct Stop With Error Exclusion "Short Circuit" In The Cabinet

    10.2.2 SS1 Direct Stop with error exclusion “short circuit” in the cabinet The application circuit shows a drive control system according to EN ISO 13849-1 PL d and Category 3 or IEC 61508 SIL 2 with PLC and safety module. Safety control equipment with one enable path and interconnection line is implemented instead of safety control equipment with two enable paths.

  • Page 33: Ss1 Direct Stop With Feedback To Plc

    10.2.3 SS1 Direct Stop with Feedback to PLC The application example shows a drive control system with PLC and safety module according to EN ISO 13849-1 PL d and category 3 or IEC 61508 SIL 2. A PLC performs the process control of the frequency inverter and can start the drive profiles via commands.

  • Page 34: Ss1 Direct Stop W/ Feedback To Plc W/ Error Exclusion "Short Circuit" In Cabinet

    10.2.4 SS1 Direct Stop w/ Feedback to PLC w/ error exclusion “short circuit” in cabinet The application circuit shows a drive control system with PLC and safety module according to EN ISO 13849-1 PL d and Category 3 or IEC 61508 SIL 2. Safety control equipment with one enable path and interconnection line is implemented instead of safety control equipment with two enable paths.

  • Page 35: Internal Dc 24 V Supply, Ss1

    10.2.5 Internal DC 24 V Supply, SS1 The application example shows the minimum circuitry for ACTIVE cube frequency inverters for realiza- tion of the safety function with an emergency stop switch in a common electrical cabinet. Supply of the safety control device is effected by the internal DC 24 V supply (max. 100 mA for all connected con- sumers).

  • Page 36: Group Stop, Ss 1

    10.3 Group Stop, SS 1 The application circuit shows a drive control system with PLC and safety module according to EN ISO 13849-1 PL d and Category 3 or IEC 61508 SIL 2. 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 37: Checklist

    - Category 3 (or smaller) according to EN ISO 13849-1 - SIL 2 (or smaller) according to IEC 61508  considers the stopping behavior of the Agile frequency inverter  permits coasting of the drive to a standstill or requires the installation of a mechanical brake.
  • Page 38  Emergency stop devices meet the following classifications: - PL d (or smaller) according to EN ISO 13849-1 - Category 3 (or smaller) according to EN ISO 13849-1 - SIL 2 (or smaller) according to IEC 61508  Emergency Stop devices have a cross fault monitoring (2-channel connection) or protected wiring? ...

  • Page 39: Safety Function Test Report

    TÜV Rheinland Industrie Service GmbH Test report no. 968/M 355.01/17 Test sample Frequency inverter Agile series, concept inspection Basis of test IEC 61508 Teil 1-7:2010 (as far as applicable) EN ISO 13849-2:2008 + AC:2009 (as far as applicable) EN 62061:2005...

  • Page 40: Change Index

    13 Change index AGL-STOV0-01SV0-06: General and Safety instructions adapted to actual Bonfiglioli Vectron documentations, information in chapter 3 according to EN 60204 revised. AGL-STOV0-01SV0-05: First release in English language. AGL-STOV0-01SV0-06 03/18...
  • Page 41 INDEX PL 16 Power supply Application example SS1 external, DC 24 V ..........25 1. Direct Stop ........... 31 internal, DC 24 V by AGL ........25 2. Direct Stop with error exclusion ....32 3. Direct Stop with Feedback to PLC ....33 4.
  • Page 42 Fax +90 (0) 232 328 04 14 www.bonfiglioli.de - info@bonfiglioli.de www.bonfiglioli.com.tr info@bonfiglioli.com.tr Bonfiglioli España Bonfiglioli United Kingdom TECNOTRANS BONFIGLIOLI S.A. Industrial Solutions Pol. Ind. Zona Franca sector C, calle F, n°6 08040 Barcelona Unit 7, Colemeadow Road Tel. (+34) 93 4478400 - Fax (+34) 93 3360402 North Moons Moat - Redditch, www.tecnotrans.com - tecnotrans@tecnotrans.com...
  • Page 44 Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry, mobile machinery and renewable energy applicacations since 1956. Bonfiglioli Riduttori S.p.A. tel: +39 051 647 3111 COD. VEC 1002 R1 fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com...

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