OPD EXP STO-SAFE TORQUE OFF USER GUIDE OPD EXP STO
Contents
1. OPD SIZE S _ TEN DN PPR SOS RR OV X3 OP DR 24V DR STO FB1 B STO FB1 A N C 0P_STO_2 STO 2 N C STO_FB2_B STO_FB2_A 24V N LE OPD SIZE L STO Safe Torque Off Rev 1 3 30 11 11 EN ZI Ed EI EI ET EI EI EX ET N Bb AON CO X3 OP DR 24V DR STO FB1 B STO FB1 A N C OP STO 2 STO 2 N C STO FB2 B STO FB2 A DV 24V er E E B 9 9 B 0 0 0 0 0 0 0 0 0 gt elolele gt 6 N Bb 0 EN RR A ar O IR OPD SIZE M X3 OP DR 24V DR2. 1834 e MODULO PILZ 9 OP DR o Hm PLC emergenza a 24V AL o a OP AL e A Example 1 Example 2 is a diagram where the operation is started by a field bus and therefore it is the PLC itself which having read the emergency signal controls the converter to activate the motor stop procedure As is example 1 also in this case the STO system is activated by the timed contacts of the Pilz module WARNING If the connection C73 0 to be able to go on run is necessary that the PLC provides a command to reset alarms To exit safe condition once you restore the security module you must wait for the time indicated in Tab 2 reset the alarm and then provide the run command SW C21 1 In case C73 1 the sequence to follow is the same as that for C73 0 but it is not necessary for the PLC provides a command of reset alarms Example 3 shows an application where the PLC is able to read both the status of the incoming STO signals and the feedback signals This means that it is possible to conduct a regular check on the PLC which compares the incoming status with the feedback status If the PLC notices a discrepancy it means there is a failure which will be reported STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 4 DR 17 47 1 0 4 1 0 4 Nat Danger oatz Failure feedback canale 1 Feedback carnale 2 MODUL O PILZ eanale 1 0
3. DR St canade 2 1 PLC ae 23 x w 24 ALS 1 DP Al ae OPEN DRIVE EXP Example 2 MV DRo EY di 85 ars M3 LDA Mai Career 68 8 Los Fahne Ai LAPS AP HS Feedback canale 1 EMERGENZA AP ara uy Feedback camale 7 Anz 1 ara ar MODULO FILZ 9 ale 1 Cars ara 0 DR 4 amada 2 7 dr 5 Se CONS ETS mt Cla v M Ans a a ami Mi E stato 881 wk Era stato 882 E stato CHI E stalo CH stao 851 Dangerous MV 6 1 LUH E AL o OPEN DRIVE EXP Example 3 STO Safe Torque Off Rev 1 3 30 11 11 EN 17 18 OPD EXP 8 TECHNICAL DATA The technical data change with the power sizes because the used components change in the safety channel EN 61800 5 2 LL OPDE 03 60 A OPDE7O 150A SIL PFH Hardware Fault Tolerance Lifetime EN ISO 13849 1 o OPDE 03 60 A OPDE 70 150 PL d d Categoria 3 3 MTTFg 39 6 anni 342 7 anni STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP STO Safe Torque Off Rev 1 3 30 11 11 EN BLU 20 OPD EXP STO Safe Torque Off Rev 1 3 30 11 11 EN
4. 1 3 30 11 11 EN 10 OPD EXP 5 DESCRIPTION OF STO OPERATION ON OPEN DRIVE 5 1 ENABLING THE STO SYSTEM If the converter is working normally that is to say the STO system is disabled is necessary to power the 24V of the adjustment X3 as well as 24VDR and STO 2 In this situation the clean monitor contacts STO FB1 and STO FB2 will both have to be open To enable the safety system follow this procedure a stop the motor disconnect operation c disconnect 24 DR d disconnect STO 2 it is possible to carry out operations a and b only by disconnecting operation if the converter settings include stop at minimum speed C28 1 In this case the converter brings the motor to the minimum speed set to zero through the parameter P50 then disconnects operation in the presence of external influences for example falling suspended loads it might be necessary to take extra precautions for example mechanical brakes to prevent any risk 3 the sequence followed for items and d is not relevant for example the signals STO 2 and 24V DR can also be temporarily disconnected CAUTION enabling the STO system while the machine is running causes total loss of motor control Enable the STO system only after its operation has been stopped following the procedure described above DANGER the terminal boards U V W F remain live No maintenance work must be conducted and electrical component
5. STO FB1 B STO FB1 A N C OP STO 2 STO 2 N C STO_FB2_B STO_FB2_A X3 OP DR 24V DR STO FB1 8 STO FB1 A N C OPD SIZE X OP STO 2 STO 2 N C STO FB2 B STO FB2 A IDE MACNO 7 88485 6 000 D FEEDBACK O 00000000 0000000 O 00000000 0000000 gt D AFE FUNCTION ANYBUS ENC SIM PTC O ON OO GG P WD X3 y CASE 1 2 3 OPD EXP STO_FB2_A STO 82 8 N C STO 2 OP STO 2 N C STO FB1 A STO FB1 B 24V DR OP DR 24V OV STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 4 EXTERNAL CONNECTIONS The following paragraphs provide indications about the OPEN DRIVE connection only as regards the feeding of the adjustment card and STO safety syst
6. conditions it is necessary to do the following C73 0 Wait at least 100ms after introducing 24V_DR then enable the alarm reset In this condition the 017 logic output power electronic card not powered reaches a low level The 00 logic output Drive ready is on high which means that the converter is ready to work C73 1 The converter behaves in the same way as with C73 0 except that it is not necessary to enable the alarm reset ATTENTION If the run command is given before the maximum time of out by STO function indicated in Tab 2 the driver shows the alarm A12 with d49 1 run without precharge STO Safe Torque Off Rev 1 3 30 11 11 EN A A OPD EXP 6 DIAGNOSTIC SYSTEM When the safe function is active the feedback signals indicate if the safe function has been executed correctly it is necessary to control these feedback signals with the aim to distinguish between Basic diagnostic compulsory Intelligent diagnostic optional 6 1 BASIC DIAGNOSTIC The basic diagnostic is compulsory then it has to be always executed because it represents a basic control for the correct working of STO function To satisfy the basic diagnostic is necessary that a The feedback signals and the digital output 023 Not Dangerous Failure are monitored at every machine start on which is mounted the drive The machine start will be executed if the feedback contacts STO_FB1 are STO FB2 are both closed
7. feedback signals both active and if the output 023 Not Dangerous Failure is high b The reset command which brings out the machine from the state of emergency stop is enabled if during the state of emergency stop the feedback contacts are both closed and the digital output 023 Not Dangerous Failure is high See paragraph 7 for some examples of connections that satisfy these prescriptions 6 2 INTELLIGENT DIAGNOSTIC The intelligent diagnostic is optional and can be used if the STO function is controlled by a PLC or by an other intelligent system It consists to perform periodically a Two test sequences one for each of the two channels which allow to detect any failure of the safety function before it is turned on will be discussed later in FB1 and FB2 control b control of the logic output state 023 Not Dangerous Failure will be discussed later in Not Dangerous Failure output logic control Below are described in detail the two controls 6 2 1 FB1 AND FB2 CONTROL Looking at the congruence between the feedback signals and the presence or absence of the control voltage in input to the two channels of the STO it s possible run the control sequences that allow you to detect some faults on safety channels CAUTION The control sequences of the two safety channels must be performed one at a time and not simultaneously The maximum time of entry and exit safe condition are shown in the follo
8. must not be touched CAUTION after power has been disconnected both channels take time to return to a safe condition The times are indicated below CHANNEL 1 Maximum time after 24V DR has been disconnected CHANNEL 2 Maximum time after STO 2 has been disconnected DANGER on brushless motors with permanent magnets in the event of simultaneous failure of the two power switches motor movement is possible up to 180 electrical equal to 180 n polar motor couples mechanical degrees In this situation the feedback contacts STO EBI and STO FB2 will both have to be closed Any discrepancy in only one of the monitor contacis compared to the converter status indicate a failure In this case the safety system might not work correcily and needs to be immediately repaired Apart from the feedback contacts available outside inside the OPEN DRIVE there is a feedback signal only for channel 1 used by the adjustment card to manage this situation When the connection enable safety stop only as signal is disabled C73 0 which is the default configuration the converter indicates this status with the alarm presence A13 con d49 1 In this situation the logic output 017 power electronic card not supplied switches to high the logic output 00 to low the drive ready is disconnected and the power insertion control is disconnected With the C73 1 connection the converter still brings to a high level the logic output 017 power electronic ca
9. 50Hz 1 g In the event of vibrations exceeding the limits indicated above suitable reduction measures will have to be adopted 2 4 PROTECTION AND POLLUTION DEGREE Protection degree IP20 Pollution degree Dam Non conductive pollution and occasionally and temporarily conductive pollution generated by condensation 2 5 STORAGE 2 5 1 Environmental Storage Conditions temperature 10 60 C humidity 5 95 Yo condensation NO 2 5 2 Recovery Procedure After Storage The converter cannot be used immediately after a storage period To avoid converter failures use the following recovery procedure PHASE 1 Non powered converter temperature humidity condensation Atmospheric pressure Recovery time After this recovery time there must be no trace of condensation inside or outside the operation well aired environment PHASE 2 For long storage periods one or more months regenerate the electrolytic condensers of the power bus Feed the converter from the terminal boards L1 L2 and L3 for 30min 1 hour without letting it run Once the regeneration process has been completed the converter can work normally STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 3 ADJUSTMENT AND DRIVERS SUPPLY 3 1 TERMINAL BOARD DESCRIPTION The following tables list the terminal boards used to feed the OPEN DRIVE cards and to perform the diagnostic work on the STO system Adjustment card feeding Descriptio
10. BLU x OPD EXP STO SAFE TORQUE OFF USER GUIDE OPD EXP SUMMARY GENERALDESCEIPMON ESS a sn 2 e SELINA en 3 2 1 CLIMATE CLAS Sea ee ee ee 3 2 2 RESISTANCE TO CHEMICALLY ACTIVE SUBSTANCES RR 000 3 2 3 RESISTANCE TO VIBRATIONS essen een 4 2 4 PROTECTION AND POLLUTION DEOGREE erre 4 2 5 STORAGE eenig 4 2 5 1 Environmental Storage Conditions ss 4 2 5 2 Recovery Procedure After Storage 4 3 ADJUSTMENT AND DRIVERS SUPPLY ec cecceeeeeeeeeeeeeeeeeees 5 3 1 TERMINAL BOARD DESCRIPTION EE 5 3 2 TERMINAL BOARD POSITIONS u a ia 7 4 EXTERNAL CONNECTIONS 9 5505555555555955495559559955995599 9 4 9 5 DESCRIPTION OF STO OPERATION ON OPEN DRIVE 10 5 1 ENABEING THE STO SYSTEM WE 10 5 2 DISABLING THE STO STO EM ne 11 6 DIAGNOSEISSYSTEN sangen 12 6 1 BASIC DIAGNOSTICO ee een 12 6 2 INTELLIGENT DlAOGNOGSTIC 12 6 2 1 FB1 AND FB2 CONTROL 12 6 2 2 NOT DANGEROUS FAILURE LOGICAL OUTPUT CONTROL o000000nan0nnnnnnnnnnnnnnnnnnne 14 7 APPLICATION ESAMDIEG 15 8 TECHNICAL DATA 18 KEY TO SYMBOLS A Caution A Danger STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 1 GENERAL DESCRIPTION The OPEN DRIVE converter implements the Safe Torque Off STO system to prevent unexpected starting according to the EN 61800 5 2 standards This system prevents the creation of a rotating magnetic field by dis
11. connected from the converter causing its controlled stop The PLC is informed that the emergency button has been pressed through the connection to its digital input After a given delay also the timed contacts of the Pilz module are opened which enable the two channels of the STO system only when the motor has already been stopped The delay time must be longer than the controlled stop time The feedback contacts of the STO systems are connected in series to the reset button which makes possible to leave the emergency stop condition Therefore resetting is enabled only if the feedback contacts are closed at the same time as the STO system is enabled If this does not happen it means that there a failure has occurred in the converter and the feedback contact will remain open This makes it possible to check the feedbacks of the STO system every time the machine is reset Warning this example works correctly with the connection C73 0 To be able to go running it s necessary provide a reset pulse alarm on terminal M1 on pin 1 e g PLC To exit by safe condition once you restore the security module it s necessary wait for the time indicated in Table 2 and then provide the pulse for alarm reset STO Safe Torque Off Rev 1 3 30 11 11 EN A OPD EXP 24V DR o pulsante di ripristino 9 1 0 4 Not Dangerous CCC Failure pf feedback canale 1 pe EMERGENZA _f feedback canale 2 L ca e 522 33
12. connecting the control voltage from the power semiconductors Thanks to these systems it will be possible to conduct short operations such as cleaning and or maintenance work on the non electrical parts of the machine without disconnecting either the drive power supply or the connection between power and engine The STO system therefore will be managed by components with limited power which means that the cost of the elements used in the switchboards will be reduced The STO system is implemented using two redundant channels each of which has its own feedback signal accessible from the outside The operating diagram is as follows IGNITER CARD 24V DR CHANNEL 1 DO Feedback channel 1 STO FB1 A Ps o CHANNEL 2 A INVERTER STO FB2 E Feedback channel 2 STO FB2 A The input to channel 1 is 24VDR and its feedback signal is STO FB1 The input to channel 2 is STO 2 and its feedback is STO FB2 Each of the feedbacks refers to a clean N C contact which can be read by an external logic managing the STO system at machine level STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 2 USE LIMITATIONS The environmental constraints of the OPEN DRIVE converter are listed in a section of the installation manual and refer to its normal operation The following paragraphs serve to clarify the use limitations of the converter with a view to making sure that its correct operation continues also when the STO system
13. em For the remaining connections please refer to the OPD installation handbook As indicated in par 3 1 the terminal board X3 can be powered by the adjustment card 24V On the other hand the terminal board S1 power the pilot drivers of the power IGBT and the relay which carries the controls of the adjustment card to the drivers The signals 24V DR referring to OP DR and STO 2 referring to OP STO 2 each relate to one channel of the STO safety system For this reason it is particularly important to pay great attention when cabling these signals from the OPEN DRIVE to the safety module used on the switchboard a Forthe X3 connection use a screened two way cable whose strap must be connected to the OP signal Normally a screened cable is not required for adjustment powering A screened cable is chosen to make sure that in the event of failure of the powering cables the safety system is disconnected The reason is that the terminal board X3 is close to the terminal board S1 the powering cables for X3 and those for S1 will reach the converter inside the same conduit b For the first channel connection 24V DR e OP DR use a screened two way cable whose strap must be connected to the OP DR signal A screened cable with the strap connected to OP DR serves to avoid disconnecting the safety system in the event of failure of the cables outside the converter An example of this is the loss of insulation and subsequent accidental contac
14. has been activated 2 1 CLIMATE CLASS Class 3K3 according to EN 60721 3 3 Environmental parameter Limits Unit of measuremen t working temperature 0 40 C humidity 5 85 Yo atmospheric pressure 70 106 kPa maximum surrounding air movement 1 m s maximum temperature gradient 0 5 C min maximum thermal irradiation 700 W m condensation precipitation with wind NO Y water other than rain NO ice formation NO Y The climate class 3K3 includes a 5 40 C use limitation but the converter can work also if the environmental temperature is 0 C The maximum operating temperature of the converter reaches 45 C In this case declass the rated power to 88 9 The atmospheric pressure limitations correspond to a 0 3000m 8 5 1 operating range In actual fact above 1000m it will be necessary to declass the rated power of the converter by 1 every 100m 3 The converter must be installed in a switchboard and not outside 2 2 RESISTANCE TO CHEMICALLY ACTIVE SUBSTANCES Class 3C1R according to EN 60721 3 3 Environmental Maximum parameter value measurement sea salts sulphur dioxide hydrogen sulphide chlorine hydrochloric acid hydrofluoric acid ammonia ozone nitrogen oxide STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 2 3 RESISTANCE TO VIBRATIONS As regards vibrations the OPEN DRIVE has the following use limitations 10Hz lt frequency lt 57Hz 0 075 mm width 57Hz lt frequency lt 1
15. inale STO 2 a segnale e STO FB2 e pt STO 2 attivo us Il segnale STO FB2 _ attivo SI Guasto nel canale 2 Non posso lavorare Controllo FB2 OK Flow chart FB2 control If the diagnostic test detects a fault the converter must be subjected to immediate repair worth a possible malfunction of the safety function in the subsequent request for intervention We recommend running these tests periodically in situations standstill In any case it is required that you also meet at least the basic requirements of diagnostics namely a and b previously described in section 6 1 6 2 2 NOT DANGEROUS FAILURE LOGICAL OUTPUT CONTROL The output control logic 023 Not Dangerous Failure allows to verify the presence of some dangerous faults To make the control is necessary to check that the logical output 023 is to a high logical level keeping energized the channels 1 and 2 See paragraph 7 for some examples that show how to connect the control output of this logic 14 STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 7 APPLICATION EXAMPLES The following are some application examples of the STO system In the various examples the OPD connector is linked to a safety module regardless of the type of connection used the safety module must be set in order to have a controlled manual start and not an automatic start Moreover the feedback contacts must be c
16. l powers the IGBT power drivers When the drive is working normally the 24V DR driver must be provided On the other hand to enable the STO system it is necessary to disconnect 24V DR SS STO FB1 B Clean N C contact max 60Vdc max 0 5 Monitor of the first STO system channel which indicates whether the IGBT drivers STO FBI A are powered or not When the terminal board1 is powered the contact is open op sto 2 24V 22V 26V min 40mA Power voltage for the second of the two STO safety system channels This channel powers the relay which disconnects the IGBT driver controls When the STO 2 drive is working normally the STO 2 must be powered On the contrary to enable to STO system it is necessary to disconnect STO 2 Clean N C contact max 60Vdc max 0 5A STO FB2 8 EA DT Pt D 2 N Bb AON O Monitor of the second STO system channel which indicates whether the relay STO FB2 A which disconnect the IGBT drivers are powered or not When the terminal board is powered the contact is open 6 STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 3 2 TERMINAL BOARD POSITIONS The X3 and S1 terminal boards are placed on the same side as the converter as shown in the figures below
17. n 24V 22V 26V min 600mA OPD3 7 12 15A min OPD22A min 1A OPD32 40 48 60A The terminal boards X3 1 and X3 2 power the adjustment card the sensor in the motor and the cooling fans of the radiator The power sizes 70A 150A generate inside them the 24V from the main supply Then on terminal X3 is available a 24V that can used by the customer only for 70A 460A 03A 60A a Provide the converter breakouts b Power the two STO function channels the power must be interrupted by appropriate safety contacts In the power size 70A 150A is also possible to feed the regulation board with an external 24V using the terminal X3 the internal generated voltage and external provided voltage will not be in conflict but will be used the source with the higher voltage This allows to a Set the driver without feeding the power side b Keep alight the regulation part even if there isn t the power supply The current absorbed by the drivers on the 24V terminal for the different sizes are the follows OPDE 3 7 12 15A min 600 OPDE 22A min 800mA OPDE 32 40 48 60A min 1A OPDE 70 150A min 500mA N B the pinout of X3 change in function of the drive size STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 24V 22V 26V min 200mA Powering voltage for the first of the two STO safety system channels This channe
18. onnected in series to the reset button In this way the machine is started and therefore operated with the safety module on and it will be mandatory to press the reset button to enable its starting This is necessary in order to conduct when the machine is started a test on the feedback signals For the proper use of feedback related to the digital 023 Not Dangerous Failure 023 must be configurated as an output physical logic associated with one of four logic outputs available In order it s possible use the direct contact present in the clean logic output LO2 and LO4 In this case it s necessary configure the physical digital output with the direct logical output 023 Alternatively you can connect to each of the digital output an external relay with its contact placed in series with the reset button In this case if the contact of the relay is n c then it s necessary configure the physical digital output with the denied logical output 023 But if the relay contact is n o 5 necessary configure the digital output with direct logical output 023 Example 1 illustrates the use of a Pilz PNOZ XV2 safety module which includes two relays each of which has two immediate contacts and two timed contacts that are triggered after an adjustable delay One of the activated systems in the converter is stop with minimum speed the connection C28 1 needs to be set If the emergency button is pressed the start consent control is immediately dis
19. rd not powered the power insertion control is disconnected but no specific alarm is generated and the logic output 00 Drive ready remains on high that is to say the drive ready remains active if no other alarms are present STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP 5 2 DISABLING THE STO SYSTEM To disable the STO system it is sufficient to power again 424V DR and STO 2 Also in this case the sequence followed is not relevant CAUTION From the moment the machine is powered it takes time to disable the safety systems on both channels The times are indicated below CHANNEL 1 Maximum time after the enabling of 24V DR CHANNEL 2 Maximum time after the enabling of STO 2 20ms OPDE 03 60A 1 1s OPDE 70 150 In the case of OPDE 70 150A drivers with supply of the AC power side for wich the customer has required a precharge time of the power side higher than that standard the maximum out time of safe function passes to OutSTO maximum time 600ms Riquired precharge time In the standard configuration the precharge time is 500ms In this situation the feedback contacts STO FB1 ed STO FB2 will both need to be open Any discrepancy in only one of the monitor contacts with respect to the converter status means that there is a failure In this case the safety system might not be working properly and it needs to be repaired immediately In the case of the adjustment card to return to the normal operation
20. t between one of the cables connected to 24V on the switchboard and 24V DR For the second channel connection STO 2e0P STO 2 use a screened two way cable whose strap must be connected to the OP STO 2 signal A screened cable with the strap connected to the OP STO 2 serves to avoid disconnecting the safety system in the event of failure of the cables outside the converter An example of this is the loss of insulation and subsequent accidental contact between one of the cables connected to 24V on the switchboard and the STO 2 signal d For the tow monitor connection the type of cable to be used depends on how the diagnostic test on the safety chain is conducted Some safety modules do not specify the type of cable to conneci the signals used by the diagnostic system The reason for this is that they are able to determine themselves whether there is a failure in these connections If the diagnostic test on the safety channels is conducted directly by the manufacturer of the switchboard it is necessary to determine whether this test is able to detect a failure in the connection cables In the diagnostic test failure of the monitor signal cables causes the test itself to fail It is not possible to determine where the failure is on the safety chain or on the monitor The use of screened two way cable for each of the two monitor therefore makes it at least possible to rule out a failure of the monitor signal connections STO Safe Torque Off Rev
21. wing table These figures refer to the maximum time between the change in status channel switching and security of its monitor CHANNEL 1 Maximum time between the 24V DR interruption and STO FB1 commutation Maximum time between the 24V DR insertion and the STO FB1 commutation Tab 3 CHANNEL 2 Maximum time between the STO 2 interruption and STO FB2 commutation Maximum time between STO 2 insertion and STO FB2 commutation 20ms OPDE 03 60A100ms OPDE 70 460A Tab 4 STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP The sequence to be performed for channel 1 is represented by the following flow chart ATTENTION For the OPDE 70 150A sizes the diagnostic function of channel 1 must be done with the second safety channel in OFF 24V present on input STO 2 For OPDE 03 60A sizes instead the state of the second channel of the safety function is not relevant Fornire 24V DR Il segnale STO FB1 attivo Togliere 24V DR Il segnale STO FB1 14 attivo SI Guasto nel canale 1 Non posso lavorare Controllo FB1 OK FBl control Flow chart The sequence to be performed for channel 2 is represented by the following flow chart ATTENTION The state of the first channel of the safety function is irrelevant to the diagnostic test of the second channel STO STO Safe Torque Off Rev 1 3 30 11 11 EN OPD EXP Fornire tensione al term
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