SEW-Eurodrive DRC Manuale utente

Drive Technology \ Drive Automation \ System Integration \ Services

Manual

Electronic Motor

DRC

Functional Safety

Edition 10/2013 20186541 / EN

SEW-EURODRIVE—Driving the world

Manual – Functional Safety – DRC Electronic Motor 3

Contents

1 General information ............................................................................................ 4

1.1 How to use this documentation................................................................... 4

1.2 Underlying standards .................................................................................. 4

1.3 Structure of the safety notes ....................................................................... 4

1.4 Rights to claim under warranty ................................................................... 5

1.5 Exclusion of liability..................................................................................... 5

1.6 Content of the documentation..................................................................... 5

1.7 Other applicable documentation ................................................................. 5

1.8 Copyright..................................................................................................... 5

1.9 Product names and trademarks.................................................................. 5

2 Integrated safety technology ............................................................................. 6

2.1 Safe condition ............................................................................................. 6

2.2 Safety concept ............................................................................................ 6

2.3 Safety functions .......................................................................................... 8

2.4 Restrictions ............................................................................................... 10

3 Safety conditions .............................................................................................. 11

3.1 Approved units .......................................................................................... 11

3.2 Installation requirements........................................................................... 12

3.3 External safety controller requirements .................................................... 14

3.4 Startup requirements ................................................................................ 16

3.5 Operational requirements ......................................................................... 16

4 Technical data ................................................................................................... 17

5 Appendix............................................................................................................ 18

5.1 Unit variants with optional standard brake ................................................ 18

5.2 Connection variants .................................................................................. 20

5.3 Connection of an external safety relay for STO ........................................ 25

5.4 Connection of an external safety controller for STO ................................. 29

Index................................................................................................................... 33

4Manual – Functional Safety – DRC Electronic Motor

1How to use this documentation

General information

1 General information

1.1 How to use this documentation

The documentation is an integral part of the product and contains important information

on operation and service. The documentation is written for all employees who assemble,

install, start up, and service this product.

The documentation must be accessible and legible. Make sure that persons responsible

for the system and its operation, as well as persons who work independently on the unit,

have read through the documentation carefully and understood it. If you are unclear

about any of the information in this documentation, or if you require further information,

contact SEW-EURODRIVE.

1.2 Underlying standards

The safety assessment of the unit is based on the following standards and safety

classes:

1.3 Structure of the safety notes

1.3.1 Meaning of signal words

The following table shows the graduation and meaning of the signal words for safety

notes, warnings regarding potential risks of damage to property, and other notes.

1.3.2 Design of the section-related safety notes

Section-related safety notes do not apply to a specific action, but to several actions per-

taining to one subject. The symbols used either indicate a general hazard or a specific

hazard.

This is the formal structure of a safety note for a specific section:

Underlying standards

Safety class / underlying standard

• Performance level (PL) according to EN ISO 13849-

1:2008

• Safety Integrity Level (SIL) according to EN 61800-5-

2:2007

Signal word Meaning Consequences if disregarded

DANGER! Imminent hazard Severe or fatal injuries

WARNING! Possible dangerous situation Severe or fatal injuries

CAUTION! Possible dangerous situation Minor injuries

NOTICE Possible damage to property Damage to the drive system or its envi-

ronment

INFORMATION Useful information or tip: Simpli-

fies handling of the drive sys-

tem.

SIGNAL WORD!

Type and source of danger.

Possible consequence(s) if disregarded.

• Measure(s) to prevent the danger.

Manual – Functional Safety – DRC Electronic Motor 5

Rights to claim under warranty

General information

1.3.3 Design of the embedded safety notes

Embedded safety notes are directly integrated into the instructions just before the de-

scription of the dangerous action.

This is the formal structure of an embedded safety note:

•SIGNAL WORD! Type and source of hazard.

Possible consequence(s) if disregarded.

– Measure(s) to prevent the hazard.

1.4 Rights to claim under warranty

A requirement of fault-free operation and fulfillment of any rights to claim under limited

warranty is that you adhere to the information in the documentation. Therefore read the

documentation before you start working with the unit.

1.5 Exclusion of liability

You must comply with the information contained in this documentation to ensure safe

operation and to achieve the specified product characteristics and performance fea-

tures. SEW-EURODRIVE assumes no liability for injury to persons or damage to equip-

ment or property resulting from non-observance of these operating instructions. In such

cases, any liability for defects is excluded.

1.6 Content of the documentation

This document contains additional safety-related information and conditions for opera-

tion in safety-related applications.

1.7 Other applicable documentation

This document supplements the operating instructions and limits the application notes

according to the following information. Use this document only together with the operat-

ing instructions.

1.8 Copyright

Unauthorized duplication, modification, distribution or any other use of the whole or any

part of this documentation is strictly prohibited.

1.9 Product names and trademarks

All product names in this documentation are trademarks or registered trademarks of

their respective titleholders.

6Manual – Functional Safety – DRC Electronic Motor

2Safe condition

Integrated safety technology

2 Integrated safety technology

The safety technology of the DRC drive unit described below has been developed and

tested in accordance with the following safety requirements:

• SIL 3 according to EN 61800-5-2:2007

• PL e according to EN ISO 13849-1:2008

This was certified by TÜV Nord. Copies of the TÜV certificate and the corresponding re-

port are available from SEW-EURODRIVE on request.

2.1 Safe condition

For safety-related operation of DRC drive units, safe torque off is defined as safe con-

dition (see STO safety function). The underlying safety concept is based on this defini-

tion.

2.2 Safety concept

• The DRC drive unit can be connected to an external safety controller or safety relay.

This disconnects the safety-related STO input via a 2-pole 24 V switching signal

(sourcing/sinking) when a connected control device (e.g. emergency stop button with

latching function) is activated. This activates the STO function (safe disconnection)

of the DRC drive unit.

• An internal, dual-channel structure with diagnostics prevents the generation of pulse

trains at the power output stage (IGBT). On the one hand, the internal supply voltage

for controlling the upper and lower IGBTs is disconnected, and on the other hand the

controlling pulse patterns are short-circuited. This means that the output stage can

no longer supply power to the motor for generating torque.

• Instead of galvanic separation of the drive from the supply system by means of con-

tactors or switches, the disconnection of the STO input described here safely pre-

vents the control of the power semiconductors in the output stage. The rotary-field

generation for the respective motor is deactivated even though the line voltage is still

present.

Manual – Functional Safety – DRC Electronic Motor 7

Safety concept

Integrated safety technology

2.2.1 Schematic representation "Safety concept for DRC"

The following figure shows a schematic representation of the safety concept for the DRC

drive unit:

2463070859

[1] Safety controller/safety relay external

[2] Connection "STO+"

[3] Connection "STO-"

[4] Motor phase

[5] Motor

24V

Safety M

UZ-

UZ+

[1]

[2]

[3]

[4]

[5]

μC

SNT SNT

8Manual – Functional Safety – DRC Electronic Motor

2Safety functions

Integrated safety technology

2.3 Safety functions

The following drive-related safety functions can be used:

•STO (safe torque off according to EN 61800-5-2) by disconnecting the STO input.

If the STO function is activated, the frequency inverter no longer supplies power to

the motor for generating torque. This safety function corresponds to a non-controlled

stop according to EN 60204-1, stop category 0.

The STO input must be disabled by a suitable external safety controller / safety relay.

The following figure shows the STO function:

2463228171

v Velocity

tTime

t1Time at which STO is triggered

Disconnection range

Manual – Functional Safety – DRC Electronic Motor 9

Safety functions

Integrated safety technology

•SS1(c) (safe stop 1, function variant c according to EN 61800-5-2) by means of suit-

able external control (e.g. safety relay with delayed disconnection)

The following sequence is mandatory:

– Decelerate the drive using an appropriate brake ramp specified via setpoints.

– Disconnect the STO input (= triggering the STO function) after a specified safety-

related time delay.

This safety function corresponds to a controlled stop according to EN 60204-1, stop

category 1.

The following figure illustrates the SS1(c) function:

2463226251

v Velocity

tTime

t1Point of time when the brake ramp is initiated

t2Point of time when STO is triggered

∆t Time between initiating the brake ramp and STO

Safe time delay range

Disconnection range

t1tt

10 Manual – Functional Safety – DRC Electronic Motor

2Restrictions

Integrated safety technology

2.4 Restrictions

•The standard brake that can optionally be integrated in DRC drive units is not

safety-related and therefore not part of the safety functions mentioned above.

If the brake controller and/or the motor brake fails, the drive can coast for much lon-

ger depending on the application (i.e. the friction and inertia of the system). In case

of regenerative loads (e.g. lifting axes, declining conveying lines), the drive can even

accelerate. This must be taken into account for a risk analysis of the system/ma-

chine. Additional safety measures might have to be implemented (e.g. safety brake

system).

→The DRC drive unit cannot be used without an additional brake system for appli-

cation-specific safety functions that require active deceleration (braking) of the dan-

gerous movement.

• When using the SS1(c) function as described in chapter "Safety functions", the brake

ramp of the drive is not monitored with respect to safety. In case of a fault, the drive

might not be decelerated after the delay time, or it might be accelerated in the worst

case. In this case, the STO function (see chapter "Safety functions") is only activated

after the set time delay has elapsed. The resulting danger must be taken into account

in the risk assessment of the system/machine. Additional safety measures might

have to be implemented.

WARNING

The safety concept is only suitable for performing mechanical work on the system/ma-

chine components.

If the STO signal is disconnected, the supply system voltage is still present at the DC

link of the DRC.

Severe or fatal injuries from electric shock.

• Before working on the electric part of the drive system, disconnect it from the sup-

ply system using an appropriate external disconnecting device and secure it

against unintentional reconnection to the power supply.

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