Lenze SM100 E94AYAB User manual

EDS94AYAB

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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



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

5

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



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

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



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

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



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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