Functional Safety GB BU 0230 Functional Safety Supplementary Manual for Frequency Inverter SK 200E
Functional safety with NORD SK 200E frequency inverters Safety information N O R D Frequency inverters Safety and operating instructions for drive power converters (as per: Low Voltage Directive 2006/95/EEC ) 1. General Depending on their protection class, drive power converters may have live, bare, moving or rotating parts or hot surfaces during operation. Unauthorised removal of covers, improper use, incorrect installation or operation causes a risk of serious personal injury or material damage.
Functional safety with NORD SK 200E frequency inverters About this document Documentation Designation: BU 0230 GB Part No.: 607 23 02 Device series: SK 205E, SK 210E, SK 215E, SK230E, SK 235E Version list Designation of previous issues Software Version Remarks BU 0230 GB, July 2009 V 1.1 R2 First issue based on BU 0530 GB / 4707 Part No.
Functional safety with NORD SK 200E frequency inverters About this document Scope of Application These instructions are only applicable to devices whose type can be derived from the following key: SK 205 E- 250 - 112 -O 215 370 235 550 -C 750 SK 205 E- 250 - 123 -A 215 370 235 550 -C 750 111 151 SK 210 E- 250 - 123 -A 230 370 -C 550 SK 205 E- 250 - 323 -A 210 370 215 550 230 750 235 111 -C 151 221 301 401 SK 210 E- 551 - 323 -A 230 751 -C 112 SK 205 E- 550 - 340 -A 210 750
Table of Contents 1 GENERAL .................................................................................................................................7 1.1 Safety and installationinformation ........................................................................7 1.2 Approvals and certificates ....................................................................................8 1.2.1 Certificate for the STO function for use as a safe shut-down method ...................... 9 1.2.
Functional safety with NORD SK 200E frequency inverters 6 SAFETY CATEGORIES ......................................................................................................... 60 6.1 IEC 60204-1:2005 ............................................................................................. 60 6.2 IEC 61800-5-2:2007 .......................................................................................... 60 6.3 IEC 61508:2010 ........................................................................
1 General 1 General This manual BU 0230 DE describes the aspects that are directly related to the functional safety of the equipment. All standard functions and parameters of the inverter are contained in the Manual (BU 0200 GB). 1.1 Safety and installation information SK 2xxE frequency inverters are devices for use in industrial high voltage systems and are operated at voltages that could lead to severe injuries or death if they are touched.
Functional safety with NORD SK 200E frequency inverters CAUTION The heat sink and all other metal components can heat up to temperatures above 70 ℃. When mounting, sufficient distance from neighbouring components must be maintained. When working on the components, allow sufficient cooling time beforehand Protection against accidental contact may need to be provided. ATTENTION The power unit can continue to carry voltages for up to 5 minutes after being switched off at the mains.
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1 General 1.3 Identification System Size 1-3 Ordering designation SK 2xxE S 1-3 SK Example: 205 E- 751 - 340-A - XXX Configuration 200 4x dig. IN, 2x dig. OUT, 2x analog IN, RS232/485, internal supply of the control unit 205 4x dig. IN, 1x dig. OUT, RS232/485, external 24V supply 210 As for "200", but with 3x dig. IN and additional "safe pulse block" 215 As for "205", but with 3x dig.
Functional safety with NORD SK 200E frequency inverters 1.4 Identification System Size 4 Order designation for SK 2xxE Size 4 SK Example: 200 E- 222 - 340-A - XXX Configuration 200 Power supply for control unit via mains connection, 24V- supply in case of mains failure possible, 4x dig. IN, 2x analog IN, 2x dig. OUT, RS232/485 210 as for "200", however 3x dig. IN and additional "safe pulse block" 220 As for "200" but with additional As interface 230 as for "200", however 3x dig.
2 Description of function 2 Function description To avoid danger to persons and to prevent damage to material, machines must be able to be switched off safely. NORDAC SK 205E, SK 210E, SK 215E, SK 230E and SK 235E series frequency inverters provide safe shut-down methods. In order to understand the function of the shut-down methods, it is first of all necessary to consider the function of the frequency inverter.
Functional safety with NORD SK 200E frequency inverters 6 Driver C = Low 1x High = power) (Primary voltage Internal voltage block" pulse "safe Option Control GND_SH circuitry Input 24V_SH Control D N G = V 4 2 = 3x stop µ Logic O / Emergency I = = T W M V U 5 T 3 T 4 T 1 T 2 T Inverter 1 2 L 3 L L Frequency Size 4: The semiconductor switches of the inverter (T1 to T6) are controlled by a highly complex pulse pattern.
2 Description of function 2.1 Safe shut-down method With the aid of a safe shut-down method the torque is now to be safely shut down. This corresponds to the safety function STO (safe torque off). In order to switch off the torque, the current to the motor must be interrupted.
Functional safety with NORD SK 200E frequency inverters Safety output or 24V or 24V 24V 44 24V SH Safety output 40 Safety output NOTE GND SH Frequency inverter For devices with an AS interface (SK 225E und SK 235E) the 24V can and may not be used as a safe shut-down method "Switch-off of the 24V supply". For the devices SK 200E, SK 210E, SK 220E and SK 230E the control unit is powered via a link circuit which is supplied from a mains unit.
2 Description of function 2.3.2 Safe stop 1, SS1 With the SS1 function, the motor is first stopped by the inverter and after standstill the device switches to the STO function. This method is the same as stop category 1 (controlled stop) as per IEC60204-1. Switching to the STO function can be monitored after reaching standstill or can be carried out via a fail-safe timing relay (delayed output of a protective switching device).
Functional safety with NORD SK 200E frequency inverters 2.4 Examples / Implementation The following illustrates several examples of solutions for the safety functions STO and SS1. 2.4.1 STO function Normally, a protective switching device is used to implement a safety function. The safety category of the function is determined by the component with the lowest category.
2 Description of function This solution is preferable, especially in cases where the switching device only checks its safety outputs in the course of an enabling cycle, as is the case with some electro-mechanical switching devices. A suitable checking interval must be specified according to the safety requirements. NOTE A separate shielded cable must be used for the "safe pulse block" or "switch-off of the 24V supply".
Functional safety with NORD SK 200E frequency inverters 2.4.2 SS1 Function A digital input is always required for the implementation of the SS1 function in order to initiate a braking process performed by the inverter. For this, the digital input used is set to the function "fast stop" [11].
2 Description of function 2.4.3 Simple restart block Safety Category 4 as per DIN ISO 13849-1 can be achieved with a direct dual-channel triggering of the "safe pulse block" with the aid of a safe switching element. The following illustration shows an example with an emergency stop switch (guided contacts, Safety Category 4).
Functional safety with NORD SK 200E frequency inverters 2.4.4 Example without safe shut-down method It is possible to implement the safety functions STO or SS1 with a digital input and a protective switching device. With this switching version, as a maximum, Safety Category 1 as per DIN EN ISO 13849-1 can be achieved, if in addition to the digital inputs, all other components (protective switching device, emergency stop button, wiring) fulfil the requirements for Category 1.
2 Description of function 2.4.5 Ruling out wiring faults In the examples above, a separate shielded cable, whose shield is connected at both ends is used each of the inputs used for the implementation of the safety function. This measures serves to rule out faults as per DIN EN ISO 13849-1 in case of a short circuit between any of the conductors. This exclusion of faults is necessary in order to fulfil the requirements of Safety Category 4 as per DIN EN ISO 13849-1.
Functional safety with NORD SK 200E frequency inverters 3 Assembly and installation The installation instructions contained within this manual only deal with issues that are related to functional safety. Additional information is contained in the manual (BU 0200 GB). 3.1 Installation and assembly The installation instructions contained in BU0200 GB must be observed! 3.
3 Assembly and installation LABELLING, FUNCTION SH: "Safe stop" function„ DOUT: Digital output ASI: Integrated AS interface 24V SH: "Safe stop" input 24V: 24V power supply GND SH: "Safe stop" reference potential AGND: Reference potential for analogue signals SYS+/-: System bus MB+/-: GND: Reference potential for digital signals Electromagnetic brake control (105V, 180V, 205V) TF+/-: Motor PTC connection DIN: Digital input CONNECTIONS AND FUNCTIONS FOR SK 2XXE VERSIONS DEPENDING ON CO
Functional safety with NORD SK 200E frequency inverters Size 4 FI type SK 200E SK 210E SK 220E SK 230E (SH) (ASI) (SH+ASI) Pin Labelling 1 43 24V (internal, output max. 750mA) 2 43 24V (internal, output max.
3 Assembly and installation 3.5 Safe pulse block A two-wire shielded cable must be used for the safe pulse block. The shield must be connected at on both ends. For mechanical switching devices the line drop in the cable must not exceed ΔUCable ≤ 3 V and for electronic protective switching devices it must not exceed ΔUCable ≤ 1 V. The peak current IIN,Peak = 500 mA for Sizes 1 to 3 or IIN,Peak = 500 mA for size 4 should be used for the calculation.
Functional safety with NORD SK 200E frequency inverters 3.5.4 EMC With EMC-compliant wiring of the "safe pulse block", the EMC guideline values (see BU 0200 GB) can be complied with up to a cable length of 100m between the protective switching device and the inverter. 3.6 24 V supply If the 24 V supply is used as the safe shut-down method, a dual conductor, shielded cable must be used. The shield must be connected at on both ends. NOTE No optional modules (e.g.
3 Assembly and installation 3.6.1 Details of the 24V supply Terminal/ Function Name Data Description / wiring suggestion Parameter [factory setting] SK 205E, SK 215E, SK 225E, SK 235E 44 24V 24 V Supply (module and system bus level) 40 GND Reference potential for the 24 V supply and the digital signals 24 VDC -/+25 % (-10 % / +25 % at OSSD) 200 mA ...
Functional safety with NORD SK 200E frequency inverters Spitzenstrom (ohne Belastung DO1) Peak current (without load fromvon DO1) 5A 21,6V 24,0V 30,0V 4A 3A 2A 1A 0A 0,0Ω 0,5Ω 1,0Ω 1,5Ω 2,0Ω 2,5Ω 3,0Ω Leitungswiderstand Cable resistance Peak current (DO1 with load ofbelastet) 200mA) Spitzenstrom mit 200mA 7A 21,6V 24,0V 6A 30,0V 5A 4A 3A 2A 1A 0A 0,0Ω 0,5Ω 1,0Ω 1,5Ω 2,0Ω 2,5Ω 3,0Ω Cable resistance Leitungswiderstand This current only occurs for a short time after a test pulse from
3 Assembly and installation R CU * l q with CU 19 * mm km Double the length of cable must be used because line drops occur in both wires. R 0.5 or R * NumberFI 3 => for a digital output without load, an input voltage of at least 22V is required. 3.6.4 EMC With EMC-compliant wiring, the EMC guideline values (see BU 0200 GB) can be complied with up to a cable length of 100m between the sprotective switching device and the inverter. 3.7 Digital inputs 3.7.
Functional safety with NORD SK 200E frequency inverters 3.8 Digital outputs The digital output can be used to indicate the status of the "safe pulse block". It should be noted that this status indication is not fail-safe. Terminal/ Function Name Data Description / wiring suggestion Parameter [factory setting] SK 200E, SK 210E, SK 220E, SK 230E 1 3 DO1 DO2 Output 1 Digital output (24V) [Fault] max. 20 mA (Size 1 to 3) Output 2 max. 50 mA (Size 4) [Fault] max.
4 Parameterisation 4 Parameterisation In this manual, only those parameters and configurations are listed, which are of immediate significance to functional safety. For additional information, please refer to the instructions in manual BU 0200 GB. ATTENTION To implement the STO function, the "block voltage"function [10] must be assigned to the appropriate parameter (P420 [-01]…[-04], depending on the digital input selected (DIN1 … DIN4).
Functional safety with NORD SK 200E frequency inverters List of the functions relevant to functional safety for the digital inputs P420[-01] ... [-04] Value 00 Function Description Signal No function Input switched off. 10 1 Disable voltage The FI output voltage is switched off; the motor runs down freely. Low 11 1 Emergency stop The FI reduces the frequency according to the programmed fast stop time P426.
4 Parameterisation List of functions relevant to the functional safety of digital output P434 Value Function Description Output ... with limiting value or function (see P435) 0 No function Output switched off. 1 External brake To control an external 24V brake relay. The output switches at a programmed absolute minimum frequency (P505). also Low For typical brakes a setpoint delay of 0.2-0.3 s should be programmed (see also P107/P114).
Functional safety with NORD SK 200E frequency inverters Parameter Setting value / Description / Note [factory setting] P481 ... [-01] ... ... [-10] 0 ... 39 Device Supervisor Parameter set Function Bus I/O Out Bits The bus I/O Out bits are perceived as multi-function relay outputs. They can be set to the same functions (P434).
4 Parameterisation Status word (ZSW) In the inverter response telegram, in the area of the process data the status word (ZSW) is transferred as the first word.
Functional safety with NORD SK 200E frequency inverters 4.2 Extra functions Parameter Setting value / Description / Note [factory setting] P506 Device Supervisor Autom. error acknowledgement 0 ... 7 Parameter set S Automatic error acknowledgement should not be used in association with a safety function. 0 = No automatic error acknowledgement. [0] A full description of the function can be found in Manual BU 0200 GB. EEPROM copy order P550 (EEPROM copy order) 0 ... 3 {0} From Firmware V1.
4 Parameterisation Parameter Setting value / Description / Note Device Supervisor Parameter set Note SimpleBox: with the Simplebox only warning messages and errors can be displayed. Display of the messages is in encoded form. For the description of the codes (warning/error numbers), please refer to the tables in BU 0200. ParameterBox: with the ParameterBox the messages are displayed in plain text.. In addition, the reason for a possible disabling of starting can also be displayed.
Functional safety with NORD SK 200E frequency inverters Parameter P708 Setting value / Description / Note Device Parameter set Supervisor Status of digital inputs 00000 ... 11111 (binary) Displays the status of the digital inputs in binary/hexadecimal code. This display can be used to check the input signals. or Bit 0 = Digital input 1 Bit 3 = Digital input 4 0000 ...
4 Parameterisation Parameter P741 Setting value / Description / Note [-01] ... Device Process data Bus Out Supervisor Parameter set S [-10] 0000 ... FFFF (hex) This parameter provides information about the actual status word and the actual values that are transferred via the bus systems.
Functional safety with NORD SK 200E frequency inverters 5 Protective switching devices The safety switching device used for the intended purpose, as well as all additional components required to implement a safety function, must fulfil the requirements of the special application in accordance to the risk analysis. The switching device outputs must fulfil the following basic conditions: 5.
5 Protective switching devices 5.3 OSSD outputs, test pulse toff ≤ 0.5ms (width of test pulse) Maximum time for which the output of the safety switching device is switched off for test purposes. D ≥ 90% (Duty) The supply voltage is applied for at least 90% of the time. I.e. for a test pulse of t off=0.5 ms the supply voltage is subsequently applied for at least ton=4.5 ms. Double pulses are permitted when the two pulses are at least 1ms apart and the condition for D is observed.
Functional safety with NORD SK 200E frequency inverters 6 Safety categories 6.1 IEC 60204-1:2005 (German version EN 60204-1:2006) The requirements of a Category 0 and Category 1 stop function can be fulfilled by the "safe pulse block". The controlled braking for Category 1 is not fail-safe via the standard functions of the frequency inverter. The switch-over to the stop function of Category 0 is fail-safe. 6.
6 Safety categories 6.4 ISO 13849-1:2006 (German version EN ISO 13849-1:2008) For the safety-relevant stop functions STO and SS1 (designation as per IEC 61800-5-2:2007), frequency inverters with the safe shut-down methods "safe pulse block" and "switch-off of the 24 V supply" fulfil the requirements for Performance Level e. This ensures that safety category 4 can be achieved.
Functional safety with NORD SK 200E frequency inverters 7 Commissioning Only the requirements for functional safety will be dealt with here. A detailed section regarding the commissioning of the standard functions of the SK 200E frequency inverter can be found in the manual BU 0200 GB. ATTENTION The frequency inverter is not equipped with a line main switch and is therefore always live when connected to the power supply. Live voltages may therefore be connected to a connected motor at standstill.
7 Commissioning NOTE FACTORY SETTING, AS DELIVERED! *) As delivered, all DIP switches are in the "0" ("off") position. Control is by means of the digital control signals (P420 [01]-[04]) and the potentiometers P1 and P2 integrated in the FI (P400 [01]-[02]) (P1 / P2 only SK 2x5E and SK 2x0E Size IV). A detailed and complete description of each parameter is contained in BU 0200 GB.
Functional safety with NORD SK 200E frequency inverters SS1: DIP switches S1:4 and S1:5 must be set to the "0" ("off") position. The setting of the DIP switches is evaluated on application of the 24 V supply and can be checked with the aid of parameter P749. A safety output of the protective switching device is connected to a digital input. It is recommended that a shielded cable is used for this.
8 Diagnosis 8 Diagnosis 8.1 Diagnostic LEDs SK 2xxE devices are equipped with various LEDs for diagnostic purposes. In addition, SK 2x5E devices Size IV SK 2x0E devices also have additional LEDs which indicate the statuses of the inputs and outputs of the frequency inverter. SK 2x5E SK 2x0E RJ12 RS 232 RS 485 Diagnostic LEDs P1 / P2 LED-FI LED-ASi Top view of SK 2x0E Size 4 resp.
Functional safety with NORD SK 200E frequency inverters Status LEDs LED Name Colour Description Signal status Meaning DS dual Inverter status off FI not on standby, green on FI on standby no mains and control voltage red/green green flashing 0.
9 Error messages 9 Error messages Basic information on this topic is contained in the operating manual BU 0200 GB. The following section describes the error messages, which are assigned to functional safety. 9.1 Table of possible error messages Display in the SimpleBox Fault Cause Group Text in the ParameterBox Details in P700 / P701 Remedy E008 8.
Functional safety with NORD SK 200E frequency inverters 9.3 Error memory The current error is saved in parameter P700 and the last five error messages are saved in parameter P701 [-01]…[-05]. Further information on inverter status at the time the error occurred are stored in parameters P702 to P706 / P799. More detailed information can be found in the manual BU 0200 GB.
10 Technical data 10 Technical data Further data which is not listed here can be obtained from the manual for the basic device (BU0200). 10.1 Environmental data Function Specification Ambient temperature -25 °C…to +40 °C (+50 °C in S3 operation) Note: The derating specifications (power, current, duration of switch-on) depending on the type of inverter and the cooling conditions must be taken into consideration. (see Manual BU 0200 GB) Storage temperature -25 °C ...
Functional safety with NORD SK 200E frequency inverters 10.3 Control terminal data in Size IV Function Specification Tools Screw terminals, 3.5 mm slot-head screwdriver Starting torque 0.5 ... 0.6 Nm Connection cross-section 0.2 … 2.5 mm : rigid or flexible 2 AWG 24-14, 2 0.25 … 2.5 mm : flexible with wire end sleeve with or without plastic tube 2 Connection cross-section 0.2 … 0.75 mm : rigid for connection of multiple wires 0.2 … 0.75 mm : flexible 2 2 0.25 … 0.
10 Technical data 10.4 Data for the digital inputs Function Specification Input voltage 24 V -37.5 % +25 %, 15 V…30 V High level 15 V … 30 V Low level 0V…5V Input resistance ~ 9.5 kΩ for the Low level ~ 2.5 kΩ…3,5 kΩ für den High Pegel Input capacitance Input 1 + 4 = 10 nF Input 2 + 3 = 1.
Functional safety with NORD SK 200E frequency inverters 10.
10 Technical data 10.6 Data for switching off the 24V supply (only for SK 205E, SK 215E Size 1 to 3) Function Specification Input voltage +24 V Voltage tolerance ±25 % Operation at OSSD -10 % +25 % Power consumption ≤ 500 mA (mean value) (18 V…30 V) (21.6 V…30 V) For details see Section 24 V supply Peak current ≤ 1 A (Peak, on switch-on) ≤ 6.5 A (Peak, on OSSD) For details see Section 24 V supply Cable length ≤ 100 m (refer to EMC, grouping) Line capacitance ≤ 2 nF * tOSSD / 0.
Functional safety with NORD SK 200E frequency inverters 11 Additional information 11.1 Maintenance and servicing information In normal use, NORDAC SK 200E frequency inverters are maintenance free. Please also refer to the "General Data" in manual BU 0200 GB. If the frequency converter is being used in a dusty environment, the cooling-vane surfaces should be regularly cleaned with compressed air.
12 Keyword index 12 Keyword index 2 24V supply ................................. 73 G Grounded Corner ....................... 40 R Repairs ....................................... 74 Restart block ............................... 37 B I S Beispiel (Restart block) .............. 37 IEC 60204-1 ............................... 60 Bus I/O Out Bits ......................... 52 IEC 61508 .................................. 60 Safe pulse block ......................... 31 IEC 61800-3 ....................
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