Lenze SM100 E94AYAB User manual

EDS94AYAB
.;2G
Ä.;2Gä
Manual
9400

E94AYAB − SM100
Safety module
L−force Drives
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Please read these instructions and the documentation of the standard device before you
start working!
Observe the safety instructions given therein!
0Fig. 0Tab. 0
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Contents i
3
EDS94AYAB EN 2.1
1 Safety engineering 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Basics 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Introduction 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Drive−based safety with L−force | 9400 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.3 Terms and abbreviations of the safety engineering 5. . . . . . . . . . . . . . . . .
1.1.4 Important notes 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.5 Safety instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.6 Hazard and risk analysis 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.7 Standards 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.8 Safety notes for the installation according to UL or UR 9. . . . . . . . . . . . .
1.1.9 Overview of sensors 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Device modules 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Slot 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Function mode of the safety modules 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Safety module SM0 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.4 Safety module SM100 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Acceptance 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Description 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Periodic inspections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety engineering
Basics
Introduction
1
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4 EDS94AYAB EN 2.1
1 Safety engineering
1.1 Basics
1.1.1 Introduction
With increasing automation, protection of persons against hazardous movements is
becoming more important. Functional safety describes the measures needed by means of
electrical or electronic equipment to reduce or remove danger caused by failures.
During normal operation, safety equipment prevents people accessing hazardous areas. In
certain operating modes, e.g. set−up mode, work needs to be carried out in hazardous
areas. In these situations the machine operator must be protected by integrated drive and
control measures.
Drive−based safety provides the conditions in the controls and drives to optimise the safety
functions. Planning and installation expenditure is reduced. In comparison to the use of
standard safety engineering, drive−based safety increases machine functionality and
availability.
1.1.2 Drive−based safety with L−force | 9400
The controllers of the L−force|9400 range can be equipped with a safety module. The
functional range of the safety module types varies in order to optimally implement
different applications.
"Drive−based safety" stands for applied safety functions, which can be used for the
protection of persons working on machines.
The motion functions are continued to be executed by the controller. The safety modules
monitor the safe compliance with the limit values and provide the safe inputs and outputs.
When the limit values are exceeded the safety modules start the control functions
according to EN 60204−1 directly in the controller.
The safety functions are suitable for applications according to IEC 61508 to SIL 3 and meet,
depending on the module, the requirements of Performance Level e (PL e) and control
category 4 according to EN ISO 13849−1.
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Safety engineering
Basics
Terms and abbreviations of the safety engineering
1
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EDS94AYAB EN 2.1
1.1.3 Terms and abbreviations of the safety engineering
Abbreviation Meaning
9400 Lenze servo controller
Cat. Category according to ISO 13849−1 (formerly EN 954−1)
OSSD Output Signal Switching Device, tested signal output
PS PROFIsafe
PWM Pulse width modulation
SD−In Safe input (Safe Digital Input)
SD−Out Safe output (Safe Digital Output)
SIL Safety Integrity Level according to IEC 61508
SM Safety Module
Opto supply Optocoupler supply for the driver control
PELV Protective extra low voltage
SELV Safety extra low voltage
OFF state Signal state of the safety sensor technology when it is released or responding
ON state Signal state of the safety sensor technology in normal operation
PM P/N switching signal paths
PP P/P switching signal paths
GSE File containing device−specific data to establish PROFIBUS communication
GSDML File containing device−specific data to establish PROFINET communication
S−Bus Safety bus
Abbreviation Safety function
SLS Safely limited speed
SOS Safe operating stop
SS1 Safe stop 1
SS2 Safe stop 2
SSM Safe speed monitor
STO Safe torque off
Formerly: safe standstill
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Safety engineering
Basics
Important notes
1
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6 EDS94AYAB EN 2.1
1.1.4 Important notes
The following pictographs and signal words are used in this documentation to indicate
dangers and important information:
Safety instructions
Structure of safety instructions:
Danger!
(characterises the type and severity of danger)
Note
(describes the danger and gives information about how to prevent dangerous
situations)
Pictograph and signal word Meaning
Danger!
Danger of personal injury through dangerous electrical voltage.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
Danger!
Danger of personal injury through a general source of danger.
Reference to an imminent danger that may result in death or
serious personal injury if the corresponding measures are not
taken.
Stop!
Danger of property damage.
Reference to a possible danger that may result in property
damage if the corresponding measures are not taken.
Application notes
Pictograph and signal word Meaning
Note! Important note to ensure troublefree operation
Tip! Useful tip for simple handling
Reference to another documentation
Special safety instructions and application notes for UL and UR
Pictograph and signal word Meaning
Warnings!
Safety or application note for the operation of a UL−approved
device in UL−approved systems.
Possibly the drive system is not operated in compliance with UL
if the corresponding measures are not taken.
Warnings!
Safety or application note for the operation of a UR−approved
device in UL−approved systems.
Possibly the drive system is not operated in compliance with UL
if the corresponding measures are not taken.
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Safety engineering
Basics
Safety instructions
1
7
EDS94AYAB EN 2.1
1.1.5 Safety instructions
Application as directed
The safety modules SMx (E94AYAx) may only be used together with Lenze drive controllers
of the L−force | 9400 (E94A...) series.
Any other use shall be deemed inappropriate!
Installation/commissioning
Danger!
Danger to life through improper installation
Improper installation of the safety engineering systems can cause an
uncontrolled starting action of the drives.
Possible consequences:
ƒDeath or severe injuries
Protective measures:
ƒSafety engineering systems may only be installed and commissioned by
qualified and skilled personnel.
ƒAll control components (switches, relays, PLC, ...) and the control cabinet
must comply with the requirements of ISO 13849−1 and ISO 138492. This
includes i.a.:
– Switches, relays in IP54 enclosure.
– Control cabinet in IP54 enclosure.
– Please refer to ISO 13849−1 and ISO 138492 for all further requirements.
ƒIt is essential to use insulated wire end ferrules for wiring.
ƒAll safety relevant cables outside the control cabinet must be protected, e.g.
by means of a cable duct:
– Ensure that there are no short circuits.
– For further measures see ISO 138492.
ƒIf an external force acts upon the drive axes, additional brakes are required.
Please observe that hanging loads are subject to the force of gravity!
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Safety engineering
Basics
Safety instructions
1
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8 EDS94AYAB EN 2.1
Danger!
If the request for the safety function is cancelled, the drive will restart
automatically.
You must provide external measures which ensure that the drive only restarts
after a confirmation (EN 60204).
Danger!
When the "safe torque off" (STO) function is used, an "emergency
switching−off" according to EN 60204 is not possible without additional
measures. There is no electrical isolation, no service switch or repair switch
between motor and controller!
Emergency switching−off" requires an electrical isolation, e.g. by a central
mains contactor!
During operation
After the installation is completed, the operator must check the wiring of the safety
function.
The functional test must be repeated at regular intervals. The time intervals to be selected
depend on the application, the entire system and the corresponding risk analysis. The
inspection interval should not exceed one year.
Residual hazards
In case of a short−circuit of two power transistors a residual movement of the motor of up
to 180 °/number of pole pairs may occur! (Example: 4−pole motor Þresidual movement
max. 180 °/2 = 90 °)
This residual movement must be considered in the risk analysis, e.g. safe torque off for
main spindle drives.
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Safety engineering
Basics
Hazard and risk analysis
1
9
EDS94AYAB EN 2.1
1.1.6 Hazard and risk analysis
This documentation can only accentuate the need for a hazard analysis. The user of
drive−based safety must concentrate on dealing with the standards and legal position:
Before putting a machine into circulation, the manufacturer of the machinemust carry out
a hazard analysis according to the Machinery Directive2006/42/EC (until 28 December
2009: 98/37/EC) to find out the hazards related to the application of the machine. To
achieve a level of safety as high as possible the Machinery Directive contains three
principles:
ƒRemoving or minimising the hazards by the construction itself.
ƒTaking the protective measures required against hazards that cannot be removed.
ƒDocumentation of the existing residual risks and training of the user regarding
these risks.
The execution of the hazard analysis is specified in EN 1050, guidelines for risk assessment.
The result of the hazard analysis determines the categoryof safety−based control modes
according to EN ISO 13849−1 which thesafety−oriented parts of the machine control must
comply with.
1.1.7 Standards
Safety regulations are confirmed by laws and other governmental guidelines and
measures and the prevailing opinion among experts, e.g. by technical regulations.
The regulations and rules to be applied must be observed in accordance with the
application.
1.1.8 Safety notes for the installation according to ULor UR
Warnings!
ƒMaximum surrounding air temperature: 55 °C.
ƒExternal fuse for 24 Vdc supply voltage. Rated 4 A DC fuse UL248−14.
1.1.9 Overview of sensors
Passive sensors
Passive sensors are two−channel switching elements with contacts. The connecting cables
and the sensor function must be monitored.
The contacts must switch simultaneously (equivalently). Nevertheless, safety functions
will be activated as soon as at least one channel is switched.
The switches must be wired according to the closed−circuit principle.
Examples of passive sensors:
ƒDoor contact switch
ƒEmergency−off control units
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Safety engineering
Basics
Overview of sensors
1
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10 EDS94AYAB EN 2.1
Active sensors
Active sensors are units with two−channel semiconductor outputs (OSSD outputs).
Drive−based safety integrated in this device series allows for test pulses < 1 ms to monitor
the outputs and cables.
P/N−switching sensors switch the positive and negative cable or signal and earth cable of
a sensor signal.
The outputs must switch simultaneously. Nevertheless, safety functions will be activated
as soon as at least one channel is switched.
Examples of active sensors:
ƒLightgrid
ƒLaser scanner
ƒControl
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