BONFIGLIOLI Agile Series Instructions for use

Agile
Application manual
Functional Safety

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General Information about the Documentation
For the series of devices AGL (Agile) is for the safety-related commissioning and
operation to be complied with the following documentation:
•Operating instructions
•This application manual
When using a communication interface the corresponding manual is additional to be
complied with. For the usage of further functions the corresponding application ma-
nuals must be complied with (in example for the integrated PLC function).
This documentation was written in German language. The German documentation is
the original one. Other language versions are translated.
This application manual contains all relevant information required for using the safe-
ty-oriented function „Safe Torque Off“ (STO).
For better clarity, the documentation is structured according to the customer-specific
requirements made on the frequency inverter.
Quick Start Guide
The Quick Start Guide describes the basic steps required for mechanical and electrical
installation of the frequency inverter. The guided commissioning supports you in the
selection of necessary parameters and the software configuration of the frequency
inverter.
Operating Instructions
The Operating Instructions describe and document all functions of the frequency
inverter. The parameters required for adapting the frequency inverter to specific ap-
plications as well as the wide range of additional functions are described in detail.
Application Manual
The application manual supplements the documentation for purposeful installation
and commissioning of the frequency inverter. Information on various subjects con-
nected with the use of the frequency inverter is described specific to the application.
If you need a copy of the documentation or additional information, contact your local
representative of BONFIGLIOLI.

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CONTENT
1General information about the documentation ............................................................. 6
1.1Instruction manuals.................................................................................... 6
1.2Pictograms and signal words used ............................................................. 7
1.3Copyright .................................................................................................... 7
2General Safety Instructions and Information on Use.................................................... 8
2.1General Information ................................................................................... 8
2.2Designated use ........................................................................................... 8
2.3Transport and Storage................................................................................ 8
2.4Handling and installation............................................................................ 9
2.5Electrical Installation.................................................................................. 9
2.6Information on Use................................................................................... 10
2.6.1Operation with products from other manufacturers ............................................10
2.7Maintenance and service .......................................................................... 10
2.8Disposal..................................................................................................... 10
3Safety Instructions on Function „Safe Torque Off“ (STO)........................................... 11
3.1Approved Devices ..................................................................................... 12
3.1.1Connection 3x AC 400/480 V............................................................................12
3.1.2Connection 1x AC 230 V / 3x AC 230 V .............................................................12
4Information of Risk Analysis and Risk Assessment..................................................... 13
5General Description of Safety Function ....................................................................... 14
5.1Integrated Safety Function....................................................................... 14
5.2Functional Safety...................................................................................... 14
5.3Classification the safety requirement....................................................... 14
6Description of ACTIVE Cube Safety Function............................................................... 15
6.1Definitions of the AGL Safety functions.................................................... 16
6.2Specification of the Safety Function 1 (SF1): STO.................................... 17
6.3Specification of the Safety Function 2 (SF2): SS1.................................... 18
6.4Description of Safety Function.................................................................. 19
6.5Two-Channel Monitoring .......................................................................... 21
6.6Diagnosis function and enforced dynamizing........................................... 23
7Requirements to be met by installation....................................................................... 23
7.1Instructions on installation of safety equipment ..................................... 23
7.2External Safety Control Equipment .......................................................... 24
7.3External DC 24 V power supply ................................................................ 24
7.3.1External DC 24 V voltage supply for group stop .................................................25
7.4DC 24 V power supply by AGL................................................................... 25
8Requirements to be met in operation.......................................................................... 25

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9Requirements to be met by acceptance inspection..................................................... 25
10Application Examples................................................................................................... 25
10.1STO according to Stop Category 0............................................................ 26
10.1.1STO Direct Stop..............................................................................................26
10.1.2STO Direct Stop with error exclusion “short circuit” in the cabinet........................27
10.1.3STO Direct Stop with Feedback to PLC..............................................................28
10.1.4STO Direct Stop with Feedback to PLC with error exclusion “short circuit” in the
cabinet 29
10.2SS1 according to Stop Category 1 ............................................................ 30
10.2.1SS1 Direct Stop...............................................................................................30
10.2.2SS1 Direct Stop with error exclusion “short circuit” in the cabinet........................ 31
10.2.3SS1 Direct Stop with Feedback to PLC...............................................................32
10.2.4SS1 Direct Stop with Feedback to PLC with error exclusion “short circuit” in the
cabinet 33
10.3Internal DC 24 V Supply, SS1 ................................................................... 34
10.4Group Stop, SS 1....................................................................................... 35
11Checklist....................................................................................................................... 36
12Safety Function Test Report......................................................................................... 37
12.1Characteristical Data: ............................................................................... 37
13STO status (diagnosis)................................................................................................. 37
14Change index ............................................................................................................... 38
15Index............................................................................................................................ 39

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1General information about the documentation
The present documentation complements the operating instructions Agile (AGL). It contains additional
safety information and requirements for the operation of Agile (AGL) in safety-oriented applications.
Use in safety-oriented machines shall be permissible only after this documentation has been read
carefully and understood. The applicable basic standards as well as application-specific and specific
national standards shall also be complied with – the standards referred to in this manual shall also be
complied with.
1.1 Instruction manuals
For better clarity, the documentation is structured according to the customer-specific requirements
made on the frequency inverter.
Quick start guide
The Quick Start Guide describes the basic steps required for mechanical and electrical installation of
the frequency inverter. The guided commissioning supports you in the selection of necessary parame-
ters and the configuration of the frequency inverter by the software.
Operating instructions
The Operating Instructions describe and document all functions of the frequency inverter. The para-
meters required for adapting the frequency inverter to specific applications as well as the wide range
of additional functions are described in detail.
Application manual
The application manual supplements the documentation for purposeful installation and commissioning
of the frequency inverter. Information on various subjects connected with the use of the frequency
inverter is described specific to the application.
If you need a copy of the documentation or additional information, contact your local representative
of BONFIGLIOLI.
The present documentation was prepared with great care and it was subjected to extensive and re-
peated reviews. For reasons of clarity, it was not possible to include all details of all types of the prod-
uct in the documentation. Neither was it possible to consider all conceivable installation, operation or
maintenance situations. 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 national BONFIGLIOLI agent.
We would also like to point out that the contents of this documentation do not form part of any pre-
vious or existing agreement, assurance or legal relationship. Neither are they intended to supplement
or replace such agreements, assurances or legal relationships. The manufacturer's obligations are
exclusively specified in the relevant purchase contract. This contract also contains all and any warran-
ty regulations which may apply to the relevant scope of supply. These contractual warranty provisions
are neither extended nor limited by the specifications contained in this documentation.
The manufacturer reserves the right to correct or amend the specifications, product information and
omissions in these operating instructions without notice. The manufacturer shall not be liable for any
damage, injuries or costs which may be caused by the aforementioned reasons.
This documentation was written in German language. Other language versions are translated.

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1.2 Pictograms and signal words used
The following pictograms and signal words are used in the documentation:
Danger!
Danger refers to an immediate threat. Non-compliance with the precaution described may
result in death, serious injury or material damage.
Warning!
Warning refers to a possible threat. Non-compliance with the warning may result in death,
serious injury or material damage.
Caution!
Caution refers to an indirect threat. Non-compliance may result in personal or material
damage.
Attention!
Attention refers to a possible operational behavior or an undesired condition that can occur in accor-
dance with the reference text.
Note
Note marks information that facilitates handling for you and supplements the corresponding part of
the documentation.
1.3 Copyright
This user manual is protected by copyright. It is solely intended for use by operating staff and must
not be copied nor disclosed to third parties.

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2General Safety Instructions and Information on Use
Warning!
The specifications and instructions contained in the documentation must be complied with
strictly during installation and commissioning. Before starting the relevant activity, read the
documentation carefully and comply with the safety instructions. The term “Qualified Staff”
refers to anybody who is familiar with the installation, assembly, commissioning and opera-
tion of the frequency inverter and has the proper qualification for the job.
2.1 General Information
Warning!
The DC-link circuit of the frequency inverter is charged during operation, i.e. there is always
the risk of contact with high voltage. Frequency inverters are used for driving moving parts
and they may become hot at the surface during operation.
Any unauthorized removal of the necessary covers, improper use, wrong installation or op-
eration may result in serious injuries or material damage.
In order to avoid such injuries or damage, only qualified technical staff may carry out the
transport, installation, commissioning, setup or maintenance work required. The standards
DIN EN 50178, IEC 60364 (Cenelec HD 384 or DIN VDE 0100), IEC 60664-1 (Cenelec HD
625 or VDE 0110-1), BGV A2 (VBG 4) as well as the applicable national regulations must be
complied with. The term „Qualified Staff“ refers to anybody who is familiar with the instal-
lation, assembly, commissioning and operation of the frequency inverter as well as the
possible hazards and has the proper qualification for the job.
Persons not familiar with the operation of the frequency inverter or children must not have
access to the device.
2.2 Designated use
Warning!
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 machine meets the requirements of the EC Machinery Directive
2006/42/EEC and DIN EN 60204. In accordance with the CE marking requirements, the
frequency inverters comply with the Low Voltage Directive 2006/95/EEC as well as DIN
EN 61800-5-1. The user shall be responsible for making sure that the requirements of the
EMC Directive 2004/108/EEC are met. Frequency inverters are only available at specialized
dealers and are exclusively intended for professional use as per DIN EN 61000-3-2.
Any use other than the use described above, will be considered as not in accordance with
the specified purpose and may result in the warranty becoming null and void.
The frequency inverters are also marked with the UL label according to UL508c, which
proves that they also meet the requirements of the CSA Standard C22.2-No. 14-95.
The technical data, connection specifications and information on ambient conditions are in-
dicated on the rating plate and in the documentation and must be complied with in any
case. Anyone involved in any kind of work at the device must have read the instructions
carefully and understood them before starting the work.
2.3 Transport and Storage
The frequency inverters must be transported and stored in an appropriate way. During transport and
storage the devices must remain in their original packaging.
The units may only be stored in dry rooms which are protected against dust and moisture and are
exposed to little temperature deviations only. Observe the conditions as per DIN EN 60721-3-1 for
storage, DIN EN 60721-3-2 for transport and the labeling on the packaging.
The duration of storage without connection to the permissible nominal voltage may not exceed one
year.

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2.4 Handling and installation
Warning!
Damaged or destroyed components must not be put into operation because they may be a
health hazard.
The frequency inverters are to be used in accordance with the documentation as well as the applica-
ble directives and standards.
It must be handled carefully and protected against mechanical stress.
Do not bend any components or change the isolating distances.
Do not touch electronic components or contacts. The devices are equipped with components which
are sensitive to electrostatic energy and can be damaged if handled improperly. Any use of damaged
or destroyed components shall be considered as a non-compliance with the applicable standards.
Removal of seals from the housing can result in invalidation of warranty.
Do not remove any warning signs from the device.
2.5 Electrical Installation
Warning!
Before any assembly or connection work, discharge the frequency inverter. Verify safe iso-
lation from power supply.
Do not touch the terminals because the capacitors may still be charged.
Comply with the information given in the operating instructions and on the frequency in-
verter label.
Follow the safety rules applying to work on electrical equipment.
Follow the safety rules applying to work on electrical equipment:
−Isolate: Isolate the installation from all possible sources of electrical power.
−Secure against reconnection. Only the persons working on the installation may re-commission the
relevant part of the installation.
−Verify there is no electrical power: Using a measuring instrument or voltage tester, ensure there is
no voltage against ground on the relevant plant component.
−Ground and short-circuit: Starting from the ground terminal, connect all conductors to one anoth-
er.1)
−Cover und shield neighboring live parts: By covering, shielding or isolation of energized plant com-
ponents contact with such parts is to be prevented.
1) Deviations from this are possible in certain circumstances.
When working at the frequency inverters, comply with the relevant accident prevention regulations,
the applicable standards BGV A2 (VBG 4), VDE 0100, standards governing work on systems with dan-
gerous voltages (e.g. DIN EN 50178) and other national directives.
Comply with the electrical installation instructions given in the documentation as well as the relevant
directives.
Responsibility for compliance with and examination of the limit values of the EMC product norm DIN
EN 61800-3 for variable-speed electrical drive mechanisms is with the manufacturer of the industrial
plant or machine. The documentation contains information on EMC-conforming installation.
The cables connected to the frequency inverters may not be subjected to high-voltage insulation tests
unless appropriate circuitry measures are taken before.
Do not connect any capacitive loads.

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2.6 Information on Use
Warning!
The frequency inverter may be connected to power supply every 60 s. This must be consi-
dered when operating a mains contactor in jog operation mode. For commissioning or after
an emergency stop, a non-recurrent, direct restart is permissible.
After a failure and restoration of the power supply, the motor may start unexpectedly if the
AutoStart function is activated.
If staff is endangered, a restart of the motor must be prevented by means of external cir-
cuitry.
Before commissioning and the start of the operation, make sure to fix all covers and check
the terminals. Check the additional monitoring and protective devices according to DIN EN
60204 and applicable the safety directives (e.g. Working Machines Act, Accident Prevention
Directives etc.).
No connection work may be performed, while the system is in operation.
2.6.1 Operation with products from other manufacturers
Please note that Bonfiglioli Vectron will not accept responsibility for compatibility with products from
other manufacturers (e.g. motors, cables, filters, etc.).
In order to achieve optimum system compatibility, Bonfiglioli Vectron offers components which ensure
easy commissioning and are perfectly adjusted to one another in operation.
Use of the device with products from other manufacturers will be at your own risk.
2.7 Maintenance and service
Warning!
Unauthorized opening and improper interventions can lead to personal injury or material
damage. Repairs on the frequency inverters may only be carried out by the manufacturer
or persons authorized by the manufacturer.
Check protective equipment regularly.
Any repair work must be carried out by qualified electricians.
2.8 Disposal
The components of the frequency inverter must be disposed of in accordance with the applicable local
and national laws, regulations and standards.

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3Safety Instructions on Function „Safe Torque Off“ (STO)
The function „Safe Torque Off“ (STO) is a functional safety provision, i.e. it protects
persons from damage, provided that projecting, installation and operation are per-
formed properly. This function does not disconnect the machine from power supply.
The safety function “Safe torque off” (STO) can be used to realize an “Emergency
Stop” according to EN 60204 while the power supply is still active on the frequency
inverter
A provision must be provided for disconnecting the machine from power supply for
maintenance work.
With a suitable external safety control device the function „Safe Stop 1 (SS1 c)“ ac-
cording to EN 61800-5-2 can be realized together with the AGL.
Danger!
Improper installation of the safety technique can cause an uncontrolled
starting of the drive. This may cause death, serious injuries and signifi-
cant material damage.
Safety functions may only be installed and commissioned by qualified
staff.
The STO function is not suitable for emergency switch off as per
EN 60204. An emergency switch off can be realized by installing a
mains contactor.
An emergency stop according to EN 60204 must be functioning in all
operation modes of the frequency inverter. Resetting of an emergency
stop must not result in uncontrolled starting of the drive.
The drive is started again when the function STO is no longer triggered.
In order to comply with standards EN 60204 and EN 1037, it must be
ensured by taking external measures that the drive only starts after e
manual confirmation.
Without a mechanical brake, the drive might not stop immediately but
coast to a standstill. If this may result in personal or material damage,
additional safety measures must be taken.
If persons may be endangered after disconnection of the motor control
by STO, access to the hazard areas must be prevented until the drive
has stopped.
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. Only
in extremely unlike combinations of component faults the motor shaft
could move jerky with sudden acceleration (maximum 180°/number of
pole pairs, for example jerky movement of 90° for 4-pole motor,
180°/2) and produce torque. It must be checked if this behavior can
cause a dangerous machine movement.
If the STO function is used, the special safety, installation and instruc-
tions on use instructions shall be complied with.

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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.
Before working (e.g. maintenance) on live parts, the machine must
always be disconnected from mains supply (main switch). This must be
documented on the machine.
When the function “Safe Torque Off” is triggered, the motor is not iso-
lated from the DC link of the frequency inverter. High voltage levels
may be present at the motor.
Do not touch live terminals.
Permanent magnet synchronous motors (PMSM) must be operated only
up to the synchronous speed. PMSM cannot be operated above the
synchronous speed because the trigger of the STO function can lead to
the destruction of the power stage.
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
AGL402-XX1-XXXXXXXS
AGL402-XX2-XXXXXXXS
AGL402-XX3-XXXXXXXS
With X as placeholder.
3.1.2 Connection 1x AC 230 V / 3x AC 230 V
AGL202-XX1-XXXXXXXS
AGL202-XX2-XXXXXXXS
AGL202-XX3-XXXXXXXS
With X as placeholder.

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4Information 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 ma-
chine.
The Standard EN 12100 – Safety of machinery - General principles for design - Risk
assessment and risk reduction describes the information required for risk assessment.
Risk assessment is effected according to the following criteria:
−degree of injury (serious/minor)
−frequency or duration of stay (frequent/seldom)
−possibilities of avoidance (hardly possible/possible)
For defined risks the Standards EN ISO 13849-1, IEC 61508 or EN 954-1 can be used
to accomplish a correct classification into Safety category, SIL (Safety Integrated
Level) or PL (Performance Level). These standards contain design principles for safe-
ty-relevant parts of control systems.
In the case of the safety function “Safe Torque Off”, the risk assessment must con-
sider the fact that the motor will coast to a standstill in the case of an error. Depend-
ing on the application, a mechanical brake may be required.
Responsibility:
The Manufacturer shall be responsible for the safety of the machine.
−risk analysis of hazards originating from the machine
−measures for reduction and elimination of the risks
−documentation of residual risk from the point of view of the manufacturer
−selection of suitable controller, installation of protective equipment, ergonomics,
documentation, warning of remaining risks
The operator of the machine is responsible for the safety of the application.
−risk analysis of hazards originating from the use of the machine
−documentation of residual risk from the point of view of the operator
−safe operation and protection of operating staff (barriers, instruction of operating
staff, etc.)
Selection of safety function:
−Risk analysis and risk assessment for machine (EN 12100)
−Risk reduction by machine design
−If not possible by design: risk reduction by protective equipment
−Identification of safety requirements
−Selection of category of safety function

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5General 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.
The safety function can be requested or triggered by an error.
In hazard areas, setup work or work for elimination or errors may be required where
the safety function is not to be activated by isolating protection devices such as
mains contactors or motor contactors. Here, the additional safety function may be
used. STO can be used as an alternative to mains or motor contactors, which can be
omitted dependent on the application.
The integrated safety functions reduce the risk of personal damage in hazard areas
and reduce installation requirements.
5.2 Functional Safety
The safety function of the control system must be ensured for normal, trouble-free
operating sates as well as in the case of an error. As a result of this requirement:
−The safety function must be checked in case errors are present. Possible methods
include: error tree analysis, FMEA, etc.) u. a.
5.3 Classification the safety requirement
The integrated safety function “Safe Torque Off” of the AGL frequency inverter meets
the following requirements according to EN 61800-5-2:
−up to safety integrity level SIL 2 according to DIN EN 61508 for STO
−up to performance level d according to EN 13849-1
−of category 3 according to EN ISO 13849-1
In the case of an error, thanks to the safety function STO, the frequency inverter
does not supply energy to the motor which would cause a revolution or torque (or a
movement or force in the case of a linear motor).
Characteristic for the classification mentioned above:
−If an error occurs, the safety function is maintained.
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.
By using appropriate safety control devices, stop category 0 and stop category 1
according to EN 60204 can be achieved in the machine. For safety control devices,
please refer to chapter 10.
Stop category 0: Stop by immediate disconnection of energy supply to the machine
drive elements, i.e. uncontrolled stop.
Stop category 1: Controlled stop, where energy is still being supplied to the drive
elements of the machine to perform the stopping operation. Energy supply is stopped
only after the drive has come to a standstill.
Note that the drive may not stop immediately but coast to a standstill. If no mechani-
cal brake is installed, or a defective brake may involve a risk, further protective
measures (in example tumbler) are to be taken.

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6Description of ACTIVE Cube Safety Function
The frequency inverters of the AGL devices series feature the integrated safety func-
tion „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.
Definitions according to EN 61800-5-2:
STO: Dem Motor wird keine Energie zugeführt, die eine Drehung (oder bei einem
Linearmotor eine Bewegung) verursachen kann. Der Frequenzumrichter liefert keine
Energie an den Motor, die ein Drehmoment erzeugen kann.
SS1 c: Das System Sicherheitsschaltgerät + Frequenzumrichter führt die Funktion
aus:
Auslösen der Motorverzögerung und nach einer anwendungsspezifischen Zeitverzöge-
rung Auslösen der STO-Funktion.
Diese Sicherheitsfunktion entspricht dem gesteuerten Stillsetzen nach EN 60204-1,
Stopp-Kategorie 1.
Definitions according to EN 60204-1:
Stop category 0: Stop by immediate disconnection of energy supply to the machine
drive elements, i.e. uncontrolled stop.
Stop category 1: Controlled stop, where energy is still being supplied to the drive
elements of the machine to perform the stopping operation. Energy supply is stopped
only after the drive has come to a standstill.
Stop functions must always have priority over start functions and must work properly
in any operation mode.
Resetting of the stop function must not cause any dangerous state.
The mechanical elements must be dimensioned properly for the stop category used.
If, for example, a mechanical brake is applied in the case of fast-rotating machines
via stop category 0, this brake must be able to stop the machine safely. Wear and
tear of the mechanical elements must be considered during projection for the operat-
ing states and indicated in the maintenance instructions.
Stop category 0 always has priority over stop category 1.

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6.1 Definitions of the AGL Safety functions
SF1: Safety Function 1
SF2: Safety Function 2
DF1: Diagnosis function 1
DF2: Diagnosis function 2
Response time:
Time that elapses between the triggering of the Safey function on the user interface
and reaching the safe state.
Example for STO: On the user interface the signal level switches from above DC 15 V
to less than DC 5 V. Latest when falling below DC 5 V the response time begins and
ends at the moment where torque can no longer be generated.
Fault Response time:
Time between the occurrence of a detectable fault and reaching the safe state of the
frequency inverter.
Example: The Safety function STO can no longer be triggerd via channel A. The de-
vice internal diagnosis detects the fault and initiates the necessary fault reaction
functions. Overall the Fault response time elapses until torque can no longer be gen-
erated.

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6.2 Specification of the Safety Function 1 (SF1): STO
Type of Safety function SF1
According to EN 61800-5-2: Safe Torque Off, STO
Active Principle of SF1 Disconnection of energy supply to the motor
Demand rate High
SIL-Level (IEC 61508) 2
Redundancy On two channels (2)
Performance Level (EN ISO 13849-1) d
Kategorie (EN ISO 13849-1) 3
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
functionality of SF 1 None
Response time SF1 Less than or equal to 150 ms
Fault Reaction time DF1 Less than or equal to 220 ms
V Speed axis
t Time axis
t1 Time frame, when STO is triggered
Area of discontinuation

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6.3 Specification of the Safety Function 2 (SF2): SS1
Type of Safety function SF2
According to EN 61800-5-2: Safe Stop 1, SS1 c
Active Principle of SF2
•
Delay of motor with suitable braking ramp
•Disconnection of energy supply to the
motor after elapsing of a safe time delay
Demand rate High
SIL-Level (IEC 61508) 2 with suitable safety switching device
Redundancy On two channels (2)
Performance Level (EN ISO 13849-1) d with suitable safety switching device
Amount of Processs interfaces
•
External safety switching device according
to requirements of risk analysis
•
Two (2) on AGL
Design of Processs interface
•
External safety switching device according
to requirements of risk analysis
•Two yellow marked spring terminals X11.3
and X13.3 (inputs STOA und STOB)
Type of Processs interface STO SPS-Type 1 compatible according to
IEC61131-2
Operation modes with limited func-
tionality of SF 2 None
Response time SF2
•
External safety switching device: accord-
ing to data sheet of device
•
AGL: Less than or equal to 150 ms
Fault Reaction time DF2
•
External safety switching device: accord-
ing to data sheet of device
•
AGL: Less than or equal to 220 ms
The security function corresponds to a controlled stop to EN 60204-1, Stop
Category 1.
V Speed axis
t Time axis
t1 Time frame, when braking ramp is triggered (non safe path)
t2 Time frame, when STO is triggered
Δt Time between activation of braking ramp and triggering STO
Are of maximum braking Time,
Set up on external safety control device.
Area of discontinuation

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6.4 Description of Safety Function
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). Mains voltage is still present. If an error occurs, the ma-
chine can still be (or remain) switched off safely.
Unlike shut-down via mains contactors or motor contactors, the integrated safety
function enables easy combination of drives in a machine to form functional groups.
The Safe Torque Off can be limited to certain plant areas in this way. Another advan-
tage is the fact that it is not necessary to wait until the frequency inverter has been
charged and discharged. Thus, readiness of the machine for operation can be res-
tored more quickly. Regular electro mechanic equipment are wearing out – through
the usage of the STO functionality, this kind of equipment is no longer necessary and
maintenance costs can be reduced.
Safe Torque Off:
−Energy supply for the rotary field of the motor is interrupted; the motor coasts to
a standstill
−Used if monitoring for standstill is not required
−Accidental start of the motor is prevented
−No galvanic isolation of motor from frequency inverter DC link
Traditional System Integrated System
with AGL and usage of STO
Ma
i
ns
K1
Frequency inverter
M

20 AGL-STOV0-01SV0-05
06/12
Further advantages:
−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 Cate-
gory 1 can be achieved
−The drive can be connected to power supply continuously; communication and
parameter configuration of the frequency inverter are maintained while the torque
is disabled 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.
Easier machine approval, because the safety function is certified via a type examina-
tion check.
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.
−Detection of an error. The drive may only start again after the error has been
acknowledged and eliminated.
Safe Torque Off
Actuation of safety relay
Detection of an error through self-diagnosis
Application example:
The danger zone near a transport conveyor is monitored by a light grid. If anybody
enters the danger zone, the light grid is interrupted. The DC 24 V supply for the digi-
tal inputs STO of the function „Safe Torque Off“ is switched off and the frequency
inverter output stage is disabled. The drive coasts to a standstill. Disconnection from
mains supply is not necessary. Communication via field bus or addressing via the
terminals is still possible. An external brake which stops the motor can be addressed.