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Safe Torque Off
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INFRANOR
GD1
GD1 – STO Manual
WARNING
This is a general manual describing a series of servo drives having output capability suitable for driving AC
brushless sinusoidal servo motors.
Please see GD1 User Guide for the operation of the drive (commissioning, configuration, …).
Instructions for storage, use after storage, commissioning as well as all technical details require the
MANDATORY reading of the manual before getting the drives operational.
Maintenance procedures should be attempted only by highly skilled technicians having good knowledge
of electronics and servo systems with variable speed (EN 60204-1 standard) and using proper test
equipment.
The conformity with the standards and the "CE" approval is only valid if the items are installed according to the
recommendations of the drive manuals. Connections are the user's responsibility if recommendations and
drawings requirements are not met.
CAUTION
Any contact with electrical parts, even after power down, may involve physical damage.
Wait for at least 10 minutes after power down before handling the drives (a residual voltage of
several hundreds of volts may remain during a few minutes).
ESD INFORMATION (ElectroStatic Discharge)
INFRANOR drives are conceived to be best protected against electrostatic discharges. However,
some components are particularly sensitive and may be damaged if the drives are not properly
stored and handled.
STORAGE
The drives must be stored in their original package.
When taken out of their package, they must be stored positioned on one of their flat
metal surfaces and on a dissipating or electrostatically neutral support.
Avoid any contact between the drive connectors and material with electrostatic potential
(plastic film, polyester, carpet …).
HANDLING
If no protection equipment is available (dissipating shoes or bracelets), the drives must
be handled via their metal housing.
Never get in contact with the connectors.
ELIMINATION
In order to comply with the 2002/96/EC directive of the European Parliament and of the Council of
27 January 2003 on waste electrical and electronic equipment (WEEE), all INFRANOR devices
have got a sticker symbolizing a crossed-out wheel dustbin as shown in Appendix IV of the
2002/96/EC Directive.
This symbol indicates that INFRANOR devices must be eliminated by selective disposal and not
with standard waste.
INFRANOR does not assume any responsibility for any physical or material damage due to improper handling or
wrong descriptions of the ordered items.
Any intervention on the items, which is not specified in the manual, will immediately cancel the warranty.
INFRANOR reserves the right to change any information contained in this manual without notice.
©INFRANOR, June 2009, All rights reserved.
Issue: 1.1
GD1
1
GD1 – STO Manual
Content
Page
CHAPTER 1 – GENERAL DESCRIPTION............................................................................................. 3
CHAPTER 2 – SPECIFICATIONS.......................................................................................................... 4
2.1 - FUNCTIONAL DIAGRAM............................................................................................................. 4
2.2 - COMMAND SYSTEM CONCEPTION .......................................................................................... 4
2.2.1 - Safety instructions ................................................................................................................. 4
2.2.2 - STO connection ..................................................................................................................... 5
2.2.3 - Timings .................................................................................................................................. 6
2.2.4 - Performance level.................................................................................................................. 7
2.2.5 - Periodic inspection routines................................................................................................... 7
2.2.6 - Residual risk .......................................................................................................................... 7
CHAPTER 3 – CONNECTION EXAMPLE ............................................................................................. 8
3.1 - EXAMPLE 1: STOP CATEGORY 0 ACCORDING TO EN 60204-1 COMPLYING WITH EN13849-1 CAT. 3 ... 8
3.2 - EXAMPLE 2: STOP CATEGORY 1 ACCORDING TO EN 60204-1 COMPLYING WITH EN13849-1 CAT. 3 ... 9
2
Contentt
GD1 – STO Manual
Chapter 1 – General description
Safe Torque Off (STO) definition according to the EN 61800-5-2 standard:
"Power, that can cause the rotation of a motor (or displacement in the case of a linear motor), is not applied to the
motor. The drive will not provide energy to the motor which can generate torque (or force in the case of a linear
motor)".
The STO function corresponds to an uncontrolled stopping in accordance with the stop category 0 of the EN
60204-1 standard.
The STO function may be used where power removal is required to prevent an unexpected start-up.
In circumstances where external influences (with vertical loads for example) are present, additional measures
(mechanical brakes for example) may be necessary to prevent any hazard.
The standard output of the drive must not be considered as a safe output. When using a mechanical brake, it will
be mandatory to introduce a safe contact from an external device in the brake actuation line.
The STO function cannot be considered as a safe insulation device for the motor. It does not prevent from any
voltage on the motor terminal block.
The integrated STO function fulfills the EN ISO 13849-1:2006 category 3 PLd requirements.
PLd corresponds to SIL2, according to "Table 4 - Relationship between PL and SIL" of 13849-1 standard.
Chapter 1 – General description
3
GD1 – STO Manual
Chapter 2 – Specifications
2.1 – FUNCTIONAL DIAGRAM
The "Safe Torque Off" function allows to keep the motor shaft free by avoiding the IGBT module commutation.
This is achieved by means of two techniques:
- IGBT command supply removal,
- PWM removal.
GEM DRIVE
DSP
PWM
PWM
POWER BOARD
STO1/
EGND
IGBT Module
Drivers
STO_OUT
MONITORING
Vcc
EGND
M
+15V
STO2/
EGND
Different parts of the functional diagram are described below:
•
The green part is the first channel of the safety function. PWM signals are disabled by inhibiting the
optocouplers commutation.
•
The blue part is the second channel of the safety function. IGBT gate signals are disabled by the power
supply shut down.
•
The red part is the monitoring function which detects faults by comparing the two channel outputs. If a fault is
detected this function locks both channels in safe state.
•
The black part is the functional part of the drive which is not used to achieve the safety function.
STO_OUT output is the state feedback to facilitate the function integration. This output is not safe. It only has
an informative function.
2.2 – COMMAND SYSTEM CONCEPTION
2.2.1 –SAFETY INSTRUCTIONS
The integration of the STO function must be the result of a risk analysis of the complete machine. All control
components must comply with the requirements of this risk analysis.
Installing and commissioning of safety functions must be performed by skilled personnel only.
Short-circuit avoidance:
Install the drive in a control cabinet with a minimum IP54 protection.
Avoid control signals proximity. Any short-circuit between two control signals must be detected:
-
-
the short circuit will either be detected by the circuit-breaking system (fuse for example); in this case, the
voltage reference is grounded, and shielded pair cables must be used (shield is connected to the
ground), or ribbon cable with all unused wires connected to the ground to prevent proximity with hot
potential signals
or a short-circuit detection device must be integrated.
Take care that, as the STO function performs the motor power removal without shutting down the power supply,
electrical risks remain unchanged when the STO function is active or inactive.
In applications with vertical axes, additional measures (mechanical brake) may be necessary.
Refer to the EN13849-2 standard for any complementary information.
4
Chapter 2 – Specifications
GD1 – STO Manual
2.2.2 – STO CONNECTION
2.2.2.1 - X2 Connector
Weidmuller D 32 pins male
Section: 0.25 mm2 (AWG22)
X2 N°
19
20
21
SIGNAL
+24V external
GND external
23
STO2
26
STO_OUT
STO1
DESCRIPTION
External 24 V supply, wired if the STO_OUT output is used
Voltage reference of the STO1/, STO2/ inputs, and STO_OUT output.
Channel 1 input for the STO function inhibition
High level releases the enabling
Channel 2 input for the STO function inhibition
High level releases the enabling
Digital output for state feedback, non safe.
During the installation, take care to avoid proximity between any STO signal and high potential.
2.2.2.2 - Specifications of inputs
3,3 V
8,2 kΩ
Logic input
2,2 nF
100 kΩ
0V external
These optocoupled inputs operate in negative logic.
The input voltage corresponding to level 1 must be between 18 V and 30 V.
2.2.2.3 - Specifications of output
+24V external
+24V external
10 kΩ
330 Ω
Driver
0V
0V external
External supply +24 V (18 V < U < 30 V)
Maximum voltage drop: 2 V
Protection against overload
Available output current per output (mA)
Number of activated outputs / Cycle ratio (%)
2
4
Chapter 2 – Specifications
100 %
200 mA
100 mA
70 %
200 mA
150 mA
50 %
200 mA
200 mA
30 %
200 mA
200 mA
5
GD1 – STO Manual
2.2.3 – TIMINGS
The STO function has an activation / release response time of 15ms / 2ms max.
However, an additional delay of 6,5 ms after STO inputs are high is necessary before the enable/inhibit signal
activation, as mentioned on the following chronogram:
STO1/
t≤50ms
STO2/
25ms
STO_OUT
1ms
15ms
Drive
state
ready
t>50ms
t≤50ms
15ms
2ms
Safe : Warning STO active displayed
0x3024,0.bit0
ready
init
safe
50ms
STO fault, channels 1 & 2 locked
0x3022,1.bit4
0x3022,2.bit23
6,5ms
A functional incoherence state between channels 1 and 2 is allowed during 50ms. The response time of the
monitoring part is 100ms to 200ms.
If the monitoring part detects incoherence between channel 1 and 2, it locks both channels in the safe state. The
STO fault cannot be reset. This state can only be exited by shutting down the 24V power supply. At this moment,
the user must find and solve the problem that caused this fault state.
The STO function has two ways to check the state of the drive: the "STO_OUT" digital output, and objects
fieldbus (STO active warning, STO channel 1 & 2 errors). All these state feedback are provided for informative
purpose and cannot be used as safe information.
!
Take care to automatic restart: When the STO function is disabled, the restart of the machine should only
be possible by an explicit demand to prevent unexpected automatic restart. Take care to this point when
the user program manages the drive start/stop.
Used alone, the STO function corresponds to an uncontrolled stop in accordance with stop category 0 of the EN
60204-1 standard. So, this function is suitable to machines with low inertia or high resistive torque.
When using high inertia or low resistive torque machines, the user should initiate a controlled stop. To achieve a
controlled stop in accordance with stop category 1 of the EN 60204-1 standard, the control system of the machine
must generate the following sequences:
ƒ Deceleration of the load by means of the drive control,
ƒ When the load is at standstill or almost, disabling the PWM.
ƒ Finally, activation of the STO function.
1
STOP
0
Deceleration ramp is
controlled by the drive
SPEED
0
1
ENABLE
PWM
0
24V
STO1
STO2
6
0
Chapter 2 – Specifications
GD1 – STO Manual
2.2.4 – PERFORMANCE LEVEL
(1)
The Safe Torque Off function fulfills category 3 /PLd requirements of the EN ISO 13849-1:2006 standard.
PLd corresponds to SIL2 according to "Table 4 - Relationship between PL and SIL" of the EN ISO 13849-1:2006
standard.
To achieve overall PL by combining safety related parts in series, refer to §6.3 of 13849-1 standard:
SRP/CS1
PL1
SRP/CS2
PL2
PLLOW NLOW
a
>3
≤3
b
>2
≤2
c
>2
≤2
d
>3
≤3
e
>3
≤3
D
D
D
D
D
D
D
D
D
D
D
SRP/CSN
PLN
PL
None, not allowed
a
a
b
b
c
c
d
d
e
NOTE
The values calculated for this look-up
table are based on reliability values at the midpoint for each PL.
(1)
See attached attestation of conformity in chapter 4.
2.2.5 – PERIODIC INSPECTION ROUTINES
The well-working of the function needs to be checked at least once a year and during the validation of the
machine safety functions.
The goal of this procedure is to verify that all subsystems of the safety function are operational. The command
system must integrate a checking mode reserved to an operator aware of potential risks due to a bad operation of
the safety system. It is highly recommended that the operator signs a register in order to sensitize him.
Step
N°
1
2
3
4
5
6
Input
STO1/ STO2/ STO_OUT
1
1
0
0
0
1
1
1
0
0
1
0
1
1
0
X
X
X
State
Motor
Powered
Free
Powered
Free
Free
X
Description
No fault is displayed.
STO active warning is displayed.
No fault is displayed.
STO fault is displayed.
STO fault is displayed and must be unresetable.
Shut down of 24V power supply to reset STO fault
At each step, the operator must verify that the motor provides or not torque,
If the drive behavior is different from the one described in the table above, the drive must be replaced.
2.2.6 – RESIDUAL RISK
In case of short-circuit between two power transistors, there is a residual risk of motor shaft rotation that can
reach: 360° (2p: number of motor poles).
2p
!
Take care of electrical risks, as the STO function performs the motor power removal without shutting
down the power supply and there is no galvanic insulation.
Chapter 2 – Specifications
7
GD1 – STO Manual
Chapter 3 – Connection example
Following diagram examples are given to make the integration of the safety function easier. The integration of the
STO function must be the result of a risk analysis of the complete machine.
3.1 – Example 1: Stop category 0 according to EN 60204-1 complying with EN13849-1 cat. 3
Low inertia axis application / high resistive torque
GD1-uuu/cc/PS-R
X2
Example of inputs
configuration
See User manual
32 AOK+
3
4
24 V
Motor temp.
Motor temp.
31 AOK1 IN1 (ENABLE)
2 IN2 (FC+)
19
20
Ext. reference
26
STO_OUT
21
STO1
23
2
24 Vdc power supply isolated
from the 230 Vac mains
11
3
S2
S4
Resolver
reference
5
4
R1
R2
GND
X9
STO2
Motor brake +
1
Motor brake -
2
X10
CAN-L
CAN-GND
DC+
DC-
+24 Vdc
+
1
2
2
4 A UL listed
GND
brake
1 +24 Vdc
brake
X12
230 Vac
single-phase
3
Power supply inside
GND
Phase
1
Neutral
GND
2
OR
3 φ 400Vac
4
4 A UL listed
+
OTHER AXES
GD1-uuu/cc/00-0
X11
CAN-H
Auxiliary
supply
24 Vdc
+/-15%
isolated
MOTOR
GND
Phase 1
Phase 2
Phase 3
GND 4
Motor U phase 1
Motor V phase 2
Motor W phase 3
Brake
supply
230 Vac
Motor
brake
- 24 Vdc/1.5A
+
Other axes in multiaxIs
X8
-
AC
S3
S1
10
X6, X7
1
2
3
4
5
6
7
8
9
RESOLVER
TC
TC
Resolver
signal
IN3 (FC-)
IN4 (Index)
24 V Ext. if logic
outputs used
X1
12
13
UL compliance
only
3
X12 GND
L1 phase
L2 phase
L3 phase
1
See UL fuses
table
Power
relay
UL compliance
only
GND
Braking resistor
1
Braking resistor
2
X11
1
X11
1
2
2
2
Total power of the application
< 4 kW in 230 V or
< 7 kW in 400 V
Mains
230 Vac
single-phase
20A max.
Mains
3x400V
2
3
4
Power
relay
See UL fuses
table
GND
GND 10
20A max
X11
1
External or
internal
braking
resistor
2
Please note that the motor control must be disabled before activating the STO function.
In the example, the digital input IN1 (enable) is used to disable the PWM control.
A light is wired with STO_OUT output to inform the drive state.
8
Chapter 3 - Connections
GD1 – STO Manual
3.2 – Example 2: Stop category 1 according to EN 60204-1 complying with EN13849-1 cat. 3
High inertia axis application / low resistive torque
In the following diagram, only the STO integration is safe. The deceleration ramp is not safe according to
EN13849-1 because it uses a common drive function.
GD1-uuu/cc/PS-R
Low resistive torque
X2
24V Ext.
S11
Motor temp.
Motor temp.
Example of inputs 32 AOK+
configuration
31 AOKSee User manual
1 IN1 (ENABLE)
2 IN2 (FC+)
3 IN3 (FC-)
4 IN4 (Index)
19 24 V Ext. if logic
outputs used
20 Ext. reference
24V
S21
S1
X1
12
13
RESOLVER
TC
TC
2
S3
S1
Resolver
signal
10
11
3
S2
S4
Resolver
reference
5
4
R1
R2
GND
X9
S12
S22
Y6
Y7
P1
Motor brake +
1
Motor brake -
2
Motor
brake
- 24 Vdc/1.5A
+
S21
X10
26
STO_OUT
P2
21
STO1
PNOZ elvp 10s
23
STO2
S11 S34
P2
1
2
3
4
5
6
7
8
9
P1
Ext. Ref.
14
24
S21
Y5
24 Vdc power supply isolated
from the 230 Vac mains
AC
230 Vac
24 Vdc
+/-15%
isolated
CAN-H
4
GND
3
+24 Vdc
4 A UL listed
+
+
2
4 A UL listed
GND
brake
1 +24 Vdc
brake
Phase
1
Neutral
2
GND
3
OR
Other axes in multiaxIs
UL compliance
only
X12 GND
L1 phase
L2 phase
L3 phase
1
See UL fuses
table
20A max
Power
relay
UL compliance
only
GND
Braking resistor
1
Braking resistor
2
X11
1
X11
1
X11
1
2
2
2
Total power of the application
< 4 kW in 230 V or
< 7 kW in 400 V
Mains
230 Vac
single-phase
20A max.
Mains
3x400V
2
3
4
See UL fuses
table
GND
GND 10
!
1
2
X12
X8
-
OTHER AXES
GD1-uuu/cc/00-0
X11
DC+
DC-
CAN-L
CAN-GND
Power supply inside
S36 Y32
Auxiliary
supply
S35
X6, X7
Brake
supply
A2
MOTOR
GND
Phase 1
Phase 2
Phase 3
GND 4
Motor U phase 1
Motor V phase 2
Motor W phase 3
230 Vac
single-phase
Y4
3 φ 400Vac
A1
Power
relay
External or
internal
braking
resistor
2
For the installation of the safety relay, see PILZ PNOZ e 1vp manuals.
See installation manual of the GD1 servodrives for the complete connection description.
In the connection diagram example above, the PILZ safety relay orders the servodrive to decelerate by the
ENABLE signal, and after a safety delay of 0.5 s, it activates the STO function of the drive.
Note that the behavior of the servodrive on the ENABLE signal activation has to be setup in the appropriate mode
(i.e. speed ramp deceleration) prior to any stop procedure.
In this example diagram, the user does not need to use shielded cables because the PILZ safety relay detects
short-circuits.
The output used to generate the Inhibit/Enable signal does not need to be a safety one because only the STO
function is safe according to EN13849-1 category 3.
A light is wired with STO_OUT output to inform the drive state.
Chapter 3 - Connections
9
GD1 – STO Manual
Chapter 4 – Appendix
4.1 – ATTESTATION OF CONFORMITY
After a deep analysis of the GD1 range, the CETIM (French Industrial and Mechanical Technical Center) third-party
attests the compliance of the GD1 range with the EN954-1 and EN 13849-1 standards:
10
Chapter 4 - Appendix
GD1 – STO Manual
4.2 – ORDER CODE
GD1 – uuu / cc – PS – R – SI – Ex1 – Ex2 – Ex3 – 00 - RS
Voltage: 230 or 400 Vac
Peak current
Power supply inside (00: without)
Additional integrated braking resistor (0: without)
Safety integrated: S1 = Safe Torque Off
Extensions Ex1, Ex2, Ex3:
Each extension slot can receive an extension board.
Can be selected: One bus interface:
PR = Profibus DP, I1 = additional input/output,
EO = Encoder Output
ET = Ethercat
00 = without
00 = reserved
Serial link RS-422 integrated (00 = standard = RS232)
Chapter 4 - Appendix
11