Afag SE-Power FSM 2.0 MOV User manual

short description „SE-Power FS Safety Module FSM 2.0 MOV“
- 1 -
Version 2.1
short description
SE-Power FS Safety Module FSM 2.0 MOV
for the servo controllers of the SE-Power FS series
Translation
English
Afag Automation AG
Fiechtenstrasse 32
CH –4950 Huttwil
Switzerland
phone: [phone]
fax: [phone]
e-mail: [e-mail]
internet: www.afag.com © 2015
The full documentation for the safety module and the documentation of the
servo controllers SE-Power FS can be found in PDF format on our website at
www.afag.com.
The present short description applies to the following versions:
SE-Power FS Safety Module FSM 2.0 MOV, from revision 1.1
Servo controller SE-Power FS, firmware from version 4.1.801.1.1 and
hardware as follows depending on the device: SE-Power FS 1kVA
from version 6.0, SE-Power FS 3kVA from version 4.1 and SE-Power
FS 6kVA from version 4.1
Parameterisation program Afag SE-Power ServoCommander from
version 4.1.801.1.1 with SafetyTool from version 1.0.2.1
1 Safety
1.1 General safety notes
Observe in addition implicit the „Safety notes for electrical drives and
controllers“ for the servo controllers SE-Power FS.
These can be found in the corresponding operating instructions.
Note
Loss of the safety function!
Non-compliance with environmental and supply conditions can lead to loss of the
safety function.
Keep the specified ambient and connection conditions, in particular the input
voltage tolerances section 11.
Note
Damage to the safety module or the servo controller by improper
use.
Improper use can result in damage.
Switch off supplyvoltages beforemounting and installation work. Do not switch
on supply voltages, where assembly and installation work has been
completed.
Never pull off or plug the module when the servo controller is energised!
Observe the regulations for handling electrostatic sensitive devices.
1.2 Proper usage
The SE-Power FS Safety Module MOV serves as an extension of the servo
controller SE-Power FS to achieve safety functions STO, SS1, SS2, SOS, SLS,
SSR, SSM, SBC according to EN 61800-5-2.
The servo controller SE-Power FS with SE-Power FS Safety Module MOV is a
product with safety features and designed for installation in machines or
automated systems and uses the following:
in perfect technical condition,
in original condition without unauthorized changes,
within the limits defined by the technical specifications of the product
(section 11),
in the industrial sector.
Note
Any damage resulting from unauthorized interference or improper use voids the
warranty and liability claims against the manufacturer.
1.3 Foreseeable Misuse
For improper use include the following foreseeable misuse:
the use in a device other than a SE-Power FS
the outdoor use,
the use in non-industrial areas (living area),
use outside the limits of the product defined in the technical data,
unauthorised modifications.
Note
The STO function is insufficient as the sole safety function for drives subject to
permanent torque (e.g. suspended loads).
Bypassing of safety equipment is impermissible.
Repairs on the module are impermissible!
The STO (Safe Torque Off) function does not provide protection against electric
shock, only against hazardous movements!
1.4 Achievable safety level,
safety function in accordance with EN ISO 13849 / EN 61800-5-2
The safety module fulfils the basic test requirements
Category 4 / PL e in accordance with EN ISO 13849-1,
SIL CL 3 in accordance with EN 62061,
and can be used in applications up to cat. 4 / PL e in accordance with EN ISO
13849-1 and up to SIL 3 in accordance with EN 62061 / IEC 61508.
The achievable safety level depends on the other components used to achieve a
safety function.
2 Requirements for product use
Make the complete documentation available to the design engineer,
installer and personnel responsible for commissioning the machine or
system in which this product is used.
Take into consideration the legal regulations applicable for the destination,
as well as:
regulations and standards,
regulations of the testing organizations and insurers,
national specifications.
2.1 Technical prerequisites
General conditions for the correct and safe use of the product, which must be
observed at all times:
Comply with the connection and environmental conditions of the safety
module (section 11), the servo drive and all connected components.
Only compliance with the limit values or load limits will enable operation of
the product in compliance with the relevant safety regulations.
Observe the instructions and warnings in this documentation.
2.2 Qualification of the specialist personnel (requirements for personnel)
The device may only be commissioned by a qualified electro technician who is
familiar with:
the installation and operation of electrical control systems,
the applicable regulations for operating safety-engineered systems,
the applicable regulations for accident protection and occupational
safety, and
the documentation for the product.
2.3 Diagnostic coverage (DC)
Diagnostic coverage depends on the integration of the servo drive with safety
module into the control loop system, the motors/position encoders used, as well
as the implemented diagnostic measures.
If a potentially dangerous malfunction is recognised during the diagnostics,
appropriate measures must be taken to maintain the safety level.
2.4 Range of applications and certification
The servo drive with built-in safety module is a safety component in accordance
with the EC Machinery Directive 2006/42/EC; the servo drive bears the CE
marking. Safety-oriented standards and test values, which the product must
comply with and fulfil, can be found inthe section „Technical data“ (section 11).
The product-relevant EU directives can be found in the declaration of conformity.
3 Product description
3.1 Supported devices
The SE-Power FS MOV safety modules can only be used in servo controllers in
accordance with section 1.2. The servo controller of the SE-Power FS MOV
series are in the default factory settings already with the SE Power FS Safety
Module MOV, with integrated functional for the safety functions STO, SS1, SS2,
SOS, SLS, SSR, SSM, SBC, equipped.

short description „SE-Power FS Safety Module FSM 2.0 MOV“
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Version 2.1
3.2 Control sections and connections
1 Servo controller SE-Power FS
2 7-segment display
3 SE-Power FS Safety Module MOV
4 I/O-interface [X40A] / [X40B]
5 Pin 1 of the interface [X40]
6 LED (operating status display)
7 DIP switch
Figure 1: Panel and connectors of the SE-Power FS Safety Module MOV
4 Function and application
The following figure shows a typical drive system with integrated functional safety
technology, comprising the following components:
servo drive SE-Power FS,
SE-Power FS Safety Module MOV,
synchronous servo motor,
linear axis with second measurement system
reliable brake unit.
Figure 2: Safety module functional principle
5 Mounting / dismounting
The servo drive must be disconnected from all current-carrying cables before
mounting and dismounting the safety module.
Warning
Danger of electric shock if the safety module is not mounted.
Touching live parts causes severe injuries and can lead to death.
Before touching live parts during maintenance, repair and cleaning work and
when there have been long service interruptions:
1. Switch off power to the electricalequipment via themains switch and secure it
against being switched on again.
2. After switch-off, wait at least 5 minutes dischargetime andcheck that power is
turned off before accessing the servo drive.
Note
Incorrect handling can damage the safety module or servo drive.
Switch off the supply voltage before mounting and installation work. Switch on
supply voltage only when mounting and installation work are completely
finished.
Never unplug a module from, or plug a module into, the servo drive when
powered!
Observe the handling specifications for electrostatically sensitive devices. Do
not touch the printed circuit board and the pins of the connector in the servo
drive. Hold the safety module only by the front plate or the edge of the board.
5.1 Mounting the safety module
1. Insert the SE-Power FS Safety Module
MOV into the empty slot for safety
modules so that the board runs in the
lateral guides of the slot.
2. Cautiously push in safety module.
Make sure that it does not catch. When
you have reached therear contact strip
within the servo drive, carefully press it
into the contact strip until it stops.
3. Then screwthe safety module with the
two screws onto the front of the servo
drive housing.
Tighten thescrews with 0,4 Nm ± 10% an.
Figure 3:
Mounting / Dismounting
5.2 Dismounting safety module
1. Unscrew screws on the safety module.
2. Loosen the safety module by gently levering it a few millimetres in the
cut-outs on the upper right and lower right corner of the front cover or grip
the safety module on the plugged in counter plug.
3. Pull the safety module out of the slot.
6 Electrical installation
6.1 Safety instructions
The requirements of EN 60204-1 must be fulfilled during installation.
Warning
Danger of electric shock from voltage sources without
protective measures.
Use only PELV circuits in accordance with EN 60204-1 for the electric logic
supply (protective extra-low voltage, PELV).
Also take into account the general requirements for PELV circuits in
accordance with EN 60204-1.
The cable is connected with two plugs. As a result, cables can remain plugged
into the plugs when replacing the safety module, for example.
Make sure that no jumpers, etc. can be used parallel to the safety wiring.
6.2 ESD protection
At unassigned plug connectors, there is the danger that damage may occur to the
device or to othersystem parts asa result of ESD (electrostatic discharge). Earth
the system parts before installation and use appropriate ESD equipment (e.g.
shoes, earthing straps, etc.).
6.3 Connection [X40]
The SE-Power FS Safety Module MOV has a combined interface for control and
acknowledgment via the plug connector [X40].
Pin
Designation
Plug
Pin
Designation
1
DIN40A
13
DIN41A
2
DIN40B
14
DIN41B
3
DIN42A
15
DIN43A
4
DIN42B
16
DIN43B
5
DOUT40A
17
DOUT41A
6
DOUT40B
18
DOUT41B
7
DIN44
19
DOUT42A
8
DIN45
20
DOUT42B
9
DIN46
21
C1
10
DIN47
22
C2
11
DIN48
23
GND24
12
DIN49
24
+24 V
7 Commissioning
Warning
Loss of the safety function!
Lack of the safety function can result in serious, irreversible injuries, e.g. due to
uncontrolled movements of the connected actuator technology.
Operate the safety module only:
in a built-in condition and
when all safety measures have been implemented.
Validate the safety function to complete commissioning.
Commissioning according to the EC Machinery Directive is the first intended use
of the machine by the end customer. Here is meant start-up by the manufacturer
during installation of the machine.
Incorrect circuitry, incorrect configuration, use of an incorrect safety module or
external components that were not selected according to the safety category,
result in loss of the safety function.
Carry out a risk assessment for your application and select the circuitry,
configuration and components accordingly.
X40A X40B
Motor
Fieldbus
or X1
µC-GG
µC1
µC2
BR+
BR-
STO, SBC, SS1, SS2, SOS, SLS, SSM, SSR
Servo driver
Safety module
Requirement via DIN4x
e.g. external brake
unit via DOUT4x
X40
Status
DIP
Motor phases U/V/W
Linear measure-
ment system
X6
X2A
X2B
X10
Holing brake in the Motor
Status
Diagnose
X2A encoder
X2B encoder
X10 encoder

short description „SE-Power FS Safety Module FSM 2.0 MOV“
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Version 2.1
7.1 Prior to commissioning
Carry out the following steps in preparation for commissioning:
1. Ensure that the safety module is correctly mounted.
2. Check the electrical installation (connecting cable, pin allocation
section 6). Are all protective earth conductors connected?
7.2 DIP switch setting
Set the DIP switches as described in the documentation for the servo drives
SE-Power FS or the corresponding fieldbus-specific product manuals.
7.3 Parameterisation with the Afag SE-Power ServoCommander
The servo drive must be completely parameterised prior to parameterisation of
the safety module using SafetyTool. Additional information on commissioning of
the servo drive can be found in the parameterisation software help or, possibly, in
the Software manual.
7.3.1 Applying the safety module
When an engineering change is detected, e.g. a module replacement, a
non-acknowledgeable error is triggered. To be able to place the application with
the servo drive back in operation, the engineering change must be explicitly
accepted or confirmed. Each exchange of a SE-Power FS Safety Module MOV,
regardless of whether by an identical SE-Power FS Safety Module MOV or
another module type (SE-Power FS Safety Module STO) must always be
confirmed.
From the factory, you receive the safety module in the “delivery status”:
The safety module is “validated as a whole” with the parameterisation of the
factory setting and is thus operational. The servo drive can be
commissioned, and the output stage and controller enable can be set.
All error messages due to a different parameterisation of the basic unit and
safety module are suppressed. As a result, base commissioning of the
servo drive is possible independently of complex safety-related peripherals.
Minimum circuitry in the delivery status:
The safety functions STO and SBC are requested via DIN40.
Restart takes place over DIN49, error acknowledgment over DIN48.
Wiring must not be bypassed and must be validated in themachine. The delivery
status can also be recognised without parameterisation software or SafetyTool by
the green-red flashing LED of the safety module (if DIN40 is switched on and no
safety function is demanded).
7.4 Parameterisation of the safety module with the SafetyTool
Parameterisation of the safety module is then performed with special software,
the SafetyTool. The SafetyTool is called up from the supplied parameterisation
software. For additional information SafetyTool Help.
7.5 Performance test, validation
Note
The safety functions must be validated after installation and after any changes to
the installation.
This validation must be documented by the person performing commissioning. To
help you with commissioning, you can find sample checklists in the document
„SE-Power FS MOV-manual“.
8 Diagnostics and fault clearance
8.1 Status display
Status and malfunctions are displayed directly on the two-colour LED of the
safety module.
8.1.1 Status display on the safety module
To display the status of the safety function, the safety module has an LED on its
front. The status LED displays the operating status of the safety module. The
display is exclusively for diagnostics and must not be used in a safety-oriented
way.
LED
Status
Internal Status
Flashes red
„System Fault“
The entire system is in the “System Fault” or
“Communication Fault” status“.

Lights up red
„Safety Condition
Violated“, error response
initiated
Violation of at least one of the currently
required safety functions.

Lights up yellow
„Safe State reached“
Requested safety functions are in the status
“Safe State Reached”.

Flashes yellow
„Safety Function
Requested“
At least one safety function requested.

Flashes red/green
„Delivery status“
Delivery status section 7.3

Flashes green
„Service“ status“
No parameters present, parameter invalid
or parameterisation procedure is running.

Lights up green
„Ready“, operational
Operational, no safety function requested,
no errors.

Off
„Initialization Running“
Initialization 1: Load parameter,
Initialization 2: Establish communication.

8.1.2 Status display of the safety functions on the servo drive
Display of safety functions on the 7-segments display
STO
S t O
SOS
S O S
SS1
S S 1
USF0
(...1, 2. 3)
U S F 0
SS2
S S 2
SBC
S b C
8.2 Error messages
The servo drive indicates malfunctions cyclically in the seven-segment display on
the front side of the servo drive. Error messages with “E” (for error), a main index
(xx) and a sub-index (y) display, e.g. E 5 1 0. Warnings have the same number,
but are represented with bars before and after, e.g. - 1 7 0 -. The following table
lists the error messages that are relevant for functional safety in the context of the
safety module.
The complete list of error messages can be found in the product manual of the
servo drive used.
Error number
Main index
Error type/class
Basic unit errors
51-x
Control signals from the safety module, module type / identifier not OK
52-x
Error in activation sequence with the safety module
Errors of the safety module
53-x
Violation of a safety function
54-x
Violation of a safety function
55-x
System error: Actual value recording / position encoder not OK
56-x
System error: Position recording / comparison not OK
57-x
System error: Inputs and outputs or internal test signals not OK
58-x
System error: Communication external / internal not OK
59-x
System error of the firmware / hardware error of the safety module
9 Operation
9.1 Obligations of the operator
The functionality of the safety device is to be checked at adequate intervals. It is
the responsibility of the operator to choose the type of check and time intervals in
the specified time period. The check is to be conducted so the flawless
functioning of the safety device in interaction with all the components can be
verified.
9.2 Maintenance and care
The safety module does not require any maintenance.
10 Repair, replacement of the safety module
10.1 Repair
Repair of the safety module is not permissible. If necessary, replace the
complete safety module.
Always replace the safety module in case of an internal defect. Send the
unchanged defective safety module, including a description of the error and
the application, back to Afag for analysis. Please contact your reseller to
clarify the modalities of the return.
10.2 Replacement of the safety module
If a safety module fails and has to be replaced, organisational measures must be
taken to ensure that an unsafe status is not created. This requires,
that the safety module is not replaced by another module type with less
function range (SE-Power FS Safety Module STO for SE-Power FS Safety
Module MOV).
that the revision status of the new safety module is identical with that of the
old safety module or is compatible.
that parameterisation of the new safety module is identical with the
parameterisation of the defective safety module.
Observe required organizational measures to avoid errors in relationship with the
module replacement. For example, you must always generate a new validation
report due to the different serial number of the safety module.
10.2.1 Disassembly and installation
Before a module is replaced, compatibility between the safety module and basic
unit must be checked.
Information on disassembling and installing the safety module can be found
under „Mounting / dismounting“ section 5.
10.2.2 Applying the safety module
After replacing the module, you must first accept the new safety module again.
section 7.

short description „SE-Power FS Safety Module FSM 2.0 MOV“
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10.2.3 Commissioning again with the SafetyTool
After accepting the replaced safety module, you must transfer the desired
parameterisation to the safety module and then validate. To do this, you must first
start the SafetyTool in the online mode. You then have the following options,
dependent on which data are present from the safety module to be replaced:
a) Reliable parameter set available of the safety module to be replaced:
Open parameter set in the SafetyTool and load it to the safety module.
Basic information of the basic unit must correspond to the parameter
set.
b) Stored SafetyTool project that conforms to the parameterisation present:
Set safety module to factory setting, if necessary.
Open SafetyTool project.
Adjust basic information of the basic unit, if they do not match.
Then validate parameter pages and load them to the safety module.
c) If no stored data is available of the safety module to be replaced:
Set safety module to factory setting, if necessary.
Continue as with initial start-up.
Independent of the variant a), b) or c), you must generate a validation report
again, with a new validation code and new serial number of the safety module. If
there is no stored SafetyTool project, it should be made available by the machine
manufacturer. After a replacement, a functional test is always required as well as
validation based on the validation plan provided by the machine manufacturer.
10.3 Decommissioning and disposal
Observe the information for dismantling the safety module in section 5.
10.3.1 Disposal
Observe the local regulations for environmentally appropriate disposal of
electronic modules. The safety module is RoHS-compliant.
The material used in the packaging has been specifically chosen for its
recyclability.
11 Technical data
Safety Technology
Safety indicators
Safety functions
STO, SS1, SS2, SOS, SLS, SSR, SSM, SBC according to
EN 61800-5-2
SIL
SIL 31)
Safety Integrity Level according to EN 61800-5-2,
EN 61508 and EN 62061
Category
41)
Category according to EN ISO 13849-1
Performance Level
PL e1)
Performance Level according to EN ISO 13849-1
1) Maximum achievable classification, limitations dependent on the safety function as well as
circuitry and the encoders.
MTTFd
[Years]
8700
Mean time to dangerous failure according to
EN ISO 13849-1
PFH
[h-1]
9,5 x 10–9
Probability of a dangerous, random hardware failure per
hour according to EN 61800-5-2, EN ISO 13849-1,
EN 62061 and EN 61508
DC
[%]
97,5
Diagnostic coverage according to EN 61800-5-2,
EN 61508 and EN ISO 13849-1 and EN 62061
HFT
1
Hardware fault tolerance according to EN 61800-5-2,
EN 62061 and EN 61508
SFF
[%]
99,5
Safe failure fraction according to EN 61800-5-2, EN 62061
and EN 61508
T
[Years]
20
Test interval according to EN 61800-5-2, EN 61508 and
EN 62061
TM
[Years]
20
Duration of use according to EN ISO 13849-1
Safety information
Type examination
The functional safety technology of the product has been
certified in accordance with section 1.4 by an independent
testing centre.
Certificate issuing authority
TÜV Rheinland, Certification Body of Machinery, NB 0035
Certificate no.
01/205/5443.00/15
Approved component
yes
General
Mechanical
Dimensions (L x B x H)
[mm]
112,2 x 99,1 x 28,7
Weight
[g]
ca. 220
Note of materials
RoHS-compliant
Certifications (Safety module FSM 2.0 –MOV for servo drive SE-Power FS)
CE marking (see declaration of
conformity)
In accordance with EU EMC Directive
In accordance with EU Machinery Directive
The device is intended for use in an industrial environment. Measures may need to be
implemented in residential areas for interference suppression.
Operating and environmental conditions
Transport
Admissible
temperature range
[°C]
–25 … +70
Humidity
[%]
0 ... 95, at max. 40 °C ambient temperature
Maximum duration
of transport
[Weeks]
maximal 4 throughout the product life cycle
Storage
Admissible
temperature range
[°C]
–25 … +55
Humidity
[%]
5 ... 95, non-condensing / protected against condensation
Admissible height
[m]
< 3000 (above sea level)
Ambient conditions SE-Power FS with SE-Power FS Safety Module MOV in the FSM slot
SE-Power FS
1kVA
3kVA
6kVA
Ambient temperature
[°C]
0 … +40
0 … +40
0 … +40
Ambient temperature with
power reduction
[°C]
+40 … +50
+40 … +50
+40 … +45
Humidity
[%]
0 … 90 (non-condensing).
No corrosive media permitted in the environment of the
device.
Admissible setup altitude above sea level
with nominal power
[m]
1000
with power reduction
[m]
1000 … 2000
Protection category
IP20 (mounted in the SE-Power FS).
Vibration / shock
Requirements of EN 61800-5-1 and EN 61800-2 are fulfilled.
Electrical operating conditions
Galvanically insulated potential
areas
Control voltage of the basic unit.
24 V control voltage (all inputs and outputs).
Potential-free signal contact C1/C2.
System voltage
[V]
< 50 (24 V PELV- power supply in accordance with EN
60204-1).
Overvoltage category in
accordance with EN 61800-5-1
3
Degree of contamination in
accordance with EN 61800-5-1
2
This must always be ensured through appropriate
measures, e.g. through installation in a control cabinet.
EMC operating conditions
Resistance to interference
Requirements for “second environment” in accordance with
EN 61800-3 (PDS of category C3)
requirements in accordance with EN 61326-3-1
Emitted interference
Requirements for “first environment with restricted
availability” in accordance with EN 61800-3 (PDS of
category C2)
Electrical data
Digital inputs DIN40A/B to DIN43A/B and DIN44 to DIN49
Input
Type 3 in accordance with IEC 61131-2
Nominal voltage
[V DC]
24
Admissible voltage range
[V]
-3 … 30
Digital outputs DOUT40A/B to DIN42A/B
Output
High side switch with pull-down
Voltage range
[V DC]
18 … 30
Admissible output current IL, nominal
[mA]
< 50
Signal contact C1/C2
Modality
Relay contact, normally open
Voltage range
[V DC]
18 … 30
Output current IL, nominal
[mA]
< 200
Short circuit / overcurrent protection
Not short circuit proof, overvoltage-resistant up
to 60 V
Service life of acknowledgment
contact
[nop]
10 x 106 (at 24 V and IContact = 10 mA, the service
life is reduced with higher load currents)
24V auxiliary voltage
Modality
Logic supply voltage routed over the servo drive
(fed in at [X9], not additionally filtered or
stabilised). Reverse-polarity protected,
overvoltage-proof up to 60 V DC
Nominal voltage
[V]
24
Output current IL, nominal
[mA]
100
Cabling [X40]
Max. cable length
[m]
< 30
Shielding
When wiring outside the control cabinet, use
screened cable. Guide shielding into the control
cabinet / attach to the side of the control cabinet
Conductor cross-section (flexible conductor, Ferrules with insulating collar)
one conductor
[mm²]
0,25 … 0,5
two conductor
[mm²]
2 x 0,25 (with twin wire end ferrules)
Tightening torque of counter plug
[Nm]
0,22 … 0,25