BONFIGLIOLI Vectron ACTIVE CUBE Applications Manual
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BONFIGLIOLI Vectron ACTIVE CUBE Applications Manual

BONFIGLIOLI Vectron ACTIVE CUBE Applications Manual

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Summary of Contents for BONFIGLIOLI Vectron ACTIVE CUBE

  • Page 1 ACTIVE CUBE Application manual Safe Torque Off...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General information about the documentation ............. 5 Instruction manuals..................5 This document .................... 6 Warranty and liability ................. 6 Obligation ....................7 Copyright ....................7 Storage ......................7 General safety instructions and information on use ............8 Terminology ....................
  • Page 4 General Description of Safety Function ............... 20 Integrated Safety Function ............... 20 Functional Safety ..................20 Classification the safety requirement ............20 Description of ACTIVE Cube Safety Function ............... 21 Two-Channel Monitoring ................22 Diagnosis function and enforced dynamizing ........... 24 Diagnosis indicators .................. 25 Requirements to be met by installation ...............

  • Page 5: General Information About The Documentation

    1 General information about the documentation The present documentation complements the operating instructions and the Quick Start Guide of the frequency inverter ACTIVE Cube (ACU). Instruction manuals For better clarity, the documentation is structured according to the customer-specific requirements made on the frequency inverter.

  • Page 6: This Document

    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. Any obligations of the manufacturer shall solely be based on the relevant purchase agreement which also includes the complete and solely valid warranty stipulations.

  • Page 7: Obligation

    Copyright In accordance with applicable law against unfair competition, this user manual is a certificate. Any copyrights relating to it shall remain with BONFIGLIOLI VECTRON GmbH Europark Fichtenhain B6 47807 Krefeld Germany These user manual is intended for the operator of the frequency inverter. Any disclosure or copying of this document, exploitation and communication of its contents (as hardcopy or electronically) shall be forbidden, unless permitted expressly.

  • Page 8: General Safety Instructions And Information On Use

    General safety instructions and information on use The chapter "General safety instructions and information on use" contains general safety instructions for the Operator and the Operating Staff. At the beginning of certain main chapters, some safety in- structions are included which apply to all work described in the relevant chapter. Special work-specific safety instructions are provided before each safety-relevant work step.

  • Page 9: Designated Use

    Designated use The frequency inverter is designed according to the state of the art and recognized safety regulations. The frequency inverters are electrical drive components intended for installation in industrial plants or machines. Commissioning and start of operation is not allowed until it has been verified that the ma- chine meets the requirements of the EC Machinery Directive 2006/42/EC and DIN EN 60204-1.

  • Page 10: Residual Risks

    Residual risks Residual risks are special hazards involved in handling of the frequency inverter which cannot be elim- inated despite the safety-compliant design of the device. Residual risks are not obviously identifiable and can be a potential source of injury or health hazard. Typical residual hazards include: Electrical hazard Danger of contact with energized components due to a defect, opened covers or enclosures or im-...

  • Page 11: Warning Information And Symbols Used In The User Manual

    Warning information and symbols used in the user manual 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 12: Recycling

    2.6.5 Recycling Symbol Meaning Recycling, to avoid waste, collect all materials for reuse 2.6.6 Grounding symbol Symbol Meaning Ground connection 2.6.7 ESD symbol Symbol Meaning ESD: Electrostatic Discharge (can damage components and assemblies) 2.6.8 Information signs Symbol Meaning Tips and information making using the frequency inverter easier.

  • Page 13: Directives And Guidelines To Be Adhered To By The Operator

    Directives and guidelines to be adhered to by the operator The operator must follow the following directives and regulations: • Ensure that the applicable workplace-related accident prevention regulations as well as other ap- plicable national regulation are accessible to the staff. •...

  • Page 14: Organizational Measures

    2.10.2 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 office compo- •...

  • Page 15: 2.10.5.1 The Five Safety Rules

    2.10.5.1 The five safety rules When working on/in electrical plants, always follow the five safety rules: 1. Isolate 2. Secure to prevent restarting 3. Check isolation 4. Earth and short-circuit, 5. Cover or shield neighboring live parts. 2.10.6 Safe operation •...

  • Page 16: Maintenance And Service/Troubleshooting

    2.10.7 Maintenance and service/troubleshooting Visually inspect the frequency inverter when carrying out the required maintenance work and • inspections at the machine/plant. • Perform the maintenance work and inspections prescribed for the machine carefully, including the specifications on parts/equipment replacement. •...

  • Page 17: Safety Instructions On Function „Safe Torque Off" (Sto)

    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.

  • Page 18: Approved Devices

    Warning! Dangerous voltage! After disconnection of an external DC 24 V power supply, the DC link of the frequency inverter is still connected to mains supply. Even if the motor control is deactivated and the motor is coasting to a standstill or has already stopped, high voltages may still be present on the motor terminals.

  • Page 19: 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 machine. The Standard EN 14121-1 – Safety of machinery - Risk assessment – Principles – describes the infor- mation required for risk assessment.

  • Page 20: 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 21: 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.

  • Page 22: 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. safety door.
  • Page 23 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 automatically. If the test re- sults negative, the frequency inverter cannot be switched on anymore. Starting is possible again only after the error has been repaired and the next test has been completed successfully.

  • Page 24: 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 25: 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 26: Requirements To Be Met By Installation

    Select the dimensions of the safety application such that 14 mA input current is available for each of the inputs STOA and STOB. If more than one ACTIVE Cube frequency inverters are connected to one safety control device, the safety control device must provide sufficient power for all of them.

  • Page 27: 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 dangerous states. External safety control devices must meet the following requirements: −...

  • Page 28: 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 con- nected.

  • Page 29: Application Examples

    Application Examples The following examples illustrate how the “Safe Torque Off” function works. According 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 frequency inverter ACU. Stop category 0: Stop by immediate disconnection of energy supply to the machine drive elements, i.e.

  • Page 30: Direct Stop, Stop Category 0

    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 fre- quency inverter are interrupted and the integrated safety function with safe pulse block with SIL 2 according to EN-61800-5-2 is activated.

  • Page 31: Direct Stop With Feedback To Plc, Stop Category 0

    10.2 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 fre- quency inverter and can start the drive profiles via commands.

  • Page 32: Direct Stop, Stop Category 1

    10.3 Direct Stop, Stop Category 1 The application example shows the minimum circuitry for ACTIVE cube frequency inverters for realiza- tion of the safety function STO “Safe Torque Off” with an emergency stop device in a common electri- cal cabinet.

  • Page 33: Direct Stop With Feedback To Plc, Stop Category 1

    10.4 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 fre- quency inverter and can start the drive profiles via commands.

  • Page 34: 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 realiza- tion of the safety function STO “Safe Torque Off” with an emergency stop switch in a common electri- cal cabinet.

  • Page 35: Group Stop, Stop Category 1

    10.6 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 36: Error Exclusion "Short Circuit" In The Cabinet

    10.7 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 implemented instead of safety control equipment with two enable paths.

  • Page 37: Checklist

    - SIL 2 (or smaller) according to IEC 61508 - Category 3 (or smaller) according to EN 954-1 − considers the stopping behavior of the ACTIVE Cube frequency inverter − permits coasting of the drive to a standstill or requires the installation of a mechanical brake.

  • Page 38: 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 39: Index Of Change

    Index of Change ACU-STOV1-01SV2-04: General and Safety instructions adapted to actual Bonfiglioli Vectron documentations, information in chapter 3 according to EN 60204 revised. 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.

  • Page 40: Index

    Two-Channel Monitoring ......22 DC 24 V Supply ........27 SELV ............27 Decommissioning ........16 Service ............ 16 Description of ACTIVE Cube Safety SIL ............19 Function ........... 21 Standard Designated use ........... 9 EN ISO 13849-1 ........19 Diagnosis function ........
  • Page 41 Bonfiglioli worldwide network. Bonfiglioli Australia Bonfiglioli New Zealand 2, Cox Place Glendenning NSW 2761 88 Hastie Avenue, Mangere Bridge, Auckland Locked Bag 1000 Plumpton NSW 2761 2022, New Zealand - PO Box 11795, Ellerslie Tel. (+ 61) 2 8811 8000 - Fax (+ 61) 2 9675 6605 Tel.
  • Page 42 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 541 R3/ACU-STOV1-01SV2-04 en fax: +39 051 647 3126 Via Giovanni XXIII, 7/A bonfiglioli@bonfiglioli.com 40012 Lippo di Calderara di Reno...

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