NORD BU0530 User Manual
GB
BU 0530
Functional Safety
Supplementary instructions for frequency inverter SK 500E
Functional Safety
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
BU 0530 GB-3712 3
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
4 BU 0530 GB-3712
Functional safety with NORD SK 500E frequency inverters About this document
Item Item Item
Item
Item 5
SK
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
SK
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
BU 0530 GB-3712 5
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 100H 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:
SK
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
1
750
750W
1 1 1
1
111
1.1kW
2 2
2
151
1.5kW
2 2
2
221
2.2kW
2 2
2
301
3.0kW
3 3
3
401
4.0kW
3 3
3
551
5.5kW
5 4
4
751
7.5kW
5 4
4
112
11kW
6 5
5
152
15kW
7 5
5
182
18.5kW
7 6
6
222
22kW
6
6
302
30kW
7
7
372
37kW
7
7
452
45kW
8
8
552
55kW
8
8
752
75kW
9
9
902
90kW
9
9
1.3 Identification system
1 General
BU 0530 GB-3712 17
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