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Afag SE-Power FS, Manual

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30 

SE-Power FS STO-manual vers. 1.6 en.12.08.2015

 

5

 

Assembly and Installation 

5.1

 

Mounting / Dismounting 

The safety module SE-Power FS Safety Module STO is suitable only for integration into the 
servo drive SE-Power FS. It cannot be operated outside the servo drive. 

 

 

Warning 

Danger of electric shock if the safety module is not mounted. 

Contact with conducting parts will cause severe injuries and may result in death.  

Before touching conducting parts during maintenance, repair and cleaning work and 
during long service interruptions:  

1.  Switch off the power to the electrical equipment and secure it to prevent a 

restart. 

2.  After switching it off, wait at least 5 minutes of discharge time and check that it 

is voltage-free before accessing the servo drive.  

 

 

 

Note 

Incorrect handling can damage the safety module or servo drive. 

  Before mounting and installation work, switch off the supply voltage. Switch on 

the  supply  voltage  only  when  the  mounting  and  installation  work  have  been 
completely finished. 

  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.  Do 

not  touch  the  printed  circuit  board  or  the  pins  of  the  manifold  rail  in  the  servo 
drive. Hold the safety module only by the front plate or the edge of the board. 

 

 

 

Summary of Contents for SE-Power FS

Page 1: ...Servo Controller SE Power FS STO Manual Complementary document to the Operating Instruction Copyright by Afag Automation AG Translation English ...

Page 2: ... Product 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 ...

Page 3: ... state machine 41 6 3 3 Window Safety module 41 6 4 Function test validation 44 7 Operation 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 8 Conversion and module replacement...

Page 4: ...4 SE Power FS STO manual vers 1 6 en 12 08 2015 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 ...

Page 5: ...h 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 t...

Page 6: ...y 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...

Page 7: ...he 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 ...

Page 8: ...ll 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 oper...

Page 9: ...e 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...

Page 10: ...formation 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 ...

Page 11: ...ction 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 w...

Page 12: ...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 Gewährlei...

Page 13: ...t 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 appli...

Page 14: ...e 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 safe...

Page 15: ...ctions 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 ...

Page 16: ...play 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 ...

Page 17: ... 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 ...

Page 18: ...wer 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 th...

Page 19: ... 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 t...

Page 20: ...s 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 simultane...

Page 21: ...d and thus do not trigger the STO function The tolerance to test pulses from sensors with OSSD signals is rated for the operating range specified in accordance with Appendix 9 1 4 Table 22 The permissible test pulse length is dependent upon the control voltage level at inputs STO A and STO B Example Input voltage for STO A and STO B 24 V OSSD signals with a test pulse length of 3 5ms are tolerated...

Page 22: ...dbus communication can be activated deactivated or a station address can be set for example via the DIP switches 4 3 Functionalities in the basic SE Power FS The following functions in the basic unit SE Power FS are not certified according to EN 61800 5 2 They are functional supplements and offer additional diagnostics options Error messages generated by the safety module such as exceeding the dis...

Page 23: ...ses etc Note The brake is activated by the servo drive s non safety firmware Note If one of the control ports STO A or STO B is deactivated with an active output the drive coasts unbraked if no holding brake is connected This can cause damage to the machine It is therefore recommended that a holding brake is connected to the servo drive Please check whether the motors with holding brake you use is...

Page 24: ...the 10ms cycle This generally results in a graded response speed as per Table 3 Function Response time Reaction Switching time from high to low T_STO A B_OFF Section 9 1 4 Table 21 Switching time from low to high T_STO A B_ON Section 9 1 4 Table 21 Detection of driver supply failure tReaction 125µs Activation of the power semiconductor PWM is switched off Activation of holding brake tReaction 10ms...

Page 25: ...on 9 1 4 Table 21 T_STO A B_ON STO A B Switching time from Low to High Section 9 1 4 Table 21 T_C1 C2_ON C1 2 Switching time closing Section 9 1 4 Table 23 T_C1 C2_OFF C1 2 Switching time opening Section 9 1 4 Table 23 T_DRIVE_V Delay of the SE Power FS 0 10ms Table 4 Time data concerning Figure 3 SE Power FS Safety Module STO STO A Status C1 C2 STO B Status LED closed open on off 1 0 SE Power FS ...

Page 26: ... motor irrespective of brake activation deactivation is displayed The set point value is only activated when the holding brake delay T_BRAKE_V has expired An error is triggered because the STO inputs are deactivated while the output stage is active Figure 4 Time behaviour when activating the safety function STO with restart SE Power FS Safety Module STO STO A STO B Status LED C1 C2 1 0 on off SE P...

Page 27: ... T_DIN5_SU Time for which the DIN5 must be Low after switching on STO A B again and status change of the STO module 20ms T_DRIVE_V Delay of the SE Power FS 0 10ms T_BRAKE_V_ON Switch off delay of the holding brake Dependent on the brake 1 T_BRAKE_V_OFF Switch on delay of the holding brake Dependent on the brake 2 1 Physical delay until the brake closes 2 Minimum time Physical delay until the brake...

Page 28: ... found in Table 6 Figure 5 Time behaviour when activating the safety function SS1 external switching with restart Safety switching device Status LED C1 C2 SE Power FS Safety Module STO 1 0 on off SE Power FS Holding brake optional T_STO A B_OFF T_DIN5_SU T_STO A B_ON Speed Servo drive enable DIN5 24 V 0 V 1 0 Output stage enable intern T_BRAKE_V_OFF T_DRIVE_V T_BRAKE_V_ON S1 K1 DIN5 closed open 1 ...

Page 29: ...21 T_STO A B_ON STO A B Switching time from Low to High Section 9 1 4 Table 21 T_DRIVE_V Delay of the SE Power FS 0 10ms T_DIN5_SU Time for which the DIN5 must be Low after switching on STO A B again and status change of the STO module 20ms T_BRAKE_V_ON Switch off delay of the holding brake Dependent of the brake 1 T_BRAKE_V_OFF Switch on delay of the holding brake Dependent of the brake 2 1 Physi...

Page 30: ...e electrical equipment and secure it to prevent a restart 2 After switching it off wait at least 5 minutes of discharge time and check that it is voltage free before accessing the servo drive Note Incorrect handling can damage the safety module or servo drive Before mounting and installation work switch off the supply voltage Switch on the supply voltage only when the mounting and installation wor...

Page 31: ...trip within the servo drive is reached carefully press it into the contact strip until it stops 3 Then screw the safety module with the two screws onto the front of the servo drive housing Tighten the screws with approx 0 35 Nm Figure 6 Mounting Dismounting 5 1 2 Dismounting the safety module 1 Unscrew screws on the safety module 2 Loosen the safety module by gently levering the front cover or by ...

Page 32: ...rements of EN 60204 1 for DC power supply behaviour during power interruptions etc The cable is connected via a plug making it easier to replace the safety module Make sure that no jumpers or the like can be inserted parallel to the safety wiring e g through the use of the maximum wire cross section of 1 5 mm or suitable wire end sleeves with insulating collars Use twin wire end sleeves for loopin...

Page 33: ...ectly the control ports STO A and STO B are to be connected in two channels with parallel wiring see Section 5 3 1 Figure 7 This interface can be part of an emergency stop circuit or a protective door arrangement for example 5 2 4 Minimum wiring for commissioning X40 If at the moment of the commissioning of the servo positioning controller there s not yet a safety orientated connection the servo p...

Page 34: ... FS Safety Module STO example of single phase servo drive SE Power FS 1 2 3 4 5 L230VAC N230VAC PE 24VDC T1 1 2 7 8 9 L1 PE 24V GND24V N X9 21 9 DIN4 DIN5 X1 1 3 2 4 STO A STO B 0V B 0V A X40 Output PLC Output stage enable Output PLC Servo drive enable Only the relevant connections are drawn Without cross circuit detection 0VDC 5 6 C1 C2 Input PLC Safety feedback T1 S1 emitter receiver OSSD1 OSSD2...

Page 35: ...is output by the floating contact C1 C2 Notes with regard to a typical circuit The servo drive with safety module does not have integrated cross circuit detection With direct light barrier wiring the light barrier detects cross circuits if designed to do so When using safety switching devices the contacts C1 C2 can be integrated in the feedback circuit of the safety switching device The typical ci...

Page 36: ...ircuit Decelerate and safe torque off SS1 Safe Stop 1 example single phase servo drive SE Power FS 1 2 3 4 5 N230VAC PE 24VDC T1 SE Power FS 1 2 7 8 9 L1 PE 24V GND24V N X9 21 9 DIN4 DIN5 X1 1 3 2 4 STO A STO B 0V B 0V A X40 Output PLC Output stage enable Output PLC Servo drive enable Only the relevant connections are drawn 0VDC 5 6 C1 C2 Input PLC Safety feedback S1 emitter receiver OSSD1 OSSD2 S...

Page 37: ...ypical circuit The safety switching device used must switch off the servo drive enable X1 9 DIN5 without a delay and the inputs STO A and STO B X40 1 3 with a delay The required delay is application dependent and must be defined specific to the application concerned The delay must be designed so that the drive is decelerated to zero even at maximum speed via the quick stop ramp in the SE Power FS ...

Page 38: ...nction Carry out a risk evaluation for your application and select the circuitry and components accordingly Note the examples Section 5 3 6 1 Before commissioning Perform the following steps to prepare for commissioning 1 Ensure that the safety module is correctly mounted see Section 5 1 2 Check the electrical installation connecting cable pin allocation see Section 5 2 Are all protective earth co...

Page 39: ...d With the integrated Functional Safety Modules SE Power FS Safety Module STO and SE Power FS Safety Module MOV these traceable modifications relate to a module replacement The configuration is performed in the window Safety module of the Afag SE Commander see Section 6 3 3 Window Safety module The Afag SE Commander parameterisation software has been expanded for the use of the SE Power FS series ...

Page 40: ...reen there is a status bar It shows the type of the servo drive and the type of the integrated Functional SE Power FS Safety Module see Figure 9 Additionally type serial number and version are indicated in the window Safety module see Section 6 3 3 Window Safety module Menu bar Tool bar Main screen Status window Status indication state machine Type indication servo drive Type indication safety mod...

Page 41: ...y the power end stage of the SE Power FS may be already safely switched off by the Functional SE Power FS Safety Module STO see also Section 6 3 3 3 Status LEDs In addition the status of the internal state machine is indicated in the window Safety module see Section 6 3 3 Window Safety module 6 3 3 Window Safety module In order to use the SE Power FS servo drives with an integrated Functional Safe...

Page 42: ...eld displays the device data that have been stored on the Functional Safety Module during factory commissioning Type Exact type designation for example FSM 2 0 STO Serial number The serial number is assigned during production and is stored on the module The serial number is unique for a product of the applicable type Revision Revision number of the hardware 6 3 3 2 Firmware The Functional SE Power...

Page 43: ... Off STO Safety circuit error Safe state SAFE TORQUE OFF this means that the power output stage of the basic unit SE Power FS is reliably switched off Z1 Normal operation Safe Torque Off STO Safety circuit error The safety conditions are violated The detected state of the two driver supply voltages does not comply with any of the defined valid states The PWM has been deactivated the power output s...

Page 44: ...possibly additional safety measures 3 User information on the residual risk Yes No 3 Were the hazards eliminated or the hazard risk reduced as far as practically possible Yes No 4 Can it be guaranteed that the implemented measures will not pose new hazards Yes No 5 Have the users been adequately informed and warned about the residual risks Yes No 6 Can it be guaranteed that the operators working c...

Page 45: ...ions Yes No Pressing the emergency stop button on the unit Is the drive shut down Yes No If only STO A is activated is the drive shut down immediately and the discrepancy time violation error Display 52 1 reported in the SE Power FS after the discrepancy time has lapsed Yes No If only STO B is activated is the drive shut down immediately and the discrepancy time violation error Display 52 1 report...

Page 46: ...d care The safety module does not require any maintenance 7 3 Protective functions 7 3 1 Voltage monitoring The input voltages at STO A and STO B are monitored If the input voltage at STO A or STO B is too high or too low the driver supply for the power semiconductors of the servo drive are safely switched off The power output stage PWM is thus switched off 7 3 2 Protection against overvoltage and...

Page 47: ...ay is intended for the unsafe status the normal status displays of the servo drive are represented Table 12 Seven segment display on the servo drive 7 4 2 Error messages When an error occurs the servo drive shows an error message cyclically in the seven segment dis play on the front of the servo drive The error message consists of an E for Error a main index xx and sub index y e g E 5 1 0 Warnings...

Page 48: ...t fit the design For module replacement Module type not yet in design Accept installed safety module or fieldbus activation module see Section 6 3 3 3 Safety module Different module version Module type or version is not supported Install a safety module or fieldbus activation module appropriate for the firmware and hardware 2 Load a firmware suitable for the module see type designation on the modu...

Page 49: ...installation Information on removing and installing the safety module can be found here Mounting dismounting the safety module see Section 5 1 Accept the serial number of the replaced safety module see Section 6 3 3 8 2 Decommissioning and disposal Observe the information for dismantling the safety module in Section 5 1 8 2 1 Disposal Observe the local regulations for environmentally appropriate d...

Page 50: ...8 3 2 SE Power FS Devices of the SE Power FS series feature in combination with the SE Power FS Safety Module have the safety function STO Safe Torque Off in accordance with EN 61800 5 2 SIL3 and or EN ISO 13849 1 Cat 4 PL e The two switch off paths are realised via the control ports STO A X40 1 and STO B X40 3 The potential free feedback contact X40 Pins 5 and 6 is also present 8 3 3 Modification...

Page 51: ...tion to the machine Note The parameter set of the SE Power must be transferred with the same values to the parameter block of the SE Power FS If these values are increased which in turn poses a higher risk a new risk assessment must be performed on the machine Note Once the servo drive has been replaced the safety function must be validated in accordance with the machine manufacturer s specificati...

Page 52: ... coverage HFT 1 Hardware failure tolerance SFF 99 2 Safe Failure Fraction PFH 1 07 x 10 10 Probability of dangerous Failure per Hour PFD 2 3 x 10 5 Probability of dangerous Failure on Demand T Years 20 Proof Test Interval Duration of use in accordance with EN ISO 13849 1 MTTFd Years 100 Mean time to dangerous failure Calculated at 1450 years limited to 100 years Table 14 Technical data Safety indi...

Page 53: ...on materials RoHS compliant Table 16 Technical data Mechanical Certifications SE Power FS Safety Module STO for servo drives SE Power FS CE marking In accordance with EU EMC Directive In accordance with EU machine directive The device is intended for industrial use Measures for interference suppression may need to be implemented in residential areas Table 17 Technical data Certifications ...

Page 54: ...chnical data Storage Ambient conditions Ambient temperature C 0 40 outside the servo drive housing Cooling By means of ambient atmosphere in the servo drive no forced ventilation Permissible setup altitude m 2000 above sea level Protection class IP20 mounted in the SE Power FS Air humidity Relative air humidity up to 90 non condensing Degree of contamination in accordance with EN 61800 5 1 2 The i...

Page 55: ...to low STO A B_OFF ms 10 typical maximum 20 at 28 8 V Switching time from low to high STO A B_ON ms 1 typical maximum 5 Maximum positive test impulse length at logic 0 µs 300 related to nominal voltage 24 V and intervals 2 s between impulses Table 21 Technical data Electrical for ports STO A and STO B Switch off time to power output stage inactive and maximum tolerance time for test pulse Input vo...

Page 56: ...chnical data Electrical data of the feedback contact C1 C2 Auxiliary supply 24V 0V X40 output Version Logic supply voltage routed out of the servo drive Feed in at X9 not additionally filtered or stabilised Reserve polarity protected overvoltage proof up to 60 V DC Nominal voltage V 24 Nominal current mA 100 short circuit proof max 300 mA Voltage drop V 1 for nominal current Table 24 Technical dat...

Page 57: ...ol cabinet use screened cable Guide screening into the control cabinet attach to the side of the control cabinet Cable cross section flexible conductors wire end sleeve with insulating collar One conductor mm 0 25 0 5 Two conductors mm 2 x 0 25 with twin wire end sleeves Tightening torque M2 Nm 0 22 0 25 Table 26 Technical data Cabling to X40 ...

Page 58: ...p a process or a motion if this creates a danger OSSD Output Signal Switching Device Output signals with 24 V cycle rates for error detection PFD Probability of Failure on Demand in accordance with IEC 61508 PFH Probability of Dangerous Failures per Hour in accordance with IEC 61508 PL Performance Level in accordance with EN ISO 13849 1 Stages a e SFF Safe Failure Fraction in accordance with IEC 6...

Page 59: ...SE Power FS STO manual vers 1 6 en 12 08 2015 59 ...

Page 60: ...Afag Automation AG Fiechtenstrasse 32 4950 Huttwil Schweiz Tel 41 0 62 959 86 86 Fax 41 0 62 959 87 87 e mail sales afag com Internet www afag com ...

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