Stober ASP 5001 User manual

ASP 5001
Operating manual Data
Concept
Example
V 5.6-S or later
10/2017 en

Table of contents
ID 442181.072
Operating manual ASP 5001
WE KEEP THINGS MOVING
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4
1.1 Further documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Further support .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7
2.1 Component part of the product .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Presentation of notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.1 1. Switchoff distance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.1 Controller .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.1.2 Control commands and status information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.2 2. Switchoff distance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Overall functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.1 1. Switchoff distance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 ASP 5001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Deselecting and requesting the safety function .. . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.1 Deselect STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Request STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Request SS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Sample application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Calculations of the failure probability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.1 DC = 60 % for Ta1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3.2 DC = 90 % for Ta1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table of contents
Operating manual ASP 5001
ID 442181.07
WE KEEP THINGS MOVING
3
7 xDS 5000 safety figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
7.1 PFH and MTTF .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.1 Size 0 to 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.2 Size 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 CCF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Introduction
ID 442181.074
Operating manual ASP 5001
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1 Introduction
The Safe Torque Off (STO) safety function can be realized with devices from the 5th generation of STOBER
inverters.
There are two switchoff distances available:
The enable function of the drive controller is used for the first switch-off distance. The diagnostics can be
performed via the binary output or a fieldbus system.
For the second switchoff distance, the ASP 5001 option is used. If the safety function is required, the controller
of the power unit is switched off via the switching elements of a safety relay and the positively-driven signal
contact is switched at the external safety circuit (NC contact).
The start-up of the motor is then also prevented when faults in the region of the power unit or the control circuit
are present as the required rotating magnetic field is no longer generated.
Advantages of the start inhibitor:
• No switching of the supply voltage required
• Faster restart possible
• Lower contact wear
• Simplified wiring
The following tables shows which inverter the ASP 5001 certified accessory is available for:
With ASP 5001, applications can be realized up to a maximum:
• PL e in category 3 to DIN EN ISO 13849-1:2008-12 or
• SIL 3 to DIN EN 61800-5-2:2008-04.
You can find the certificate at www.stoeber.de.
Inverter Size
Size 0 Size 1 Size 2 Size 3
MDS 5000A Certified Certified Certified Certified
FDS 5000A Certified Certified — —
SDS 5000A Certified Certified Certified Certified

Introduction
Operating manual ASP 5001
ID 442181.07
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5
1
1.1 Further documentation
You can find the latest document versions at www.stoeber.de.
You can find the latest document versions at www.stoeber.de.
You can find the latest document versions at www.stoeber.de.
The devices of the 5th generation of STOBER inverters can be optionally connected with different fieldbus
systems. The connection is described in the following manuals:
You can find the latest document versions at www.stoeber.de.
Manual Contents ID
Commissioning
Instructions MDS 5000
Reinstallation, replacement, function
test
442297
Operating manual 
MDS 5000
Set up the inverter 442285
Manual Contents ID
Commissioning
Instructions FDS 5000
Reinstallation, replacement, function
test
442293
Operating manual
FDS 5000
Set up the inverter 442281
Manual Contents ID
Commissioning
Instructions SDS 5000
Reinstallation, replacement, function
test
442301
Operating manual
SDS 5000
Set up the inverter 442289
Manuals ID
PROFIBUS DP operating manual 441687
CANopen operating manual 441686
EtherCAT operating manual 441896
PROFINET operating manual 442340
USS operating manual 441707

Introduction
ID 442181.076
Operating manual ASP 5001
1
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1.2 Further support
If you have technical questions that are not answered by this document, please contact:
• Phone: [phone]
• E-mail: [e-mail]
If you have questions about the documentation, please contact:
• E-mail: [e-mail]
If you have questions about training sessions, please contact:
• E-mail: [e-mail]

Notes on safety
Operating manual ASP 5001
ID 442181.07
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2
2 Notes on safety
WARNING!
The inverter and its accessories pose dangers.
Read and observe the safety warnings in this section before you use the ASP 5001 in your application.
The ASP 5001 option does provide galvanic separation of the mains supply network. Dangerous voltages may
also be present at the motor terminals for the required safety function! The function is not a protection device
against electric shockaccording to DIN EN 60204-1.
• Secure the system during maintenance or repair work by switching to zero-potential and using an
appropriate system protection!
• Observe the regulations for emergency stop situations!
The accessory ensures that the rotary field is switched off.
• Secure vertically moving axles against falling!
Note that controlling the Safe Torque Off safety function with OSSD signals can lead to unexpected machine
behavior. The inverter enable can not evaluate OSSD signals or tolerate them in the presetting.
• Activate the OSSD tolerance of the interface by entering a delay corresponding to the OSSD signal in the
A43 Enable Switchoff Delay parameter. Note that the OSSD signals are not evaluated but suppressed!
2.1 Component part of the product
As this documentation includes important information for the safe and efficient handling of the product, always
keep it in the immediate vicinity of the product until product disposal and ensure it can be accessed by
qualified personnel at any time.
Also pass on this documentation if the product is handed over or sold to a third party.

Notes on safety
ID 442181.078
Operating manual ASP 5001
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2.2 Qualified personnel
Since the devices may harbor residual risks, all configuration, transportation, installation and commissioning
tasks including operation and disposal may only be performed by trained personnel who are aware of the
possible risks.
Personnel must have the qualifications required for the job. The following table lists examples of occupational
qualifications for the jobs:
In addition, the valid regulations, the legal requirements, the reference books, this technical documentation
and, in particular, the safety information contained therein must be carefully
• read,
• understood and
• complied with.
2.3 Residual dangers
A residual movement of up to 180°/pole pair can arise despite an activated safety function in the event of a
short circuit of two power transistors! (Example: 4-pole motor: maximum residual movement 180°/2 = 90°).
• Consider this residual movement for the risk analysis!
The motor coasts if the safety function is activated for a running motor. Controlled stopping is no longer
possible.
• Consider this when configuring your system!
Activity Possible occupational qualifications
Transportation and storage Worker skilled in storage logistics or comparable
training
Configuration - Graduate engineer (electro-technology or
electrical power technology)
- Technician (m/f) (electro-technology)
Installation and connection Electronics technician (m/f)
Commissioning 
(of a standard application)
- Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Programming Graduate engineer (electro-technology or
electrical power technology)
Operation - Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Disposal Electronics technician (m/f)

Notes on safety
Operating manual ASP 5001
ID 442181.07
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2
2.4 Presentation of notes on safety
NOTICE
Notice
means that property damage may occur
if the stated precautionary measures are not taken.
CAUTION!
Caution
with warning triangle means that minor injury may occur
if the stated precautionary measures are not taken.
WARNING!
Warning
means that there may be a serious danger of death
if the stated precautionary measures are not taken.
DANGER!
Danger
means that serious danger of death exists
if the stated precautionary measures are not taken.
Information
refers to important information about the product or serves to emphasize a section in the
documentation to which the reader should pay special attention.

Concept
ID 442181.0710
Operating manual ASP 5001
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3 Concept
WARNING!
Improper use poses a danger to life.
Safe technical integration of the 5th generation of STÖBER inverters is not permitted without the ASP
5001.
Using the STÖBER safety concept, configurations can be established up to and including
• PL e in category 3 to DIN EN ISO 13948-1:2008-12 or
• SIL 3 in HF1 to DIN EN 61800-5-2:2008-04.
The Safe Torque Off (STO) safety function is integrated in the inverter.
For a suitable external configuration, the Safe Stop 1 (SS1) safety function to DIN EN 61800-5-2:2008-04 or
a category 1 stop to DIN EN 60204-1:2007-06 can be realized. In this way, STO constitutes a safe fallback
solution.
The devices from the 5th generation of STÖBER inverters meet the requirements for category 3 and HF1
configurations. Accordingly, the device has two switchoff distances that are independent of each other.
Current supply
for electronic
PDS(SR)- Power-Drive-System
(Safety Release)
control
part
Power pack
Motor
Frequency
V+
state
Encoder
STO channel A
STO channel A feedback
STO channel B
STO channel B feedback
Power supply
ASP 5001

Concept
Operating manual ASP 5001
ID 442181.07
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3
3.1 1. Switchoff distance
3.1.1 Controller
The 1st switchoff distance is the enable channel of the control electronics. The control electronics evaluate
the two signals: The enable at X1.3 and the additional enable signal. Enable and additional enable have AND
logical operations internally in the device, i.e. both signals must be active so that the power output stage is
switched on. The enable at X1.3 must always be activated. In the A60 Additional Enable Source parameter,
• set which source the signal supplies and
• how the signal evaluates the additional enable.
The following table shows the options available.
If your application differs to the standard applications provided by STÖBER ANTRIEBTECHNIK GmbH & Co.
KG, you must conduct tests to ensure that the 1st switchoff distance, – i.e. enable and additional enable,– is
always effective.
3.1.2 Control commands and status information
The 1st switchoff distance is acknowledged by the A900 SysEnableOutput signal via a binary output or
fieldbus. The signal must be dynamically checked by the higher level controller, i.e for a change in state.
For example, the A900 coordinate is entered in the F61 parameter for the output on BA1. If the
acknowledgement is via a fieldbus system, activate the watchdog function of the bus system. Observe the
fieldbus documentation for this (see section 1.1 Further documentation).
Read the E200 Device Status Byte parameter from the fieldbus. The acknowledgement is provide from Bit 0
Enabled.
Setting in A60 parameter Control of the enable channel
1:High Additional enable is continually active. The
power output stage is activated via the
enable at X1.3.
2:Parameter For this setting in A60, the status of the
A180 bit 0 parameter is evaluated. A180 is
described by the fieldbus.
3:BE1 to 28:BE13-inverse The signal of the additional enable is
evaluated via the set terminal as not
inverted or inverted.

Concept
ID 442181.0712
Operating manual ASP 5001
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3.2 2. Switchoff distance
The 2nd switchoff distance is realized with the ASP 5001. A positively driven safety relay is integrated on the
ASP 5001.
In order for the power output stage of the inverter to be controlled by the control part, the STO safety function
must be deselected at terminal X12.3.
The switching state of the ASP 5001 is acknowledged via the NC contact at terminals X12.1 and X12.2. If the
STO safety function is deselected, the contact is opened. If the ASP 5001 is not controlled, the contact is
closed and the safety function is requested.
3.3 Overall functionality
Note that the following parameters can affect the safety function:
•A39 Tmax Fast Stop
•A43 Enable Switchoff Delay
•A44 Enable Quick Stop
•A55 Manual Function Button
•A60 Additional Enable Source
• The F61 BA1 Source to F70 BA10 Source parameters
Observe these when configuring, commissioning and modifying your project.
Make sure
• that the setting of the parameters matches your application.
• so that the desired overall functionality is achieved after commissioning and each modification.
Information
Note that the ASP 5001 is optional for sizes 0, 1 and 2. The accessories may only be installed and
repaired by STÖBER ANTRIEBSTECHNIK. For this reason, order the inverter with the ASP 5001
installed for these sizes.
For size 3, the ASP 5001 is installed as standard.

Data
Operating manual ASP 5001
ID 442181.07
WE KEEP THINGS MOVING
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4
4Data
You can find the data of the enable path and the ASP 5001 in this section.
4.1 1. Switchoff distance
The configurable binary outputs are provided at different terminals. Also observe the projecting manuals (see
section 1.2 Further support). The binary outputs have the following technical data:
•I
A max = 50 mA
•U
A max≤UE
•T
A type = 1 ms
4.2 ASP 5001
Terminal description X12
Terminal description X1
Pin Designation Function Data
3GND
Enable
High level≥12 V
High level< 8 V
IE max = 16 mA
UE max = 30 V
4 + input
Safety-relevant data of the enable path
Acknowledgement MTTFDDCavg Mission Time
Without feedback
system
377 years 60 % 20 years
With feedback system 377 years 90 % 20 years
Pin Id. Function
1NCcontact
(break contact
element)
Feedback system; must be integrated in the safety circuit of the
controller!
2
3 Relay coil 1 (+) Controllera)
a) For a UL-compliant application, the use of a 4 AT fuse in the 24 vdc power supply line is mandatory. The fuse must be approved 
according to UL 248.
4 Relay coil 2 (-)
1234

Data
ID 442181.0714
Operating manual ASP 5001
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B10D values of the ASP 5001
Coil data
Date Value
Voltage 20 VDC – 28 VDC
Nominal current IN70 mA
Safety circuit Free-wheeling diode
Contact data
Date Value
Minimum switching voltage 10 V
Maximum switching voltage 30 V
Minimum switching current 10 mA
Maximum switching current 300 mA
Maximum switching frequency 0.1 Hz
Information
The feedback contact must be monitored by the higher-level safety controller.
Minimum service life of relay
Utilization category Current Switching cycles
DC-12 300 mA 450000
DC-13 300 mA 250000
Utilization category Current B10D value
DC-13 1 A Size 0 – size 2: 10000000 cycles
Size 3: 7000000 cycles
Information
The diagnostic coverage for a positively-driven safety relay is 99 % acc. to DIN EN ISO 13849-
1:2008-12.

Data
Operating manual ASP 5001
ID 442181.07
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4
Maximum conductor cross-section
Connection type Maximum conductor cross-section
[mm2]
Rigid 1.5
Flexible 1.5
Flexible with cable end, without
plastic sleeve
1.5
Flexible with cable end, with plastic
sleeve
0.5
2 leads with the same cross-section
with double cable end
—

Deselecting and requesting the safety function
ID 442181.0716
Operating manual ASP 5001
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5 Deselecting and requesting the safety
function
In this section, you will find out how to deselect and request the safety function.
Deselecting a safety function means the safe state is left and regular operation of the drive is allowed.
Requesting a safety function means that regular operation is left and the inverter is brought to the safe state.
5.1 Deselect STO
Deselect STO
1. Switch on the signal at terminal X12.3/4.
The NC contact at terminal X12.1/2 is opened.
2. Turn on the controller enable.
The feedback system confirms the enable.
You have deselected the STO safety function.
Device state
()E48
1:Switchondisable 2:Readytoswitchon
4:Enabled
Terminal X12.3/4
(Relay coil)
Terminal X12.1/2
(NC contact)
Enable
Response message
Control unit ( )A900
Reference value
Actual value
STO
Information
To enable the power output stage, other signals may be required in addition to the controller
enable, e.g.

Deselecting and requesting the safety function
Operating manual ASP 5001
ID 442181.07
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5
5.2 Request STO
Request STO
1. Switch off the signal at terminal X12.3/4 and the controller enable.
The NC contact at terminal X12.1/2 is closed.
The acknowledgement is switched off.
You have requested the safety function.
Device state
()E48
4:Enabled
1:Switchondisable
Terminal X12.3/4
(Relay coil)
Enable
Terminal X12.1/2
(NC contact)
Response message
Control unit ( )A900
Reference value
Actual value
STO

Deselecting and requesting the safety function
ID 442181.0718
Operating manual ASP 5001
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5.3 Request SS1
tmax= application-dependent, maximum permitted delay time after which the relay coil must be shut off.
Request SS1
1. Turn off the controller enable.
A projected quick stop is performed (see A44 parameter). When the quick stop is completed, the
feedback system of the control unit reports that the power unit is no longer enabled.
2. Switch off the signal at terminal X12.3/4.
The NC contact at terminal X12.1/2 is closed.
You have requested the safety function.
Device state
()E48
1:Switchondisable
2:Readytoswitchon
4:Enabled
7:Quickstop
Enable
Response message
Control unit ( )A900
Terminal X12.3/4
(Relay coil)
Terminal X12.1/2
(NC contact)
Reference value
Actual value
STO
t
max
Information
Note that when SS1 is requested, steps 1 and 2 must occur within a maximum permitted delay time
(tmax). The maximum permitted delay time an integral part of the SS1 safety function. The duration
depends on your application.

Sample application
Operating manual ASP 5001
ID 442181.07
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6
6 Sample application
6.1 Description
This example shows the implementation of the STO safety function when using an inverter from the 5th
generation of STOBER inverters (xDS 5000) in conjunction with a moving and separating safety device and
a safety relay.
The safety function in this example is triggered by opening the safety doors, which is detected via the position
switch (B1/B2) of the safety relay (K1).
Both switchoff paths (T1a, T1b) are controlled in the xDS 5000 via the enable contacts of K1. As well as the
STO safety function, the SS1 safety function can also be realized by using a suitable safety relay (K1) if K1
has corresponding enable contacts with a time delay available.
Switch-off path 1
The switch-off path 1 in the xDS 5000 (T1a) is activated via the controller enable input. The generation of the
pulse pattern is blocked in the control unit by switching the signal at this input to low level. This occurs
immediately for the STO safety function after requesting the safety function. For the SS1, a stop ramp must
be parameterized in the xDS 5000 so that the drive can be initially stopped in a controlled manner before the
generation of the pulse pattern is blocked. The control unit can respond to the safety relay (K1) via the binary
output and a coupling relay (K2).
Switch-off path 2
The second switch-off path in the inverter provides a safety relay (T1b) with a NO contact (make contact
element) that switches off the controller for the driving stage. This relay is accommodated on the ASP 5001
option. Switchoff occurs immediately after the request for the safety function for the STO and with a
corresponding time delay for the SS1. The positively-driven NC contact (break contact element) of the safety
relay (T1b) is included in the feedback loop of the safety device (K1) for fault coverage.
Fig. 6-1Schematic diagram
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(QDEOHG

Sample application
ID 442181.0720
Operating manual ASP 5001
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6.2 Calculations of the failure probability
The calculation for the STO and SS1 safety functions were carried out on the basis of the safety-related block
diagrams represented in Fig. 6-2 Safety-related block diagram that were derived from the principal circuit
diagram (see section 5.1).
Version 1.1.2 of the SISTEMA software assistant was used for a part of the calculations.
Fig. 6-2Safety-related block diagram
Switching can be divided into three subsystems. Here, the safety device with the position switches (B1/B2)
forms the SB 1 subsystem, the safety switching device (K1) forms the SB 2 subsystem and switchoff paths in
xDS 5000 (T1a/T1b) are combined in the SB 3 subsystem.
The K1 safety switching device is a finished product that meets the requirements of category 4 and PL e. The
failure probability is specified by the manufacturer as PFH = 2.31 10-9 1/h.
For both other SB 1 and SB 3 subsystems, the failure probability (PFH) is calculated as follows.
In order to determine the failure probability for the overall safety function of the sensor to the actuator, the PFH
values of the individual subsystems are added at the end.
MTTFd
• SB 1: An exclusion of faults for the electrical contact is possible for the B1 position switch with positive
opening operation. For the electrical NO contact of B2, a B10d value of 2 000 000 cycles is assumed. This
also applies for the mechanical part of B1 and B2. For 365 workdays, 16 work hours and a cycle time of
5 minutes (300 s), nop = 70 080 cycles/year for these components.
MTTFdfor the B1 position switch is 285 years and 143 years for B2.
Both values are reduced to 100 years in SISTEMA (high).
• SB 3:
A MTTFdvalue of 100 years can be assumed for the subsystem using the table in section 3.3. for a cycle
time of 5 minutes.
B1
B2
K1
T1a
T1b
sub system
input
SB1
parts of
sub systems
parts of
sub systems
sub system
logic
SB2
sub system
output
SB3