Afag SE-Power FS User manual

Servo Controller
SE-Power FS
STO-Manual
Complementary document to the Operating Instruction
© Copyright by Afag Automation AG
Translation: English

2 SE-Power FS STO-manual vers. 1.6 en.12.08.2015
Index:
1General.................................................................................................................... 8
1.1 Documentation ........................................................................................................ 8
2Used symbols.........................................................................................................10
3Safety and requirements for product use................................................................11
3.1 Safety.....................................................................................................................11
3.1.1 General safety information......................................................................................11
3.1.2 Intended use...........................................................................................................12
3.1.3 Possible incorrect application .................................................................................12
3.1.4 1.1.4 Achievable safety level, Safety function according to EN ISO 13849-1 / EN
61800-5-2.............................................................................................................................13
3.2 Requirements for product use.................................................................................13
3.2.1 Technical requirements ..........................................................................................13
3.2.2 Qualification of the specialist personnel (requirements for personnel).....................14
3.2.3 Diagnostic coverage (DC).......................................................................................14
3.2.4 Range of applications and certification....................................................................14
4Product description SE-Power Safety Module STO ................................................15
4.1 Product overview....................................................................................................15
4.1.1 Purpose..................................................................................................................15
4.1.2 Supported devices..................................................................................................15
4.1.3 Control sections and connections...........................................................................16
4.2 Function and application.........................................................................................17
4.2.1 Description of the safety function STO....................................................................18
4.2.2 Overview of interface [X40].....................................................................................19
4.2.3 Control ports STO-A, 0V-A / STO-B, 0V-B [X40].....................................................20
4.2.4 Feedback contact C1, C2 [X40]..............................................................................21
4.2.5 Auxiliary supply 24V, 0V [X40]................................................................................22
4.2.6 Status display.........................................................................................................22
4.2.7 DIP switch ..............................................................................................................22
4.3 Functionalities in the basic SE-Power FS ...............................................................22
4.4 Time behaviour.......................................................................................................25
4.4.1 Basic time behaviour STO......................................................................................25
4.4.2 Time behaviour for activating STO during operation with restart.............................26
4.4.3 Time behaviour for activating SS1 during operation with restart..............................28
5Assembly and Installation.......................................................................................30
5.1 Mounting / Dismounting..........................................................................................30
5.1.1 Mounting the safety module....................................................................................31

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5.1.2 Dismounting the safety module...............................................................................31
5.2 Elektrical installation...............................................................................................32
5.2.1 Safety instructions ..................................................................................................32
5.2.2 ESD protection .......................................................................................................32
5.2.3 Connection [X40]....................................................................................................32
5.2.4 Minimum wiring for commissioning [X40]................................................................33
5.3 Typical circuits........................................................................................................34
5.3.1 Safe Torque Off (STO) ...........................................................................................34
5.3.2 Delays and safe torque off (SS1, „Safe Stop 1“) .....................................................36
6Commissioning.......................................................................................................38
6.1 Before commissioning ............................................................................................38
6.2 DIP switch setting...................................................................................................38
6.3 Parameterisation with the Afag SE-Commander.....................................................39
6.3.1 Type indication servo drive and safety module .......................................................40
6.3.2 Status indication of the state machine.....................................................................41
6.3.3 Window “Safety module”.........................................................................................41
6.4 Function test, validation..........................................................................................44
7Operation................................................................................................................46
7.1 Obligations of the operator......................................................................................46
7.2 Maintenance and care............................................................................................46
7.3 Protective functions ................................................................................................46
7.3.1 Voltage monitoring..................................................................................................46
7.3.2 Protection against overvoltage and reverse polarity................................................46
7.4 Diagnostics and troubleshooting.............................................................................47
7.4.1 Status indicators.....................................................................................................47
7.4.2 Error messages......................................................................................................47
8Conversion and module replacement......................................................................49
8.1 Safety module replacement....................................................................................49
8.1.1 Repair.....................................................................................................................49
8.1.2 Removal and installation.........................................................................................49
8.2 Decommissioning and disposal...............................................................................49
8.2.1 Disposal..................................................................................................................49
8.3 Replacing the previous series SE-Power with the SE-Power FS.............................50
8.3.1 SE-Power ...............................................................................................................50
8.3.2 SE-Power FS..........................................................................................................50
8.3.3 Modifications to the connection wiring.....................................................................50
8.3.4 Information for configuration ...................................................................................51
9Technical appendix.................................................................................................52

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9.1 Technical data........................................................................................................52
9.1.1 Safety engineering..................................................................................................52
9.1.2 General...................................................................................................................53
9.1.3 Operating and environmental conditions.................................................................54
9.1.4 Elektrical data.........................................................................................................55
10 Glossary.................................................................................................................58

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List of figures:
Figure 1: Operator panel and connections SE-Power FS Safety Module STO...........................16
Figure 2: “Safe Torque Off” – Operating principle for the SE-Power FS .....................................18
Figure 3: Basic time behaviour when activating and deactivating the safety function STO ........25
Figure 4: Time behaviour when activating the safety function STO with restart..........................26
Figure 5: Time behaviour when activating the safety function SS1 (external switching) with
restart............................................................................................................................28
Figure 6: Mounting / Dismounting................................................................................................31
Figure 7: Connection of the SE-Power FS Safety Modul STO, example of single-phase servo
drive SE-Power FS .......................................................................................................34
Figure 8: Typical circuit “Decelerate and safe torque off” (SS1, “Safe Stop 1”), example single-
phase servo drive SE-Power FS...................................................................................36
Figure 9: Indication of the type of safety module and extended status window ..........................40
Figure 10: Quick-Access Toolbar with the button “Safety” ............................................................41
Figure 11: Window “Safety module” STO (left) and MOV (right)...................................................42

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List of tables:
Table 1: Overview safety-activation-modules for the SE-Power FS...........................................15
Table 2: Function of the module connections.............................................................................20
Table 3: Detection and response times of the driver supply voltage..........................................24
Table 4: Time data concerning Figure 3.....................................................................................25
Table 5: Time data concerning Figure 4.....................................................................................27
Table 6: Time data concerning Figure 5.....................................................................................29
Table 7: Pin assignment [X40]....................................................................................................33
Table 8: Meaning of the LEDs for the status display in the window “Safety module”.................43
Tabelle 9: Fragen für die Validierung nach EN ISO 12100-1:2010 (Beispiel)...............................44
Table 10: Questions for validation in accordance with EN ISO 13849-1 and 2 (example) ..........45
Table 11: LED- display on the safety module...............................................................................47
Table 12: Seven segment display on the servo drive...................................................................47
Table 13: Error messages relating to the safety module..............................................................48
Table 14: Technical data: Safety indicators..................................................................................52
Table 15: Technical data: Safety specifications............................................................................52
Table 16: Technical data: Mechanical ..........................................................................................53
Table 17: Technical data: Certifications........................................................................................53
Table 18: Technical data: Transport.............................................................................................54
Table 19: Technical data: Storage................................................................................................54
Table 20: Technical data: Ambient conditions..............................................................................54
Table 21: Technical data: Electrical for ports STO-A and STO-B ................................................55
Table 22: Typical switch-off time and minimum tolerance time for test pulse (OSSD signals) ....55
Table 23: Technical data: Electrical data of the feedback contact C1/C2....................................56
Table 24: Technical data: Electrical data of the auxiliary supply output.......................................56
Table 25: Technical data: Electrical isolation [X40]......................................................................56
Table 26: Technical data: Cabling to [X40]...................................................................................57
Table 27: Terms and abbreviations ..............................................................................................58

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This manual is a complementary document to the operating instructions and applies to:
Type
Order No.
SE-Power FS Safety Module FSM 2.0 STO
50393463
Version of this
documentation:
SE-Power FS STO-manual vers. 1.6 en.12.08.2015
Caution!
As this manual is a complementary document to the operating instructions it
alone is not sufficient to carry out installation and commissioning of the
device.
Please pay attention to the notes in:
1.1 Documentation
The information's in this manual refers to the following hardware variants and
Firmware versions of the servo positioning controller SE-Power and the version
of the Parameterization program Afag SE-Commander
Firmware: from version 4.0 KM-Release 1.1
Parameterization program: from version 4.0
Hardware: SE-Power FS with Safety Module
FSM 2.0 STO from revision 1.5

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1General
1.1 Documentation
For the Servo Controllers of the SE-Power series are considerably documentations available.
There are main documents and complementary documents.
The documents contain safety instructions that must be followed.
Main document:
present
documentation / description
☐
SE-Power FS Operating manual
Description of the technical data and the functions of the device as well as
notes on the plug assignment, installation and operation of the SE-Power FS
servo controller series.
It is meant for persons who want to get familiar with the SE-Power FS servo
controller
Caution!
The operating manual is the main document and must be read by all means
before installation and start-up of all devices of the SE-Power FS series.
Complementary documents to the operating manual:
present
documentation / description
☐
SE-Power FS mounting instructions
This manual is included during delivery of the SE-Power FS devices and
provides an extract from the manual represents the installation instructions
contained therein make sure that they can easily operate the servo drive.
☒
SE-Power FS STO-manual
Description of the technical data and the device functionality, installation, and
operation of the safety module STO.
☐
SE-Power FS MOV-manual
Description of the technical data and the device functionality, installation, and
operation of the safety module MOV.
☐
SE-Power Software-manual
Description of the software SE-Commander with the individual functions.
☐
SE-Power CANopen-manual
Description of the implemented CANopen protocol according to CiA DSP402
and DS301.

SE-Power FS STO-manual vers. 1.6 en.12.08.2015 9
☐
SE-Power Profibus-manual
Description of the implemented PROFIBUS-DP protocol, the technical data and
the device functionality, installation, and operation of the fieldbus-module „SE-
Power Profibus Interface“.
☐
SE-Power EtherCAT-manual
Description of the fieldbus control by using the CoE (CANopen over EtherCAT)
protocol, the technical data and the device functionality, installation, and
operation of the fieldbus-module „SE-Power EtherCAT Interface“.
☐
SE-Power FS programming example Siemens S7 V5.5
Description of the configuration and program from the programming example
for Siemens S7 V5.5.
☐
SE-Power FS programming example Siemens S7 TIA V12
Description of the configuration and program from the programming example
for Siemens S7 TIA V12.
These documents are available for download on our homepage:
www.afag.com

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2Used symbols
Information
Important information and notes.
Caution!
No observance may result in severe property damages.
DANGER!
No observance may result in property damages and in personal injuries.
Caution! Life-threatening voltages.
The safety instruction contains a pointer to the occurrence of a possibly life-
threatening voltage.

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3Safety and requirements for product use
3.1 Safety
3.1.1 General safety information
Caution!
The operating manual is the main document and must be read by all means
before installation and start-up of all devices of the SE-Power FS series
Note
Danger of loss of the safety function.
Non-compliance with environmental and connection conditions can lead to loss of
the safety function.
Observe the specified environmental and connection conditions, in particular the
input voltage tolerances Technical data, Appendix 9.1.
Note
Incorrect handling can damage the safety module or the servo drive.
Before mounting and installation work, switch off the supply voltage. Switch on
the supply voltage only when the mounting and installation work is complete.
Never unplug a module from, or plug a module into the servo drive when it is
energised!
Observe the handling specifications for electrostatically-sensitive devices.

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3.1.2 Intended use
The safety module SE-Power FS Safety Module STO serves as an expansion of the servo
drive SE-Power FS to achieve the safety function:
Safely switched-off torque –“Safe Torque Off” (STO) with SIL3 according to EN 61800-5-
2 / EN 62061 / IEC 61508 or category 4 / PL e according to EN ISO 13849-1.
The servo drive SE-Power FS with safety module SE-Power FS Safety Module STO is a
product with safety-relevant functions and is intended for installation in machines or
automation systems and for use as follows:
in a faultless technical condition
in its original condition, without any modifications by the user
within the product’s limits as defined by the technical data (  Appendix 9.1)
in an industrial environment.
The Functional Safety Modules SE-Power FS Safety Module can be operated in all servo
drives of the product family SE-Power FS. Those are equipped with the slot for safety
modules (“FSM slot”). The safety modules cannot be inserted into one of the extension slots
for technology modules (TECH1 or TECH2).
Note
Bei Schäden, die aus unbefugten Eingriffen oder nicht bestimmungsgemäßer
Verwendung entstehen, erlischt der Gewährleistungs- und Haftungsanspruch
gegenüber dem Hersteller.
3.1.3 Possible incorrect application
Improper use includes the following possible cases of incorrect application:
use in a device other than the servo drive SE-Power FS
use outdoors
use in a non-industrial area (residential area)
use in applications where switching off can result in hazardous movements or conditions.
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!

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The STO (Safe Torque Off) function does not provide protection against electric
shock, only against hazardous movements!
SE-Power FS Operating manual
3.1.4 Achievable safety level, Safety function according to
EN ISO 13849-1 / EN 61800-5-2
The safety module fulfils the basic test requirements:
Category 4 / PL e according to EN ISO 13849-1,
SIL CL 3 according to EN 61800-5-2 / EN 62061 / IEC 61508,
and can be used in applications up to cat. 4 / PL e according to EN ISO 13849-1 and SIL 3
according to EN 62061 / IEC 61508.
The achievable safety level depends on the other components used to achieve a safety
function.
3.2 Requirements for product use
Make this documentation available to the design engineer and installer or person
responsible for commissioning the machine or system in which this product will be used.
Ensure compliance with specifications in the documentation at all times. Also take into
account the documentation for the other components and modules (e.g. servo drive,
lines, etc.).
Take into account the legal regulations applicable to the destination, as well as:
-regulations and standards
-regulations of the testing organisations and insurers
-national specifications.
For emergency stop applications, protection against automatic restart must be provided
according to the required safety category. This can be achieved through an external
safety switching device, for example.
3.2.1 Technical requirements
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 ( 
Appendix 9.1), the servo drive and all connected components.
The product can be operated in accordance with the relevant safety guidelines only if the
limit values or load limits are observed.
Observe the warnings and instructions in this documentation.

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3.2.2 Qualification of the specialist personnel (requirements for personnel)
The device may only be placed in operation by a qualified electrical engineer who is familiar
with:
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
product documentation.
3.2.3 Diagnostic coverage (DC)
Diagnostic coverage depends on the connection between the servo drive with safety module
and the control loop system as well as the implemented diagnostic measures.
If a potentially hazardous disturbance is recognised during diagnosis, appropriate measures
for maintaining the safety level must be implemented.
Note
Check whether cross-circuit detection of the input circuit and the connection wiring
is required in your application.
If needed, use a safety switching device with horizontal cross-circuit detection to
activate the safety module.
3.2.4 Range of applications and certification
The servo drive with built-in safety module is a safety component in accordance with the
machinery directive; the servo drive bears the CE mark.
Standards and test values which the product must comply with and fulfils can be found in the
section „Technical data“(  Appendix 9.1). The product-relevant EU directives can be found
in the declaration of conformity.

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4Product description SE-Power Safety Module STO
4.1 Product overview
4.1.1 Purpose
As processes become increasingly automated, protecting people from potentially hazardous
movements is gaining in importance. Functional safety describes the measures offered by
electrical or electronic devices that are required to reduce or eliminate malfunction-induced
hazards. In normal operation, safety devices prevent human intervention in hazardous areas.
In certain operating modes, during set-up for example, people also need to be in hazardous
areas. In such situations, the machine operator must be protected by drive and internal
control measures.
Integrated functional safety technology provides the conditions required by controller and
drive for the optimised realisation of safety functions. Planning and installation complexity is
reduced. The use of integrated functional safety technology increases machine functionality
and availability over the levels achieved by conventional safety technology.
Type
Description
Safety Module STO
(FSM 2.0 –STO)
Safety module with STO function and DIP switches.
Safety Module MOV
(FSM 2.0 –MOV)
Safety module with the safety functions STO, SS1, SS2, SOS, SBC,
SLS, SSR, SSM and DIP switches.
Table 1: Overview safety-activation-modules for the SE-Power FS
4.1.2 Supported devices
The SE-Power FS Safety Module STO can only be used in servo drives in conformity with
Section 3.1.2.
As a standard, the SE-Power FS series servo drives come supplied with the ordered safety
module (STO or MOV) for integrated functional safety.
The use of the SE-Power FS Safety Module STO enables the safety functions, described in
this product manual for the integrated functional safety of safety stops, to be expanded.
For the use of the SE-Power FS Safety Module MOV it requires the manual: „SE-
Power FS MOV-Manual“.

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4.1.3 Control sections and connections
The SE-Power FS Safety Module STO has the following control sections, connections and
display components.
1 Servo drive SE-Power FS with slot for a Functional Safety Module
2 Digital I/O-interface [X40] for control of the STO function
3 Pin 1 of the interface [X40]
4 LED for status display (functional safety status)
5 DIP-switch (activation/configuration of the fieldbus communication in the servo drive)
Figure 1: Operator panel and connections SE-Power FS Safety Module STO

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4.2 Function and application
The safety module SE-Power FS Safety Module STO has the following performance
characteristics:
“Safe Torque Off” (STO) function,
Potential-free feedback contact for the operating status,
Designed as a plug-in module that can be plugged in from the outside thus enabling
retrofits,
Suitable solely for SE-Power FS servo drives series.
The “Safe Stop 1” (SS1) function can be realised by employing a suitable external safety
switching device and appropriate servo drive SE-Power FS circuitry.

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4.2.1 Description of the safety function STO
Use the function “Safe Torque Off” (STO) whenever you have to reliably disconnect the
energy supply to the motor in your particular application.
The function “Safely Torque Off” switches off the driver supply for the power semiconductor,
thus preventing the power end stage supplying the voltage required by the motor see Figure
2.
1 Safety circuit (switch, relay, safety switching device)
2 SE-Power FS Safety Module STO
3 Power end stage in the SE-Power FS (only one phase illustrated)
4 Driver supply
5 Motor connection
6 LED (green / yellow), status display
7 Feedback contact
Figure 2: “Safe Torque Off” – Operating principle for the SE-Power FS
0 V
7
4
4
3
5
6
2
1
>=1
DC
DC
STO_A
GND_A
GN
C1
C2
YE
DC
DC
STO_B
GND_B
3x
U, V, W
+VDC
-VDC
+24 VDC

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The power supply to the drive is reliably disconnected via the active safety function STO
“Safe Torque Off”. The drive cannot generate torque and so cannot perform any hazardous
movements. With suspended loads or other external forces, additional measures must be
taken to reliably prevent sagging (e.g. mechanical holding brake). In the STO “Safe Torque
Off” state, the standstill position is not monitored.
The machine must be stopped in a safe manner, e.g. via a safety switching device. This
applies specifically to vertical axes without self-locking mechanism, clamping unit or
counterbalance.
Note
There is a risk that the drive will advance in case of multiple errors in the SE-Power
FS.
If the output stage of the servo drive fails while in the STO status (simultaneous
short circuit of 2 power semiconductors in different phases), a limited dwell
movement of the rotor may result. The rotation angle / path correspond to a pole
pitch. Examples:
Rotary axis, synchronous machine, 8-pin movement < 45° at the motor shaft.
Linear motor, poles pitch 20 mm movement < 20 mm at the moving part.
4.2.2 Overview of interface [X40]
On its front, the safety module provides an 8-pin connection [X40] for control ports, feedback
contact and a 24 V auxiliary supply for external sensors Section 5.2.
The safety function STO is requested solely via the two digital control ports STO-A and STO-
B. A safety circuit for additional interfaces at the SE-Power servo drive is neither required nor
intended
Cross-circuit detection in the input circuit is not carried out by the safety module.
The status of the servo drive is reported back to an external safety switching device through
a potential-free acknowledgment contact (normally open). This enables downwards-
compatible activation in a mixed configuration, comprising an SE-Power (previous series with
the “Safe Stop” function to be realised via the connection [X3]) and the SE-Power FS 
Section 8.3.
The interface [X40] permits the direct connection of active and passive sensors, since a 24 V
supply voltage (auxiliary supply) with corresponding reference potential is lead out.

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Connections
Description
STO-A (Pin 1)
0V-A (Pin 2)
Control port A for the STO function with corresponding reference potential. 1)
Request for “Safe Torque Off” (STO) at Low (0 signal), together with
STO-B
STO-B (Pin 3)
0V-B (Pin 4)
Control port B for the STO function with corresponding reference potential. 1)
Request for “Safe Torque Off” (STO) at Low (0 signal), together with
STO-B.
C1 (Pin 5)
C2 (Pin 6)
Feedback contact for the “Safe Torque Off” (STO) status, e.g. to an external
controller.
Feedback contact opened: „Safe Torque Off“ (STO) not active
Feedback contact closed: „Safe Torque Off“ (STO) active
24 V (Pin 7)
0 V (Pin 8)
Auxiliary supply, e.g. for safety peripherals (24 V DC logic supply of the
servo drive).
1) Control inputs 24 V, high active, based on EN 61131-2, deviating signal level, see
Section 9, Table 21.
Table 2: Function of the module connections
The connections are electrically isolated from each other in groups and from the 24 V-
supplies to the servo drive  Section 9, Table 24.
4.2.3 Control ports STO-A, 0V-A / STO-B, 0V-B [X40]
The safety function STO (Safe Torque Off) is requested via the two control ports STO-A and
STO-B. They permit the direct connection of safe semiconductor outputs (electronic safety
switching devices, active safety sensors, e.g. light curtains with OSSD signals) and of switch
contacts (safety switching device with relay outputs, passive safety sensors, e.g. forcibly-
guided position switches)  e.g. Section 5.2.3, Figure 7.
To request the safety function STO (Safe Torque Off), the 24 V control voltage at both
control ports STO-A and STO-B is switched off (0 V).
If the two control ports are switched off simultaneously or within a defined discrepancy time,
the STO function is active.
For control ports STO-A and STO-B, an under voltage monitoring mechanism is integrated to
eliminate the possibility of invalid voltage ranges for the downstream electronics, as well as
an overvoltage monitoring mechanism to protect against overvoltage.
Table 21 in Section 9.1.4 describes the technical data for the control ports within the
specified operating range of the logic voltages.
Tolerance ranges are defined for the input voltage range of control ports STO-A and STO-B.
The amount of energy stored in the safety module components (e.g. capacitors) depends on
the input voltage level. During switching operations, these energies must be charged or
discharged. Consequently, switch-off time values for the transition to the safe state (STO)
and the tolerance time vis-a-vis OSSD signals (buffer time) depend on the input level
The time response requirements are contained in the technical specifications in Section
9.1.4. The time Response itself is described in section 4.4.