NORD BU0530 User Manual

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BU 0530

Functional Safety

Supplementary instructions for frequency inverter SK 500E

Functional Safety

Functional safety with NORD SK 500E frequency inverters Safety information

NORD frequency inverters

Safety and operating instructions for drive power converters

(as per: Low Voltage Directive 2006/95/EEC)

1.General

During operation, drive power converters may, depending on their protection class, have live, bare, moving or rotating parts or hot surfaces.

Unauthorised removal of covers, improper use, incorrect installation or operation causes a risk of serious personal injury or material damage.

Further information can be found in this documentation. All transportation, installation commissioning and maintenance work

must be carried out by qualified personnel (compliant with IEC 364 or. CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110 and national accident prevention regulations).

For the purposes of these basic safety instructions, qualified personnel are persons who are familiar with the assembly, installation, commissioning and operation of this product and who have the relevant qualifications for their work.

2. Proper use in Europe

Drive power converters are components intended for installation in electrical systems or machines.

When installed in machines, the drive power converter must not be commissioned (i.e. commencement of the proper use) until it has been ensured that the machine meets the provisions of the EC Directive 2006/42/EEC (Machinery Directive); EN 60204 must also be complied with.

Commissioning (i.e. implementation of the proper use) is only permitted if the EMC directive (2004/108/EEC) is complied with.

Drive power converters with a CE label meet the requirements of the Low Voltage Directive 2006/95/EEC. The stated harmonized standards for drive current inverters are used in the declaration of conformity.

Technical data and information for connection conditions can be found on the rating plate and in the documentation, and must be complied with.

The drive power converters may only be used for safety functions which are described and explicitly approved.

3. Transport, storage

Information regarding transport, storage and correct handling must be complied with.

4. Installation

The installation and cooling of the equipment must be implemented according to the regulations in the corresponding documentation.

The drive power converter must be protected against impermissible loads. Especially during transport and handling, components must not be deformed and/or insulation distances must not be changed. Touching of electronic components and contacts must be avoided.

Drive power converters have electrostatically sensitive components, which can be easily damaged by incorrect handling. Electrical components must not be mechanically damaged or destroyed (this may cause a health hazard!).

5. Electrical connection

When working on live drive power converters, the applicable national accident prevention regulations must be complied with (e.g. BGV A3, formerly VBG 4).

The electrical installation must be implemented according to the applicable regulations (e.g. cable cross-section, fuses, earth lead connections). Further instructions can be found in the documentation.

Information regarding EMC-compliant installation – such as shielding, earthing, location of filters and installation of cables – can be found in the drive power converter documentation. These instructions must be complied with even with CE marked drive power converters. Compliance with the limit values specified in the EMC regulations is the responsibility of the manufacturer of the system or machine.

6. Operation

Systems in which drive power converters are installed must be equipped, where necessary, with additional monitoring and protective equipment as per the applicable safety requirements, e.g. legislation concerning technical equipment, accident prevention regulations, etc.

The parameterisation and configuration of the drive power converter must be selected so that no hazards can occur.

All covers must be kept closed during operation.

7. Maintenance and repairs

After the drive power converter is disconnected from the power supply, live equipment components and power connections should not be touched immediately, because of possible charged capacitors. Observe the applicable information signs located on the drive power converter.

Further information can be found in this documentation.

These safety instructions must be kept in a safe place!

2 BU 0530 GB-3712

Functional safety with NORD SK 500E frequency inverters About this document

Designation of previous issues

Software Version

Comments

BU 0530 GB, November 2007 Part. No. 607 5302 / 4707

First issue

BU 0530 GB, July 2010 Part. No. 607 5302 / 2710

V1.8 R2

and above

Supplement to SK 511E and sizes 5 - 6 Updating of references to standards Inclusion of new certifications

BU 0530 DE, September 2012 Part. No. 607 5302 / 3712

V2.0 R2

and above

Supplement to SK 511E and sizes 7 - 9 Updating of references to standards Inclusion of new certifications

NOTE

This supplementary operating manual is only valid in conjunction with the operating manual supplied for the respective frequency inverter.

Documentation

Designation: BU 0530 GB Part No.: 607 53 02 Device series: SK 510E, SK 511E, SK 515E, SK 530E, SK 535E, SK 540E and SK 545E

Version list

Publisher

Getriebebau NORD GmbH & Co. KG

Rudolf-Diesel-Str. 1  D-22941 Bargteheide  http://www.nord.com/ Tel.: +49 (0) 45 32 / 289-0  Fax +49 (0) 45 32 / 289-2555

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Functional safety with NORD SK 500E frequency inverters About this document

Intended use of the frequency inverter

Compliance with the operating instructions is necessary for fault-free operation and the

acceptance of any warranty claims. These operating instructions must be read before working with the device!

These operating instructions contain important information about servicing. They must therefore be kept close to the device.

SK 500E series frequency inverters are devices for industrial and commercial systems used for the operation of three-phase asynchronous motors with squirrel-cage rotors and Permanent Magnet Synchronous Motors - PMSM (SK 54xE and above). These motors must be suitable for operation with frequency inverters, other loads must not be connected to the devices.

SK 500E frequency inverters are devices for stationary installation in control cabinets. All details regarding technical data and permissible conditions at the installation site must be complied with.

Commissioning (implementation of the intended use) is not permitted until it has been ensured that the machine complies with the EMC directive 2004/108/EEC and that the conformity of the end product meets the machine directive 2006/42/EEC (note EN 60204).

 Getriebebau NORD GmbH & Co. KG, 2012

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Functional safety with NORD SK 500E frequency inverters About this document

Item Item Item

Item

Item 5

510

E-

250 - 323 - 511 370 -CP -KAR

515 550 -ERS

530 750 -XXX

535 111

540 151

545 221

301 401

551

751

112

152 182

510

E-

550 - 340 -

511 750 350 -CP -KAR

515 111 -ERS

530 151 -XXX

535 221

540 301

545 401

551

751

112 152 182 222

302

372 452 552 752

902

Scope of Application

These instructions are only applicable to devices whose type can be derived from the following key:

Item 1.: Configuration

510: as for 500 (standard I/O) + "Safe pulse block" 511: as for 510, however with additional 2 x CANbus/CANopen 515: as for 510, however with 24V control supply, 2 x CANbus/CANopen 520: as for 500, however with additional 2x CANbus/CANopen, 2x dig. IN, 2x dig. OUT, incremental

encoder input 530: as for 520 (extended I/O) + "Safe pulse block" 535: as for 530, however with 24V control supply 540: as for 530, however additionally with PLC functionality and multi-encoder interface 545: as for 540, however with 24V control supply

Item 2.: Power in encoded form: abc

2 significant places, 3rd place multiplier: P=(10*a+b)*10

(c+1)

in W

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Functional safety with NORD SK 500E frequency inverters About this document

Item 3.: Mains in encoded form: abc

a: Number of mains phases bc: Mains voltage (Nominal voltage/10) in two significant places 230 V devices up to 2.2 kW are also suitable for single phase operation. The suffix A after the mains voltage stands for an integrated mains filter (Class A)

Item 4.: Heat sink (blank: standard; CP: Cold Plate)

Item 5.: Custom versions (e.g. KAR, ERS; XXX stands for further versions in general)

The customised versions are only variants which differ in the areas of the I/O, bus system, or connectors and terminals. These versions have no effect on the "Safe pulse block".

6 BU 0530 GB-3712

1 General

SAFETY AND OPERATING INSTRUCTIONS FOR DRIVE POWER CONVERTERS .............. 2

1 GENERAL ................................................................................................................................. 9

1.1 Safety and installationinformation ........................................................................ 9

1.2 Approvals and certificates .................................................................................. 10

1.2.1 Certifications for the function STO .......................................................................... 11

1.2.2 Certifications for the function SS1 ................................................................ ........... 13

1.2.3 Certificate for the sole use of the digital inputs ........................................................ 15

1.3 Identification system ........................................................................................... 17

2 FUNCTION DESCRIPTION .................................................................................................... 19

2.1 Safe shut-down method ..................................................................................... 21

2.1.1 Safe pulse block ...................................................................................................... 21

2.1.2 Digital inputs ........................................................................................................... 21

2.2 Safety functions .................................................................................................. 22

2.2.1 Safe torque off, STO ............................................................................................... 22

2.2.2 Safe stop 1, SS1 ..................................................................................................... 22

2.3 Examples / Implementation ................................................................................ 23

2.3.1 STO function ........................................................................................................... 23

2.3.2 SS1 Function .......................................................................................................... 25

2.3.3 Simple restart block................................................................................................. 26

2.3.4 Example without safe shut-down method................................................................ 27

2.3.5 Ruling out wiring faults ............................................................................................ 28

3 ASSEMBLY AND INSTALLATION ........................................................................................ 29

3.1 Installation and assembly ................................................................................... 29

3.2 Wiring guidelines ................................................................................................ 29

3.3 Mains supply (X1-PE, L1, L2/N, L3) ................................................................... 29

3.4 Connecting the control cables ............................................................................ 29

3.4.1 Connecting the safe pulse block (X8 – VIS 24V, VIS 0V) ....................................... 30

3.4.2 Connection terminals .............................................................................................. 31

3.4.3 Details of the "Safe pulse block" control connections.............................................. 33

3.4.4 Details of the "Digital inputs" control connections ................................................... 34

3.4.5 Details of the "Digital outputs" control connections ................................................. 38

4 PARAMETERISATION ........................................................................................................... 40

5 PROTECTIVE SWITCHING DEVICES ................................................................................... 44

5.1 Output voltage .................................................................................................... 44

5.2 Switching capacity and current load ................................................................... 44

5.3 OSSD outputs, test pulse ................................................................................... 44

6 SAFETY CATEGORIES ......................................................................................................... 45

6.1 IEC 60204-1:2005 .............................................................................................. 45

6.2 IEC 61800-5-2:2007 ........................................................................................... 45

6.3 IEC 61508 ........................................................................................................... 45

6.4 ISO 13849-1:2006 .............................................................................................. 46

7 COMMISSIONING................................................................................................................... 47

8 DIAGNOSIS AND FAULTS .................................................................................................... 49

8.1 Diagnosis ............................................................................................................ 49

8.2 Faults .................................................................................................................. 49

8.2.1 Table of possible error messages ........................................................................... 49

8.2.2 Error display ............................................................................................................ 49

8.2.3 Error memory .......................................................................................................... 49

9 TECHNICAL DATA ................................................................................................................. 50

9.1 Environmental data............................................................................................. 50

9.2 Control terminal data .......................................................................................... 50

9.3 Data for the digital inputs .................................................................................... 51

9.4 Data for the safe pulse block .............................................................................. 52

BU 0530 GB-3712 7

Functional safety with NORD SK 500E frequency inverters

10 ADDITIONAL INFORMATION ............................................................................................. 53

10.1 Maintenance and servicing information ........................................................... 53

10.2 Abbreviations in this manual ............................................................................ 53

11 KEYWORD INDEX ............................................................................................................... 54

8 BU 0530 GB-3712

1 General

This manual BU 0530 ES 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 0500 GB).

1.1 Safety and installationinformation

SK 500E frequency inverters are equipment for use in industrial high voltage systems and are operated at

voltages that could lead to severe injuries or death if they are touched.

 Installation and other work may only be carried out by qualified electricians and with the device

disconnected. The operating instructions must always be available to these persons and must be strictly observed by them.

 Local regulations for the installation of electrical equipment and accident prevention must be

complied with.

 The equipment continues to carry hazardous voltages for up to 5 minutes after being switched

off at the mains. The equipment may only be opened or the cover or control element removed 5 minutes after the equipment has been disconnected from the power supply. All covers must be put back in place before the mains voltage is switched back on again.

 For single phase operation (115/230 V) the mains impedance must be at least 100H for each

conductor. If this is not the case, a mains choke must be installed.

1 General

 For safe isolation from the mains, all poles of the supply cable to the frequency inverter must be

able to be disconnected.

 Even during motor standstill (e.g. caused by an electronic block, blocked drive or output terminal

short circuit), the line connection terminals, motor terminals and braking resistor terminals may still conduct hazardous voltages. A motor standstill is not identical to electrical isolation from the mains.

 Parts of the control board, and especially the connector socket for the removable technology

units also carry hazardous voltages. The control terminals are mains voltage free.

 Note: with certain settings, the frequency inverter can start up automatically after the mains are

switched on.

 The circuit boards contain highly-sensitive MOS semiconductor components that are particularly

sensitive to static electricity. Avoid touching circuit tracks and components with the hand or metallic objects. Only the terminal strip screws may be touched with insulated screwdrivers when connecting the cables.

 The frequency inverter is only intended for permanent connection and may not be operated

without effective earthing connections which comply with the local regulations for large leakage currents (> 3.5 mA). VDE 0160 stipulates the installation of a second earthing conductor or an earthing conductor cross-section of at least 10 mm2.

 A universal leakage current-sensitive circuit breaker (type B) according to EN 50178/VDE 0160

must be used.

 SK 500E frequency inverters are maintenance free. The cooling surfaces must be regularly

cleaned with compressed air if the ambient air is dusty.

 Installation of the frequency inverter in an IP54 switching cabinet is mandatory.  The clamp cover must be used!

BU 0530 GB-3712 9

Functional safety with NORD SK 500E 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

DANGER TO LIFE!

The power unit can continue to carry voltages for up to 5 minutes after being switched off at the mains. Inverter terminals, motor cables and motor terminals may carry voltage!

Touching open or free terminals, cables and equipment components can lead to severe injury or death!

Work may only be carried out by qualified specialist electricians and with the electrical supply to the equipment disconnected!

CAUTION

Children and the general public must be kept away from the equipment! The equipment may only be used for the purpose intended by the manufacturer.

Unauthorised modifications and the use of spare parts and additional equipment which has not been purchased from or recommended by the manufacturer of the device may cause fire, electric shock and injury.

Keep these operating instructions in an accessible location and give them to all operators!

WARNING

This product is intended for use in an industrial environment and is subject to sales restrictions according to IEC 61800-3. In a domestic environment, this product can cause high frequency interference, in which case the user may be required to take appropriate measures.

An appropriate measure would be the inclusion of a recommended mains filter.

1.2 Approvals and certificates

The certificates listed below refer to functional safety. Certifications relating to the frequency inverter (EMC, UL, etc.) are listed in the main manual (BU0500).

The certificates for size 8 and 9 frequency inverters (45 ... 90kW) were not available at the time of publication, however, they will be provided towards the end of 2012.

10 BU 0530 GB-3712

1.2.1 Certifications for the function STO

1 General

BU 0530 GB-3712 11

Functional safety with NORD SK 500E frequency inverters

12 BU 0530 GB-3712

1.2.2 Certifications for the function SS1

1 General

BU 0530 GB-3712 13

Functional safety with NORD SK 500E frequency inverters

14 BU 0530 GB-3712

1.2.3 Certificate for the sole use of the digital inputs

1 General

BU 0530 GB-3712 15

Functional safety with NORD SK 500E frequency inverters

16 BU 0530 GB-3712

Name for ordering SK 5xxE

Example:

520

E-

751

340-A

XXX

Configuration

500

5x dig. IN, 2x analog IN, 2x relay OUT, 1x analog OUT, RS232/485

505*

as for "500", however 24 V supply for the control unit

510*

as for "500", but with additional "safe pulse block"

511*

as "510", but additionally with 2x CANbus/CANopen

515*

as for "510", however 24 V supply for the control unit

520

as "500", but additionally with 2x CANbus/CANopen, 2x dig. IN, 2x dig. OUT, incremental encoder input

525*

as for "520", however 24 V supply for the control unit

530

as for "520", however with additional "safe pulse block" and positioning control

535

as for "530", however 24 V supply for the control unit

540

as for 530, however additionally with PLC functionality and multi-encoder interface

545

as for "540", however 24 V supply for the control unit

Power

Mains

112

323-A

340-A

350-A

250

250W

I I

Size S

370

370W

1 1

550

550W

1 1 1

750

750W

1 1 1

111

1.1kW

2 2

151

1.5kW

2 2

221

2.2kW

2 2

301

3.0kW

3 3

401

4.0kW

3 3

551

5.5kW

5 4

751

7.5kW

5 4

112

11kW

6 5

152

15kW

7 5

182

18.5kW

7 6

222

22kW

302

30kW

372

37kW

452

45kW

552

55kW

752

75kW

902

90kW

1.3 Identification system

1 General

BU 0530 GB-3712 17

Functional safety with NORD SK 500E frequency inverters

Name for ordering SK 5xxE

Example:

520

E-

751

340-A

XXX

Mains

112-O

Single phase, 115V, without filter, only devices without "Safe pulse block" (SK 500E, 505E, 520E and 525E, SK 530E only position control)

323-A

3-phase, 230 V, internal A-filter (1/3 phases up to 2.2 kW)

340-A

3-phase, 400 V, internal A-filter

350-A*

3-phase, 500V, internal A-filter

Option

No option

Cold Plate

XXX

Further options possible

* only available on request!

18 BU 0530 GB-3712

2 Description of function

Sizes 1 - 4

Sizes 5 - 7

I/O

Emergency stop

µC

Frequency Inverter

Control voltage

VIS 0V (88)

VIS 24V (89)

Safe pulse block

VOS 0V (87)

VOS 24V (86)

Driver

Logic

T1 T3 T5

Gate supply

T2 T4 T6

Gate supply

Driver

Internal power supply

Frequency inverter

Safe pulse block

Mains

Motor

I/O

Control

µC

U V W

Logic

VI_S +24V

2 Function description

To avoid danger to persons and to prevent damage to material, machines must be able to be switched off safely. The frequency inverters SK 510E, SK 511E, SK 515E, SK 530E, SK 535E, SK 540 and SK 545E provide a method for safe switch-off (Safe pulse block).

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.

The mains voltages are rectified and the resulting DC voltage is reconverted to AC according to the requirements of the operating status of the motor (frequency and voltage).

Internal structure of the safe pulse block:

BU 0530 GB-3712 19

Functional safety with NORD SK 500E frequency inverters

Sizes 7 - 9

I/O

Emergency stop

Driver

µC

Frequency Inverter

Logic

Control voltage

Gate supply

VIS 0V (88)

VIS 24V (89)

VOS 0V (87)

VOS 24V (86)

Primary power

PWM-IC

Safe pulse block

The semiconductor switches of the inverter (T1 to T6) are controlled by a highly complex pulse pattern. This pulse pattern is generated by the microcontroller (µC) and amplified by the driver. The drivers convert the logic signals on the control voltages of the semiconductor switch. The semiconductor switches are switched via the control voltage and the pulse pattern is amplified and applied to the motor terminals. Due to the low-pass effect of the motor, a three-phase pulse width modulated sine wave voltage - a three-phase system, results from the pulsed voltage. The motor generates a torque.

20 BU 0530 GB-3712

2 Description of function

NOTE

On triggering the safe shut-down method, a mechanical brake connected to the terminals 1 (K1.1) and 2 (K1.2) can be applied (see parameter 434 in the BU 0500 GB manual). If the drive unit is not previously switched off, the brake must be designed as an operational brake.

DIN1 ...

GND

DIN4

Frequency inverter

Filter for OSSD

optional

24V

Safety output

24V

Safety output

24V

GND SH

24V SH

Frequency inverter

Safety output

24V

Safety output

24V

Safety output

24V

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. The pulse block is provided for this.

2.1.1 Safe pulse block

Devices equipped with a "safe pulse block" have an additional DC/DC converter, which produces the supply voltage for the driver from a 24V supply (24V_SH, GND_SH).

If the external 24 V voltage is switched off then the DC/DC converter does not transmit any power to the drivers. As the drivers are now no longer supplied with power, no control pulses reach the relevant semiconductor switches of the inverter. The flow of current in the semiconductor switches and the motor is interrupted. I.e. after a certain reaction time of the electronics and the reduction time of the motor current, the motor does not develop a driving torque.

The switch-off of the 24V supply (24V_SH, GND_SH) must be carried out by a fail-safe switching device. For this, either the connection 24V_SH (Terminal 89) or the connection GND_SH (Terminal 88) may be disconnected from the 24V source. For preference, the 24V_SH connection is disconnected.

2.1.2 Digital inputs

In order to implement a safety function, the digital inputs can be used as auxiliary inputs, e.g. for the triggering of a braking process. It should be noted that the digital inputs only fulfil minimum safety requirements. A safe shut-down method is always required!

The digital inputs, other I/Os and the 24V supply have a common earth. This means that a digital input may only be switched off by disconnecting the associated connection (21 for DIN1 to 24 for DIN 4). Switch-off via GND is not possible!

When operating with an OSSD1 a filter is only required for environments with strong interference. If only low levels of functional safety are required, the safety function can also be implemented with the digital

inputs. It is recommended that this is only considered if the risk assessment has shown that slight (normally temporary) injuries could result on failure of the safety function (see also Section 6 ). In case of doubt, a safe shut-down method should always be used.

Output Signal Switching Device

BU 0530 GB-3712 21

Functional safety with NORD SK 500E frequency inverters

NOTE

Control of a mechanical brake by means of the inverter is not fail-safe! A mechanical brake connected to terminals 1 (K1.1) and 2 (K1.2) can be applied on triggering

of the STO function. This means that in this case, the brake must be designed as an operating brake, as the drive unit and all of its rotating mass is stopped by the mechanical brake.

Slippage of lifting gear when triggering the STO function must be prevented by suitable brakes

where necessary!

NOTE

Controlled braking is triggered via a digital input and only complies with low safety requirements! If controlled braking fails then the device switches over to STO. If necessary, the braking process must be monitored.

NOTE

Control of a mechanical brake by means of the inverter is not fail-safe! In case of failure of controlled braking, a mechanical brake connected to terminals 1 (K1.1) and

2 (K1.2) may be overloaded, as this brake is applied when the STO function is triggered.

If necessary, slippage of lifting gear must be prevented by the use of suitable brakes.

2.2 Safety functions

A stop function can be executed by means of a safe shut-down method. As this has priority over other control functions this stop-function is suitable for stopping in emergencies. This ensures that the torque is shut down by means of a safe shut-down method. This function is known as "safe torque off" or STO.

It is also possible to first stop the motor in a controlled manner and then to switch off the torque. This function is referred to as "safe stop 1" or SS1.

2.2.1 Safe torque off, STO

With the STO function the drive torque is switched off as quickly as possible (see Technical Data  Reaction Time) and the drive until (motor and machine) run down to a standstill. This behaviour corresponds to Stop Category 0 (uncontrolled braking) as per EN 60204-1. A certain time therefore elapses until the drive unit does not perform any further dangerous movements and a safe state is achieved. Monitoring of whether or when the drive unit has achieved a safe state is not integrated into the frequency inverter.

According to the switching equipment used and with the use of a safe shut-down method, an STO function with Safety Category 4 as per DIN EN ISO 13849-1 can be implemented.

2.2.2 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).

22 BU 0530 GB-3712

2 Description of function

NOTE

If the "Safe pulse block" triggers for an enabled frequency inverter, error E018 (18.0 safety circuit) is triggered.

DIN1

GND

24V SH

24V

Frequency inverter

Use of the "Safe pulse block"

Reset

Emergency stop button

Reset circuit

Safety output 1

Safety output 2

Supply voltage

Input circuit

with short-

circuit detection

Shielded cable to

eliminate errors as per

DIN EN ISO 13849-2

Filter

for

OSSD

optional

GND SH

24V SH

24V

Frequency inverter

Use of the "Safe pulse block"

Reset

Emergency stop button

Reset circuit

Shielded cable to eliminate

errors as per

DIN EN ISO 13849-2

Input circuit with shortcircuit

detection

Supply

voltage

Safety output

2.3 Examples / Implementation

The following illustrates several examples of solutions for the safety functions STO and SS1.

2.3.1 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.

In this example, Safety Category 4 as per DIN ISO 13849-1 can be achieved. The prerequisite for this is that the emergency stop button, the protective switching device and the wiring fulfil the requirements for Category

4. For example, this can be achieved as follows:

 Redundant protective switching device with self-monitoring  Dual-channel input circuit with short-circuit recognition (and appropriate emergency stop button)  Safety output with periodic switch-off tests (OSSD)  Elimination of errors as per DIN ISO 13849-2 for the wiring between the switching device and the input

terminals of the safe shut-down method used, by the use of a shielded cable and connection of the shield at both ends.

The typical reaction time can be reduced by the additional use of a digital input (e.g.: DIN1), which must be parameterised for the function "Block voltage":

Note: The optional filter on the digital input is only required in environments with heavy interference.

A second safety output is required to control the digital input.

BU 0530 GB-3712 23

Functional safety with NORD SK 500E frequency inverters

NOTE

A separate shielded cable must be used for the "safe pulse block" or "switch-off of the 24V supply". When using a protective switching device with short-circuit monitored OSSD-outputs, the safety outputs can be combined in a single cable.

NOTE

Only the "safe pulse block" or "switch-off of the 24V" supply fulfil the requirements of Safety Category 4. This does not apply to the digital input.

The frequency inverter can only fulfil safety category 1 during the period between activation of the safe pulse block via a digital input and activation via terminals 88 and 89.

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.

24 BU 0530 GB-3712

2 Description of function

NOTE

The requirements of Safety Category 4 / Performance Level e can only be fulfilled with a safer shut-down method. Safety Category 1 (and PL c) can be achieved for the digital inputs and therefore for controlled braking.

DIN1

GND

GND SH

24V SH

24V

Reset

24V

Filter

for

optional

Frequency inverter

Use of the "Safe pulse block"

Emergency stop

Supply voltage

Reset circuit

Input circuit with shortcircuit

detection Safety output 1

Safety output 2

Shielded cable to eliminate

errors as per

DIN EN ISO 13849-2

2.3.2 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].

Note: The optional filter on the digital input is only required in environments with heavy interference.

When the safety function is requested, a controlled stopping procedure is first triggered via the digital input (in this case DIN1). Here it must be ensured that the drive is brought to standstill within the parameterised fast stop time (P426). After the elapse of a delay time which is controlled by the switching device, the safe shutdown method is triggered. The delay time must be dimensioned so that the delay is longer than the fast stop time plus the DC follow-up time (P559). The delay time must be selected so as to be fail-safe.

Here it should be noted that controlled braking can fulfil the requirements for Safety Category 1. Safety Category 4 as per DIN EN ISO 13849-1 can be achieved with final switch-off by the triggering of a safe shutdown method "safe pulse block" or "switch-off of the 24V supply". For this, the same conditions as described in the examples for the STO function apply. If controlled braking fails then the device switches over to STO (after the set delay).

BU 0530 GB-3712 25

Functional safety with NORD SK 500E frequency inverters

NOTE

After triggering the "safe pulse block“, the inverter shows the acknowledgeable fault E018 (18.0 Safety circuit).

NOTE

In this example, there is no reset circuit as is the case with the protective switching devices. If the result of risk analysis is that cancellation of the stop command must be acknowledged by intended manual action then the resetting requirements can be fulfilled organisationally (e.g. by an emergency-stop button with key releasing device and storage of the key away from the machine).

NOTE

We recommend that the "automatic fault clearance“ (P506) and "automatic start-up" (P428) functions are not used in combination with each other (See BU 0500 GB), as the drive would otherwise immediately start up after unlocking the emergency-off button.

GND SH

24V SH

Frequency inverter

Emergency stop button

24V

Shielded cable to eliminate errors as per DIN EN ISO 13849-2

2.3.3 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).

To achieve safety category 4, fault exclusion as per EN 13849-2 Sec. D.5 must be possible for the upstream components (hard-wiring and dual-channel buttons with independent, positive-opening contacts). I.e., in this example, the emergency-stop button and the wiring must be designed in such a way that short-circuiting at the emergency-stop button and to other live systems can be ruled out.

26 BU 0530 GB-3712

2 Description of function

NOTE

As a maximum, this example achieves Safety Category 1 or Performance Level c. This circuit version is not SIL-capable

(See Section 6).

DIN1 ...

GND

DIN4

24V

Reset

24V

Frequency inverter

optional

Emergency stop button

Reset circuit

Safety output

Use of a digital input

STO: P420[-01...-04]=10, "Disable voltage"

SS1: P420[-01...-04]=11, "Fast stop"

Filter

for

OSSD

Shielded cable to eliminate

errors as per DIN EN ISO 13849-2

Supply voltage

Input circuit with shortcircuit

detection

2.3.4 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.

This switching version should only be considered if only low requirements for functional safety need to be fulfilled and if the risk assessment has shown that failure of the safety function can only result in slight (usually temporary) injuries (see also Section 6 ). In case of doubt, the "Safe pulse block" should always be used.

Note: The optional filter is only required in environments with heavy interference.

To implement the safety function STO, the digital input is parameterised to the function "Disable voltage". With the safety function SS1 the digital input is assigned the function "Fast stop" (parameter P420[-01...-04])

and the fast stop time is set via parameter P426. It must be ensured that the drive is brought to standstill within the parameterised fast stop time.

BU 0530 GB-3712 27

Functional safety with NORD SK 500E frequency inverters

GND SH

24V SH

24V

Frequency inverter

Safety output 1

Safety output 2

Monitored outputs

DIN1

GND

24V

optional

Safety output 1

Filter

for

OSSD

24V SH

GND SH

24V

Safety output 2

Monitored outputs without short-circuit detection

Frequency inverter

DIN1

GND

24V

optional

Safety output 1

Filter

for

OSSD

24V SH

GND SH

24V

Safety output 2

Monitored outputs

without short-circuit

Frequency inverter

2.3.5 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. According to this, a single detected fault or an accumulation of undetected faults must not lead to the loss of the safety function. A short circuit from an external voltage, e.g. from a 24V control cable, to the 24V input of a safe shut-down method could lead to the loss of a safety function. I.e. this fault must be prevented by means of suitable measures.

The use of a separate shielded cable for each input is not mandatory. For example, the cables for the digital inputs and the safe shut-down method may be jointly laid in a shielded cable, if the monitored safety outputs of the switching device is equipped with short-circuit detection (See Fig.). If necessary, the effectiveness of the short-circuit detection must be demonstrated.

Other measures (separate cable duct, installation in armoured conduit) are possible. More precise details result from the risk assessment and the FMEA for the specific application.

For the "safe pulse block" it is also conceivable that this is triggered via two safety outputs, one switching the 24V output and the other switching the GND output.

In this case a shielded cable is not strictly necessary if both safety outputs are monitored. If, for example, other 24V control cables are laid in the same cable duct and an error in the form of a short-circuit from 24V_SH to a control cable (=24V) is assumed, this fault would be detected by the output monitoring of the switching device and the "safe pulse block" would be triggered by the second safety output. More precise details result from the FMEA for the specific application.

If a shielded cable is not used for the wiring of the safety function, the effects of electromagnetic fields may need to be taken into account. Hence the use of a 1 m long cable (in a separate cable duct) in an environment without strong electromagnetic fields is relatively safe, while the installation of a long cable in the direct vicinity of a powerful transmitter or a medium voltage distributor may cause the failure of the safety function. Because of this, the use of shielded cables is generally recommended.

28 BU 0530 GB-3712

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 0500 DE).

3.1 Installation and assembly

SK 5xxE series frequency inverters have protection class IP20 and may only be installed in an area with protection class IP54 (or higher).

The installation instructions contained in BU0500 GB must be observed!

3.2 Wiring guidelines

With regard to this item, please observe the appropriate chapter of BU 0500 DE and the following chapters in this manual.

3.3 Mains supply (X1-PE, L1, L2/N, L3)

devices with "safe pulse block“ may only be operated at TN networks, TT networks and grounded corner! The

equipment has not been designed for operation at IT networks.

3.4 Connecting the control cables

Detailed information regarding the connection of the control cables (terminal designation, terminal positions etc) can be found in the main manual for the frequency inverter (BU0500).

BU 0530 GB-3712 29

Functional safety with NORD SK 500E frequency inverters





*19



 5,0R

VAInumberRU

PeakINFUcable

14,0*5*5,0**



3.4.1 Connecting the safe pulse block (X8 – VIS 24V, VIS 0V)

SK 51xE SK 53xE and SK 54xE series frequency inverters are equipped with the option "Functional safety". Connection of the corresponding control cables is made via terminal block X8. Up to and including size 4, this terminal block and all other control connections are located under the front cover (See Section 3.4.2 "Connection terminals"). For sizes 5 to 7, the terminal block X8 is located on the underside of the frequency inverter (motor output side).

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 ΔU electronic protective switching devices it must not exceed ΔU I

= 400 mA should be assumed.

IN,Peak

Operation at OSSD

The safe pulse block is specially designed for use with an OSSD. The capacity between the wires (including the shielded capacities) must not exceed a value of 20nF for each

inverter connected.

Additional restrictions may apply here with regard to the protective switching device.

EMC

When the „safe pulse block“ has been wired correctly for EMC, the recommended EMC values (See BU 0500

GB) can be complied with up to a cable length of 20m between the safety switching device and the inverter.

Multi-device operation

When operating several inverters at one safety switching device, the switching capacity of the switching device and the load rating of the 24V power-feeding supply must be observed.

The shield must be applied to all inverters. The permissible line drops on the cable must be observed!

Example:

≤ 1 V. For the calculation, a peak current of

Cable

≤ 3 V and for

Cable

 5x frequency inverter at an electronic safety switching device!  The 5x FIs are arranged next to each other in a switching cabinet  20m must be bridged between the FI and the switching device!  Shielded cable 2x1.5 mm2

with

Double the length of cable must be used because line drops occur in both wires.

=> OK!

30 BU 0530 GB-3712

3.4.2 Connection terminals

Frequency inverter

Size 1 ... 4 and 8 ... 9

Rigid cable cross-section

0.14 … 1.5mm²

Flexible cable cross-section

0.14 … 1.5mm²

AWG standard

AWG 28-16

Flexible cable cross section with wire end sleeve, without plastic tube

0.25 … 1.5mm²

Flexible cable cross section with wire end sleeve, and with plastic tube

0.25 … 0.5mm²

Nominal ratings of safe pulse block

Terminal X8:86 (output - provision of +15V / +24V)

+24 V

(max. 300mA)

Terminal X8:87

GND

Terminal X8:88

GND

Terminal X8:89 (Input: “Safe pulse block”)

+24 V ± 25% or +24 V -20% + 25% for operation with OSSD

100mA (AV) (Size 1 - 4) 50mA (AV) (Size 8 - 9)

400mA (peak) after switching-on or after

a test pulse from an OSSD

CAUTION: For this safe pulse block function,

the bridges must be removed!

As delivered, terminals 87-88 and 86-89 are bridged in order to enable commissioning or

operation without the safety function (or ext. 24V).

X8: VIS 24V  24V

input of pulse block

NOTE:

15V output for commissioning

without safety switching device

or safety function.

NOTE:

For size V and above, the ter-

minal block X8 is located on the

motor output side of the fre-

quency inverter.

3 Assembly and installation

Connection terminals: Plug-in clip connectors can be released with a small screwdriver

Deviating position of terminal block X8 for sizes 5 to 7

Output Signal Switching Device

BU 0530 GB-3712 31

Functional safety with NORD SK 500E frequency inverters

Frequency inverter

Sizes 5 ... 7

Rigid cable cross-section

0.2 … 6mm²

Flexible cable cross-section

0.2 … 4mm²

AWG standard

AWG 24-10

Tightening torque for screw terminals

0.5 … 0.6Nm

Nominal ratings of safe pulse block

Terminal X8:86 (output - provision of +24V)

+24 V

(max. 300mA)

Terminal X8:87

GND

Terminal X8:89 (Input: “Safe pulse block”)

+24 V ± 25% 100mA (AV) (Size 5 - 6) 140mA (AV) (Size 7)

400mA (peak) after switching-on or after

a test pulse from an OSSD

Terminal X8:88

GND

In deviation from the illustration above, from size 5 and above, the position of terminal block X8 for the connection of the safe pulse block is located on the underside of the device (motor connection side).

Connection data:

32 BU 0530 GB-3712

3.4.3 Details of the "Safe pulse block" control connections

NOTE

As delivered, for commissioning without safety switching device, terminals 87-88 and 86-89 are bridged. In order to be able to use the safety function, the bridges must be removed.

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

√ √

Terminal X8:

VO_S 15V

VO_S 0V

VI_S 0V

VI_S 24V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

SK 540E and above

Supply voltage

15V  20%

When setting-up without using a safety function, wire directly to V_IS 24V.

P420 et

seqq.

P420 [-…]

Reference potential

24V  25%, ≤140mA See technical data in

BU0530!

Fail-safe input

Input, safe pulse lock

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

Terminal X8:

VO_S 24V

VO_S 0V

V_S 0V

VI_S 24V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

SK 540E and above

Supply voltage

18-30V, each to VI 24V

When setting-up without using a safety function, wire directly to V_IS 24V.

P420 et

seqq.

P420 […]

Reference potential

24V  25%, ≤140mA See technical data in

BU0530!

Fail-safe input

Input, safe pulse lock

Terminal block X8 – Safe pulse lock (not with 115V devices)

3 Assembly and installation

BU 0530 GB-3712 33

Functional safety with NORD SK 500E frequency inverters

NOTE

AGND and DGND are common reference potentials for analog or digital inputs. 5V / 15V can be collected by several terminals if required. The sum of collected currents must

not exceed 250mA / 150mA.

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√ √

√

Terminals X5:

DIN1

DIN2

DIN3

DIN4

DIN5

VO 15V

GND / 0V

VO 5V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

Digital input 1

[ON right]

7.5...30V, Ri=6.1k Not suitable for

thermistor evaluation.

HTL encoders can only be connected to DIN2 and DIN4

Limiting frequencies: max. 10 kHz min. 15 Hz

Each digital input has a reaction time of ≤ 5ms.

Control with internal 15V:

21 22 23 24 25 42 40 41

15V

motor - PTC

Control with external 7.5-30V:

21 22 23 24 25 42 40 41

7.5 … 30V

motor - PTC

GND / 0V

P420

Digital input 2

[ON left]

P421

Digital input 3

[parameter set bit0]

P422

Digital input 4

[Fixed frequency 1,

P429]

P423

Digital input 5

[no function]

2.5...30V, Ri=2.2k Not suitable for

evaluation of a safety device.

Suitable for thermistor evaluation with 5V.

NOTE: For the motor thermistor P424 = 13 must be set.

P424

15V supply voltage output

15V  20%

Supply voltage provided by the frequency inverter for connection to the digital inputs or the supply of a 10-30V encoder.

Reference potential for digital signals

0V digital

Reference potential

5V supply voltage output

5V  20%

Voltage supply for motor-PTC

3.4.4 Details of the "Digital inputs" control connections

Terminal block X5 – Digital In

34 BU 0530 GB-3712

3 Assembly and installation

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

Terminals X5:

44*

* Terminal 44: up to Size 4: VI Size 5 and above: VO

DIN1

DIN2

DIN3

DIN4

DIN5

V…

24V

GND /

VO 5V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

Digital input 1

[ON right]

7.5...30V, Ri=6.1k Not suitable for

thermistor evaluation.

HTL encoders can only be connected to DIN2 and DIN4

Limiting frequencies: max. 10 kHz min. 15 Hz

Each digital input has a reaction time of ≤ 5ms.

21 22 23 24 25 44 40 41

18 … 30V

motor - PTC

GND / 0V

P420

Digital input 2

[ON left]

P421

Digital input 3

[parameter set bit0]

P422

Digital input 4

[Fixed frequency 1,

P429]

P423

Digital input 5

[no function]

Only S1 – S4

2.5...30V, Ri=2.2k Not suitable for

evaluation of a safety device.

Suitable for thermistor evaluation with 5V.

NOTE: For the motor thermistor P424 = 13 must be set.

Above Size 5 Thermistor on

X13:T1/T2

P424

Size 1 to Size 4 VI 24V supply voltage input

18…30V at least 800mA (input)

Voltage supply for the FI control unit. This is essential for the function of the frequency inverter.

Size 5 and above VO 24V supply voltageoutput

24V ± 25% max. 200mA (output)

Supply voltage provided by the frequency inverter for connection to the digital inputs or the supply of a 10-30V encoder.

The 24V control voltage is generated by the FI, however it can also be supplied via the terminals X12:44/40. Supply via terminal X5:44 is not possible.

Reference potential for digital signals

0V digital

Reference potential

5V supply voltage output

5V  20%

Voltage supply for motor-PTC

BU 0530 GB-3712 35

Functional safety with NORD SK 500E frequency inverters

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

Terminals X5:

DIN1

DIN2

DIN3

DIN4

TF-

TF+

VO 15V

GND / 0V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

SK 540E and above

Digital input 1

[ON right]

7.5...30V, Ri=6.1k Not suitable for

thermistor evaluation.

HTL encoders can only be connected to DIN2 and DIN4

Limiting frequencies: max. 10 kHz min. 15 Hz

Each digital input has a reaction time of ≤ 5ms.

Control with internal 15V:

21 22 23 24 39 38 42 40

motor - PTC

15V

Control with external 7.5-30V:

21 22 23 24 39 38 42 40

motor - PTC

GND / 0V

7.5 … 30V

P420 [-01]

Digital input 2

[ON left]

P420 [-02]

Digital input 3

[parameter set bit0]

P420 [-03]

Digital input 4

[Fixed frequency 1,

P429]

P420 [-04]

Thermistor input -

potential isolated thermistor input, which cannot be disabled, for monitoring the motor temperature with a PTC

Thermistor input + 42

15V supply voltage output

15V  20%

Supply voltage provided by the frequency inverter for connection to the digital inputs or the supply of a 10-30V encoder.

Reference potential for digital signals

0V digital

Reference potential

36 BU 0530 GB-3712

3 Assembly and installation

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√ Terminals X5:

DIN1

DIN2

DIN3

DIN4

TF-

TF+

VI 24V

GND / 0V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

SK 540E and above

Digital input 1

[ON right]

7.5...30V, Ri=6.1k Not suitable for

thermistor evaluation.

HTL encoders can only be connected to DIN2 and DIN4

Limiting frequencies: max. 10 kHz min. 15 Hz

Each digital input has a reaction time of ≤ 5ms.

21 22 23 24 39 38 44 40

motor - PTC

GND / 0V

18 … 30V

P420 [-01]

Digital input 2

[ON left]

P420 [-02]

Digital input 3

[parameter set bit0]

P420 [-03]

Digital input 4

[Fixed frequency 1,

P429]

P420 [-04]

Thermistor input -

potential isolated thermistor input, which cannot be disabled, for monitoring the motor temperature with a PTC

Thermistor input + 44

24V supply voltage input

18…30V at least 800mA (input)

Voltage supply for the FI control unit. This is essential for the function of the frequency inverter.

Reference potential for digital signals

0V digital

Reference potential

BU 0530 GB-3712 37

Functional safety with NORD SK 500E frequency inverters

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

√ √

Terminals X7:

27 5 7

RS485 +

RS485 -

DIN6

DIN7

DOUT1

DOUT2

VO 15V

GND / 0V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

SK 540E and above

Data cable RS485

Baud rate 9600…38400Baud

Termination resistor R=120

BUS connection parallel to RS485 on RJ12 plug

NOTE: The termination resistance of DIP switch 1 (see RJ12/RJ45) can also be used for terminal 73/74.

P503 P509

Digital input 6

[no function]

7.5...30V, Ri=3.3k

As described for terminal block X5, DIN1 to DIN5.

Not suitable for the evaluation of a motor thermistor.

P425

P420 [-06]

Digital input 7

[no function]

P470

P420 [-07]

Only SK 54xE Alternatively: Output 5 (DOUT3)

[no function]

Digital output 15V, max. 20mA

max. 100k load

With SK 54xE the digital input (DIN7) can also be used as a digital output (DOUT3).

If P434 [-05] and P420 [-07] are parameterised with functions, a High signal of the DOUT function results in a High signal for the DIN function.

P434 [-05]

Output 3 (DOUT1)

[no function]

For evaluation in a control system. The scope of functions corresponds to that of the relay (P434).

P450

P434 [-03]

Output 4 (DOUT2)

[no function]

P455

P434 [-04]

Only SK 54xE Alternatively: Digital input 8

[no function]

7.5...30V, Ri=3.3k

With SK 54xE the digital output (DOUT2) can also be used as a digital input (DIN3).

If P434 [-04] and P420 [-10] are parameterised with functions, a High signal of the DOUT function results in a High signal for the DIN function.

P420 [-10]

15V supply voltage output

15V  20%

Voltage supply for connection to the digital inputs or the supply of a 1030V encoder

Reference potential for digital signals

0V digital

3.4.5 Details of the "Digital outputs" control connections

A digital output can be used to indicate the status of the "safe pulse block". It must be noted that this status indication is not fail-safe.

Terminal block X/ – Digital I/O

38 BU 0530 GB-3712

3 Assembly and installation

Relevance

SK 500E

SK 505E

SK 510E

SK 511E

SK 515E

SK 520E

SK 530E

SK 535E

SK 540E

SK 545E

√

√ Terminals X7:

27 5 7

44*

* Terminal 44: up to Size 4: VI Size 5 and above: VO

485+

RS485 -

DIN6

DIN7

DOUT1

DOUT2

V… 24V

GND / 0V

Designation

Terminal

Function

[factory setting]

Data

Description / wiring suggestion

Parameter

up to SK 535E

SK 540E and above

Data cable RS485

Baud rate 9600…38400Baud

Termination resistor R=120

BUS connection parallel to RS485 on RJ12 plug

NOTE: The termination resistance of DIP switch 1 (see RJ12/RJ45) can also be used for terminal 73/74.

P503 P509

Digital input 6

[no function]

7.5...30V, Ri=3.3k

As described for terminal block X5, DIN1 to DIN5.

Not suitable for the evaluation of a motor thermistor.

P425

P420 [-06]

Digital input 7

[no function]

P470

P420 [-07]

Only SK 54xE Alternatively: Output 5 (DOUT3)

[no function]

Digital output S1 to S4 18-30V according to

VI 24V, max. 20mA, max. 100k load

Above Size 5

DOUT1 and DOUT2:

24V, max. 200mA max. 100k load

With SK 54xE the digital input (DIN7) can also be used as a digital output (DOUT3).

If P434 [-05] and P420 [-07] are parameterised with functions, a High signal of the DOUT function results in a High signal for the DIN function.

P434 [-05]

Output 3 (DOUT1)

[no function]

For evaluation in a control system. The scope of functions corresponds to that of the relay (P434).

P450

P434 [-03]

Output 4 (DOUT2)

[no function]

P455

P434 [-04]

Only SK 54xE Alternatively: Digital input 8

[no function]

7.5...30V, Ri=3.3k

With SK 54xE the digital output (DOUT2) can also be used as a digital input (DIN3).

If P434 [-04] and P420 [-10] are parameterised with functions, a High signal of the DOUT function results in a High signal for the DIN function.

P420 [-10]

Size 1 to Size 4 VI 24V supply voltage input

18…30V at least 800mA (input)

Voltage supply for the FI control unit. This is essential for the function of the frequency inverter.

Size 5 and above VO 24V supply voltageoutput

24V ± 25% max. 200mA (output)

Supply voltage provided by the frequency inverter for connection to the digital inputs or the supply of a 10-30V encoder.

The 24V control voltage is generated by the FI, however it can also be supplied via the terminals X12:44/40. Supply via terminal X7:44 is not possible.

Reference potential for digital signals

0V digital

BU 0530 GB-3712 39

Functional safety with NORD SK 500E frequency inverters

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).

For the SS1 function, the "fast stop" function [11] is assigned to the appropriate parameter. In addition, the stopping time must be entered in parameter P426 and the DC run-on time must be entered in parameter P559.

For function SS1, the fast stop time (P426) must be rated so that the drive is stopped within this time. The DC follow-up time follows after the fast stop time (see above). The delay time of the delayed output of the protective switching device must be rated so that it is longer than the fast stop time plus the DC follow-up time.

Parameter

Setting value / Description / Note

Device

Supervisor

Parameter set

P420

Digital input 1

(Digital input 1)

up to

SK 535E

0 ... 74 { 1 }

Enable right as factory setting, control terminal 21 (DIN1) Various functions can be programmed. These can be seen in the following table.

P420 [-01]

... [-10]

Digital inputs

(Digital input functions)

SK 540E and

above

0 ... 80 { [-01] = 1 } { [-02] = 2 } { [-03] = 8 } { [-04] = 4 } all other { 0 }

Up to 10 inputs which can be freely programmed with digital functions are available in the SK 54xE. Of these inputs, analog inputs 1 and 2 of the frequency inverter do not comply with EN61131-2 (Type 1 digital inputs).

[-01] = Digital input 1 (DIN1): Enable right, (default), Terminal 21 [-02] = Digital input 2 (DIN2): Enable left, (default), Terminal 22 [-03] = Digital input 3 (DIN3): Parameter switching, (default), Terminal 23 [-04] = Digital input 4 (DIN4): Fixed frequency 1 (P429), (default), Terminal 24 [-05] = Digital input 5 (DIN5): No function, (default), Terminal 253 [-06] = Digital input 6 (DIN6): No function, (default), Terminal 26 [-07] = Digital input 7 (DIN7): No function, (default), Terminal 274 [-08] = Digital function Analog1 (AIN1), "Digital function of analog input 1": Terminal 145 [-09] = Digital function Analog2 (AIN2), "Digital function of analog input 2": Terminal 16c

[-10] = Digital input 8 (DIN8): No function, (default), Terminal 7b

P421

Digital input 2

(Digital input 2)

up to SK

535E

0 ... 74 { 2 }

Enable left as factory setting, control terminal 22 (DIN2) Various functions can be programmed. These can be seen in the following table.

P422

Digital input 3

(Digital input 3)

up to SK

535E

0 ... 74 { 8 }

Parameter set switching Bit 0 as factory setting, control terminal 23 (DIN3) Various functions can be programmed. These can be seen in the following table.

4 Parameterisation

In this manual, only those parameters and configurations are listed, which are of immediate significance to functional safety. For additional information, please observe the instructions in manual BU 0500 GB.

Parameter list

Up to and including Size 4, digital input 5 is not available. In place of this a potential-free isolated thermistor input is implemented, whose function cannot be

disabled. If no thermistor is present the two terminals TF- and TF+ must be bridged. Parameterisation of this input does not have any effect.

Digital input 7 (DIN7) can also be used as digital output 3 (DOUT3 / Binary output 5). It is recommended that either an input function (P420 [-07] or an output function (P434 [-05]) is parameterised. However, if and input function and an output function are parameterised, a High signal from the output function will result in the activation of the input function. This IO-exclusion is hence used as a kind of "flag". This also applies for digital input 8 (DIN8) and digital output 2 (DOUT2 / binary output 4).

The analog inputs 1 and 2 (AIN1 / 2) can also process digital functions. Care must be taken that either an analog function (P400 [-01]/[-02]) or a digital function (P420 [-08]/[-09]) is parameterised in order to prevent misinterpretation of the signals.

40 BU 0530 GB-3712

4 Parameterisation

Parameter

Setting value / Description / Note

Device

Supervisor

Parameter set

P423

Digital input 4

(Digital input 4)

up to

SK 535E

0 ... 74 { 4 }

Fixed frequency 1 (P429) as factory setting, control terminal 24 (DIN4) Various functions can be programmed. These can be seen in the following table.

P425

Digital input 6

(Digital input 6)

From SK 520E

to SK 535E

0 ... 74 { 0 }

No function as factory setting, control terminal 26 (DIN6) Various functions can be programmed. These can be seen in the following table.

P426

Quick stop time

(Quick stop time)

0 ... 320.00 s { 0.10 }

Setting of the stop time for the fast stop function which can be triggered either via a digital input, the bus control, the keyboard or automatically in case of a fault.

The emergency stop time is the time for the linear frequency decrease from the set maximum frequency (P105) to 0Hz. If an actual setpoint <100% is being used, the emergency stop time is reduced correspondingly.

P434

Relay 1 function

(Analog output 1 function (Relay 1– MFR1))

up to SK

535E

0 ... 39 { 1 }

Control terminals 1/2:Settings 3 to 5 and 11 work with a 10% hysteresis, i.e. the relay contact closes (Function 11 opens) when the limit value is reached and opens (function 11 closes) when a 10% smaller value is undershot. This behaviour can be inverted with a negative value in P435.

Various functions can be programmed. These can be seen in the following table.

BU 0530 GB-3712 41

Functional safety with NORD SK 500E frequency inverters

Parameter

Setting value / Description / Note

Device

Supervisor

Parameter set

P434 [-01]

... [-05]

Digital output function

(Digital output function)

SK 540E and

above

0 ... 39 { [-01] = 1 } { [-02] = 7 } all other { 0 }

Up to 5 outputs (2 of which are relays), which can be freely programmed with digital functions are available in the SK 54xE. These can be seen in the following table.

[-01] = Output 1 / MFR1, relay output 1: external brake, (default), Terminals 1/2 [-02] = Output 2 / MFR2, relay output 2: Fault, (default), Terminals 3/4 [-03] = Output 3 / DOUT1, digital output 1: No function, (default), Terminal 5 [-04] = Output 4 / DOUT2, digital output 2: No function, (default), Terminal 76 [-05] = Output 5 / DOUT3, digital output 3: No function, (default), Terminal 27a

P441

Relay 2 function

(Output 2 function (Relay 2 - MFR2))

up to

SK 535E

0 ... 39 { 7 }

Control terminals 3/4: Functions are identical to P434!

P450

Relay 3 function

(Function output 3 (DOUT1)) )

from SK 520E

to SK 535E

0 ... 39 { 0 }

Control terminals 5/40: Functions are identical to P434! Digital output, 15V against DGND (for SK 5x5E devices, deviations of the signal level are possible).

P455

Relay 4 function

(Function output 4 (DOUT2))

from SK 520E

to SK 535E

0 ... 39 { 0 }

Control terminals 7/40: Functions are identical to P434! Digital output, 15V against DGND (for SK 5x5E devices, deviations of the signal level are possible).

P470

Digital input 7

(Digital input 7)

from SK 520E

to SK 535E

0 ... 74 { 0 }

No function as factory setting, control terminal 27 (DIN7) Various functions can be programmed. These can be found in the tables for P420…P425.

P559

DC Run-on time

(DC run-on time)

S P

0.00 ... 30.00 s { 0.50 }

Following a stop signal and the braking ramp, a direct current is briefly applied to the motor to fully bring the drive to a stop. Depending on the inertia, the time for which the current is applied can be set in this parameter.

The current level depends on the previous braking procedure (current vector control) or the static boost (linear characteristic).

Digital input 7 (DIN7) can also be used as digital output 3 (DOUT3 / Binary output 5). It is recommended that either an input function (P420 [-07] or an out-

put function (P434 [-05]) is parameterised. However, if and input function and an output function are parameterised, a High signal from the output function will result in the activation of the input function. This IO-exclusion is hence used as a kind of "flag". This also applies for digital input 8 (DIN8) and digital output 2 (DOUT2 / binary output 4).

42 BU 0530 GB-3712

4 Parameterisation

Value

Function

Description

Signal

No function

Input switched off.

-----

Disable voltage 7

The FI output voltage is switched off; the motor runs down freely.

Low

Fast stop ³

The FI reduces the frequency according to the programmed fast stop time P426.

Low

Valu

Function

Description

Signal*

No function

Input switched off.

Low

External brake

For the control of a mechanical brake on the motor. The relay switches at a programmed absolute minimum frequency (P505). For typical brakes a setpoint delay of 0.2 … 0.3 seconds (see also P107) should be programmed.

A mechanical brake can be directly AC switched. (Please note the technical specifications of the relay contacts)

High

Fault

General fault message, fault is active or not yet acknowledged.

 Error – contact opens



(ready – contact closes)

Low

STO inactive

The relay / bit deactivates if STO or the Safe Stop are active.

High

* For relay contacts (High = "Contact closed", Low = "Contact open")

List of the functions or the digital inputs P420 ... P425, P470 which are relevant to "Functional safety"

List of possible functions for the relays and digital outputs P434, P441, P450, P455

A complete list of all possible functions can be found in Manual BU 0500 GB.

Also effective for bus control (RS232, RS485, CANbus, CANopen, DeviceNet, Profibus, InterBus, AS-Interface)

BU 0530 GB-3712 43

Functional safety with NORD SK 500E frequency inverters

Load per connected frequency inverter

“Safe pulse block”

Continuous current (mean value)

≤ 50 - 140 mA, according to size

Switch-on current

≤ 400 mA (for t ≤ 2 ms)

Supporting capacitance (downstream of inverse polarity protection)

max. 30 µF

Peak current after an OSSD4 test pulse (periodic)

≤ 400 mA (for t ≤ 300 ms)

Permissible test pulses for an OSSD

0 1 -1 0 1 2 3 4 5 6 7 8 9

Time in ms

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:

5.1 Output voltage

 Mechanical protective switching device: 24V±25% (18V…30V)  Electronic protective switching devices with OSSD5 outputs: 24V-20%+25% (19.2V…30V)

The stated voltages should be available at the input terminals of the inverter. I.e. the line drop in the cable used may need to be taken into account.

5.2 Switching capacity and current load

The safety outputs of the switching devices used must be able to withstand the following loads:

Please note:

Due to the supporting capacitors of the safe shut-down method, there is an increased current consumption for a short time on switch-on and after a test pulse from an OSSD4. The "safe pulse block" is equipped with an active current limiter in order to reduce the load on safety outputs to a minimum.

5.3 OSSD8 outputs, test pulse

 t

≤ 0.5ms (width of test pulse)

off

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 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.

The following sequence results at maximum pulse width: First test pulse, where t voltage is then connected for 0.5 ms, followed by the second test pulse where t supply voltage is connected for at least 8.5 ms!

=0.5 ms the supply

off

= 0.5 ms, the supply

off

= 0.5 ms, and then the

off

Output Signal Switching Device

44 BU 0530 GB-3712

6 Safety categories

Shut-down method

“Safe pulse block”

SIL

PFH

cannot be established (PFH=0)

SFF

100 %

20 years

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.

6.2 IEC 61800-5-2:2007

(German version EN 61800-5-2:2007) The requirements for the functions "Safe shut-down torque (STO) and "Safe stop 1" (SS1) can be fulfilled with

the shut-down method "safe pulse block. With the function SS1, there is no safe monitoring of motor speed reduction or motor speed reduction by the

frequency inverter. If a risk analysis has shown that monitoring is necessary, this must be carried out via an external safe control unit. The solutions for the function SS1 described in the examples correspond to characteristics as per IEC 61800-5-2:2007, Section 4.2.2.3, Paragraph c) "Triggering of motor speed reduction and triggering of the STO function after an application-specific time delay". The motor speed reduction is carried out via the standard functionality of the frequency inverter and is not fail-safe. The switch-over to the STO function is fail-safe.

6.3 IEC 61508

Part 1: 2010 Parts -3, -4, -5: 1998 + Corrigendum 1999 Parts -2, -6, -7: 2000 (German version EN 61508, Part 1: 2010, Parts 2 to 7:2001) 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 SIL 3.

SIL Safety Integrity Level PFH Probability of hazardous failures per hour DC Diagnostic coverage level SFF Proportion of safe failures TM Period of use

The digital inputs do not have SIL capability

BU 0530 GB-3712 45

Functional safety with NORD SK 500E frequency inverters

Shut-down method

“Safe pulse block”

PL e DC

cannot be established (PFH=0)

MTTFd

"high" (>100 years)

20 years

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. Safety category 4 can not be achieved.

PL Performance Level DC Diagnostic coverage level MTTF TM Period of use

The digital inputs which are used for the implementation of safety-relevant stop functions are primarily intended as auxiliary inputs and can fulfil the requirements of Safety Category 1 and Performance Level c.

The mean time until a hazardous failure

46 BU 0530 GB-3712

7 Commissioning

ATTENTION

DANGER TO LIFE!

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.

ATTENTION

The connected motor may only be started after the parameters specific to the application in question have been set by qualified personnel.

Special care is necessary during commissioning until the correct behaviour of the safety functions has been demonstrated by means of validation. If necessary, possible hazards during commissioning must be avoided by organisational means.

7 Commissioning

Once the power supply has been connected to the frequency inverter, it will be operational within a few moments. In this state, the frequency inverter can be set to the requirements of the application, i.e. it can be configured. A detailed and complete description of each parameter is contained in BU 0500 GB.

During commissioning, the following steps with regard to functional safety must be carried out:

STO:

 One safety output of the safety switching device is connected to the safe pulse block (Terminal 89

(24V_SH) and terminal 88 (GND_SH). According to the required safety category, if necessary, a wiring fault (short-circuit between any arbitrary

wires) must be able to be ruled out. It is recommended that a two-conductor shielded cable is used for the safe shut-down method (See also

Section 2.3.5 "Ruling out wiring faults"). The shield must be applied on both sides!

 The typical reaction time can be reduced by the additional use of a digital input.

With the Safe Pulse Block, the diagnostic path "Status at the input terminals", which is in the form of the digital input parallel to the safe pulse block, can be used. For this, the digital input with the function "Block voltage" is used.

It is recommended that a separate shielded cable is used for each safe shut-down method and for the digital inputs used for functional safety. (see also Section 2.3.5 "Ruling out wiring faults"). The shield must be applied on both sides!

 The On/Off switching delay of the digital input must not be used: P475 [-0x] = 0 s!  According to the application, disabling of the safety function may cause a hazard, so that a monitored start

is necessary. In this case, the automatic start may not be used, P428 = "Off" [0].

BU 0530 GB-3712 47

Functional safety with NORD SK 500E frequency inverters

NOTE

The additional 15V/24V output of the inverter (terminal block X8, terminal 86, 87) has been provided for commissioning the inverter without a safety switching device. In this case, the 15V/24V can be directly connected to the 24V input voltage of the pulse block.

As delivered, terminals 87-88 and 86-89 are bridged in order to enable commissioning or operation without the safety function (or without ext. 24V).

NOTE

It must be proven by suitable validation that the requirements for the specially intended purpose have been met.

SS1:

 One safety output of the safety switching device is connected to a digital input (terminal block X5, terminals

21 ... 24). It is recommended that a shielded cable is used for this. The shield must be applied on both sides!

 The safe pulse block is connected to a delayed safety output of the safety switching device used (terminal

89 (24V_SH) and terminal 88 (GND_SH). It is recommended that a separate shielded cable is used for this. The shield must be applied on both sides!

 The selected digital input must be assigned the „fast stop“ [11] function.  For the function SS1, the parameter P426 "fast stop time" and if necessary P559, "DC follow-on time" must

be parameterised according to the requirements of the application. The delay time of the delayed output of the protective switching device must be rated so that it is longer than the fast stop time plus the DC followon time.

is necessary. In this case, the automatic start may not be used, P428 = "Off" [0].

Validation

48 BU 0530 GB-3712

8 Diagnosis and faults

Display in the ControlBox

Fault Text in the ParameterBox

Cause Group

Details in

P700 / P701

E018

18.0

Safety circuit

While the frequency inverter was enabled, the Safe pulse block safety circuit was triggered.

8 Diagnosis and faults

8.1 Diagnosis

Detailed information can be found in the operating instructions for the basic device (BU0500).

Status information It is possible to access status information by means of the ParameterBox, SimpleBox or via a field bus. This

information is not provided on a fail-safe basis, but rather only for information purposes! The status of the "safe pulse block" and the digital inputs and outputs can be accessed via the information

parameters and if necessary by means of the status word with communication via a field bus (See Section 4 "Parameterisation").

In order to be able to query the reaction of the "safe pulse block", the digital output, a Bus Out bit or a free bit of the status word (Bit 10 or Bit 13) must be assigned function 39 (STO inactive). The status of this bit can be read out via the parameters P711 (digital output), P741 [-01] (status word) or P741 [-05] (Bus Out bits) or can be transferred via the bus protocol.

8.2 Faults

Detailed information can be found in the operating instructions for the basic device (BU0500).

8.2.1 Table of possible error messages

The fault messages to be assigned to functional safety are listed in the following table.

8.2.2 Error display

ControlBox / SimpleBox: The 4-digit, 7 segment display of these boxes indicates a fault with its number and

the prefix "E". If the cause of the error is no longer present, the error display flashes and the error can be acknowledged with the OK key.

ParameterBox: The error messages are shown in plain text.

8.2.3 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 0500 GB.

BU 0530 GB-3712 49

Functional safety with NORD SK 500E frequency inverters

Function

Specification

Ambient temperature

0℃ ... +40°C (S1–100% ED), 0℃ ... +50°C (S3–70% ED 10min.)

Storage temperature

-20℃ ... +60℃

Transport temperature

-20℃ ... +70°C

Relative humidity

5%...85%, condensation is not permissible

Installation altitude above sea level

≤ 2,000m

Overvoltage category

Degree of fouling

Protection class (inverter)

IP20

Space requirements

IP54

Long-term storage

After one year at the latest, the frequency inverter must be connected to the mains supply for 60 minutes. In addition, the fail-safe input (safe pulse block) must be supplied with voltage ´(24V) or must be operated in its start-up configuration. This cycle must be maintained for the storage period.

EMC

When using wiring that conforms to EMC requirements, as per BU 0500 DE, the thresholds can be observed up to a line length of 20 m between the safety switching device and the inverter.

Function

Specification

Sizes 1 to 4, 8 and 9

Terminal cross-section of the control terminals terminals X3 to X8

0.14mm

…1.5mm

rigid, flexible

28…16 AWG

0.25mm

…1.5mm

flexible with wire and sleeves and without plastic tube

0.25mm

…0.5mm

flexible with wire and sleeves and with plastic tube

Sizes 5 to 9

Terminal cross-section of the control terminals terminals X3 to X7

0.14mm

…1.5mm

rigid, flexible

28…16 AWG

0.25mm

…1.5mm

flexible with wire and sleeves and without plastic tube

0.25mm

…0.5mm

flexible with wire and sleeves and with plastic tube

Terminal X8

0.2mm

…6mm

rigid, flexible

24…10 AWG

0.2mm2…6mm2 flexible with wire and sleeves and without plastic tube

0.2mm

…4mm

flexible with wire and sleeves and with plastic tube

9 Technical data

For further data, which is not listed here, please refer to the main manual for the basic device (BU0500).

9.1 Environmental data

9.2 Control terminal data

50 BU 0530 GB-3712

9.3 Data for the digital inputs

Function

Specification

(only DIN1…4,6,7)

Input voltage

+24V

Voltage tolerance

-50% +25% (12V…30V)

High level (VT+)

≥ 11V

Low level (VT+)

≤ 3.5V

Input resistance

6.1kΩ (typical)

Input capacitance

10nF (typical)

Reaction time

≤ 5ms

Requirements made of OSSDs

Test pulse width ≤ 500 µs Duty (high level) ≥ 90 % Distance between double pulses ≥1ms (note the duty factor)

Safety integrity level (IEC 61508)

non, the digital inputs do not have SIL capability Probability of a hazardous failure

DIN1 to DIN4: PFH = 588.39 FIT

Proportion of safe failures

DIN1 to DIN4: SFF = 37.34%

Safety category (as per to EN ISO 13849-1)

Cat. 1

Performance Level (As per EN 13894-1)

PL c

The mean time until a hazardous failure

MTTFd = "High" (>100 years) Diagnostic coverage level

No DC

Lifetime

TM = 20 years

9 Technical data

BU 0530 GB-3712 51

Functional safety with NORD SK 500E frequency inverters

Function

Specification

Input voltage

+24V

Voltage tolerance

±25% (18V…30V)

Operation at OSSD

-20% +25% (19.2V…30V)

Power consumption

Size 1 - 6: 100mA, Size 7 140mA, Size 8 - 9 50mA (mean value)

Peak current

400mA (peak, when switching on or at the OSSD9) size 1 - 4

Cable length

≤ 20m (refer to EMC, grouping)

Line capacitance

≤ 10nF for each inverter connected

Switch-on delay

≤ 200ms

Reaction time

≤ 200ms (15ms - 35ms typical)

Cycle time

≥ 1s

Requirements made of OSSDs

Test pulse width ≤ 500µs Duty (High level) ≥ 90% Distance between double pulses ≥1ms (observe the duty factor)

Safety integrity level (IEC 61508)

SIL3

Probability of a hazardous failure

PFH=0

Safety category (as per EN ISO 13849-1)

Cat. 4 with dual-channel triggering (separation of VI_S 24V and VI_S 0V) Cat. 3 with single-channel triggering of the safe pulse block

Performance level (as per to EN 13894-1)

PL e Lifetime

TM=20 years

9.4 Data for the safe pulse block

Output Signal Switching Device

52 BU 0530 GB-3712

10 Additional information

NOTE

If possible, the reason for returning the component/device should be stated. If

necessary, at least one contact for queries should be stated. This is important in order to keep repair times as short and efficient as possible. On request you can obtain a suitable goods return voucher from Getriebebau NORD

GmbH.

10 Additional information

10.1 Maintenance and servicing information

SK 500E frequency inverters are maintenance free. Please also note the "General data" in Section 7.1. of Manual BU 0500 GB.

If air intake filters have been built into the control cabinet, then these should also be regularly cleaned or replaced.

If you contact our technical support, please have the precise device type (rating plate/display), accessories and/or options, the software version used (P707) and the series number (name plate) at hand.

Repairs

The device must be sent to the following address if it needs repairing:

NORD Electronic DRIVESYSTEMS GmbH

Tjüchkampstr. 37

26605 Aurich, Germany

For queries about repairs, please contact:

Getriebebau NORD GmbH & Co. KG

Tel.: 04532 / 289-2515 Fax: 04532 / 289-2555

If a frequency inverter or accessories are sent in for repair, no liability can be accepted for any added components, e.g. such as line cables, potentiometer, external displays, etc.!

Please remove all non-original parts from the frequency inverter.

Internet information

You can also find the comprehensive manual in German and in English on our Internet site.

www.nord.com

10.2 Abbreviations in this manual

AS-i ..... AS interface

BW ...... Brake resistor

EMC ..... Electromagnetic compatibility

FI ......... Frequency inverter

OSSD .. Output Signal Switching Device

BU 0530 GB-3712 53

S ...........Supervisor Parameter, P003

SH ........."Safe stop"

SS1 .......safe stop 1

STO .......safe torque off

SW .......Software version, P707

Functional safety with NORD SK 500E frequency inverters

11 Keyword index

Assembly .................................... 29

Control terminals ......................... 50

DC run-on time (P559) ................ 42

Digital input 1 (P420) .................. 40

Digital input 2 (P421) .................. 40

Digital input 3 (P422) .................. 40

Digital input 4 (P423) .................. 41

Digital input 6 (P425) .................. 41

Digital input 7 (P470) .................. 42

Digital inputs ......................... 21, 51

Digital inputs (P420) .................... 40

Digital output

Funct. (P434) ................... 42

Digital output ............................... 38

EMC ............................................ 30

Environmental data ..................... 50

Error memory .............................. 49

Example (Restart block) .............. 26

Example (SS1) ............................ 25

Examples (STO) ......................... 23

Exclusion of faults ....................... 28

Functional Safety ........................ 30

Grounded Corner ........................ 29

IEC 60204-1 ............................... 45

IEC 61508 .................................. 45

IEC 61800-3 ............................... 10

IEC 61800-5-2 ............................ 45

Installation .................................. 29

Internet ....................................... 53

IP 29

ISO 13849-1 ............................... 46

IT network .................................. 29

Low Voltage Directive .................. 2

Mains connection ....................... 29

mechanical brake ....................... 22

Mechanical brake ....................... 22

OSSD ................................... 30, 44

Performance Level ..................... 46

Protection class .......................... 29

Quick stop time (P426) ............... 41

Relay 1

function (P434) ................. 41

Relay 2

function (P441) ................. 42

Relay 3

function (P450) ................ 42

Relay 4

function (P455) ................ 42

Repairs ....................................... 53

Restart block .............................. 26

Safe pulse block ......................... 19

Safe pulse block ......................... 21

Safe pulse block ......................... 30

Safe pulse block ......................... 52

Safe shut-down methods ............ 21

Safety category .......................... 46

Safety functions .......................... 22

Safety information ........................ 2

SIL .............................................. 45

SS1 ............................................ 48

SS1 ...................................... 22, 40

Status information ...................... 49

STO ................................ 22, 40, 47

STO (Safe Pulse Block).............. 30

Technical data ............................ 50

TN Network ................................ 29

TT Network ................................. 29

Wiring: ........................................ 29

54 BU 0530 GB-3712

11 Index

BU 0530 GB-3712 55

Mat. Nr. 607 5302 / 3712

NORD BU0530 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 General

1.1 Safety and installationinformation

1.2 Approvals and certificates

1.2.1 Certifications for the function STO

1.2.2 Certifications for the function SS1

1.2.3 Certificate for the sole use of the digital inputs

1.3 Identification system

2 Function description

2.1 Safe shut-down method

2.1.1 Safe pulse block

2.1.2 Digital inputs

2.2 Safety functions

2.2.1 Safe torque off, STO

2.2.2 Safe stop 1, SS1

2.3 Examples / Implementation

2.3.1 STO function

2.3.2 SS1 Function

2.3.3 Simple restart block

2.3.4 Example without safe shut-down method

2.3.5 Ruling out wiring faults

3 Assembly and installation

3.1 Installation and assembly

3.2 Wiring guidelines

3.3 Mains supply (X1-PE, L1, L2/N, L3)

3.4 Connecting the control cables

3.4.1 Connecting the safe pulse block (X8 – VIS 24V, VIS 0V)

3.4.2 Connection terminals

3.4.3 Details of the "Safe pulse block" control connections

Terminal block X8 – Safe pulse lock (not with 115V devices)

3.4.4 Details of the "Digital inputs" control connections

Terminal block X5 – Digital In

3.4.5 Details of the "Digital outputs" control connections

Terminal block X/ – Digital I/O

4 Parameterisation

5 Protective switching devices

5.1 Output voltage

5.2 Switching capacity and current load

6 Safety categories

6.1 IEC 60204-1:2005

6.2 IEC 61800-5-2:2007

6.3 IEC 61508

6.4 ISO 13849-1:2006

7 Commissioning

8 Diagnosis and faults

8.1 Diagnosis

8.2 Faults

8.2.1 Table of possible error messages

8.2.2 Error display

8.2.3 Error memory

9 Technical data

9.1 Environmental data

9.2 Control terminal data

9.3 Data for the digital inputs

9.4 Data for the safe pulse block

10 Additional information

10.1 Maintenance and servicing information

10.2 Abbreviations in this manual

11 Keyword index