Siemens SINAMICS DCM User Manual

SINAMICS DCM
DC Converter Application document for functional safety STO, SS1 (ISO 13849-1)
Compact User Manual
09/2016
A5E34871844AM
Introduction
1
Principle of the dual channel architecture
2
STO stop Category 0 with one switching device
3
SS1 stop Category 1 with one switching device
4
STO, two switching devices in series
5
SS1, two switching devices connected in series
6
STO stop Category 0, several power units
7
SS1 stop Category 1 for several power units
8
Evaluating the safety functions according to EN ISO 13849 when using one switching device
9
Evaluating the safety functions according to EN ISO 13849 when using two switching devices
10
Evaluation of the safety function according to EN 62061
11
Standards
12
Recommended safety relays
13
Connection circuit diagrams for the switching devices
14
Recommended circuit breakers and power contactors
15
Siemens AG Division Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY
A5E34871844AM
09/2016 Subject to change
Copyright © Siemens AG . All rights reserved
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DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
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Note the following:
WARNING
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Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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Table of contents
1 Introduction................................................................................................................................. 11
1.1 Important note ................................................................................................................... 11
1.2 Preliminary remarks........................................................................................................... 11
1.2.1 Safe Torque Off (STO) ...................................................................................................... 12
1.2.2 Safe Stop 1 (SS1, time-controlled) ..................................................................................... 12
1.2.3 Using EMERGENCY STOP ............................................................................................... 13
1.3 Application overview .......................................................................................................... 13
1.4 Armature circuit with one switching device ......................................................................... 14
1.5 Armature circuit with two switching devices ........................................................................ 14
1.6 Field circuit description ...................................................................................................... 15
1.7 Safety shutdown (E-STOP)................................................................................................ 16
1.8 Parameterizing the digital outputs ...................................................................................... 17
1.9 Parameterizing the digital input for SS1 OFF3 ................................................................... 18
1.10 Abbreviations and circuit diagram symbols ........................................................................ 19
2 Principle of the dual channel architecture ....................................................................................... 21
3 STO stop Category 0 with one switching device .............................................................................. 23
3.1 Description ........................................................................................................................ 23
3.2 STO circuit example with one 3WL circuit breaker ............................................................. 24
3.3 STO circuit example with one power contactor................................................................... 25
4 SS1 stop Category 1 with one switching device ............................................................................... 27
4.1 Description ........................................................................................................................ 27
4.2 SS1 circuit example with one 3WL circuit breaker .............................................................. 28
4.3 SS1 circuit example with one power contactor ................................................................... 29
5 STO, two switching devices in series ............................................................................................. 31
5.1 Description ........................................................................................................................ 31
5.2 STO circuit example with two 3WL circuit breakers connected in series ............................. 32
5.3 STO circuit example with two power contactors connected in series .................................. 33
6 SS1, two switching devices connected in series .............................................................................. 35
6.1 Description ........................................................................................................................ 35
6.2 SS1 circuit example with two 3WL circuit breakers connected in series .............................. 36
6.3 SS1 circuit example with two power contactors connected in series ................................... 37
Table of contents
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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7 STO stop Category 0, several power units ..................................................................................... 39
7.1 Description .........................................................................................................................39
7.2 STO circuit example with two power units and circuit breakers............................................40
7.3 STO circuit example with two power units and power contactors .........................................41
8 SS1 stop Category 1 for several power units .................................................................................. 43
8.1 Description .........................................................................................................................43
8.2 SS1 circuit example with two power units and circuit breakers ............................................45
8.3 SS1 circuit example with two power units and circuit breakers ............................................46
9 Evaluating the safety functions according to EN ISO 13849 when using one switching device .............. 47
9.1 Evaluation of "Detect" .........................................................................................................48
9.2 Evaluation of "Evaluate" .....................................................................................................49
9.3 Evaluation of "Respond" .....................................................................................................50
9.3.1 Evaluation of "Respond" with one power switching device ..................................................50
9.3.1.1 Evaluation of an 3WL circuit breaker...................................................................................50
9.3.1.2 Evaluation of a power contactor ..........................................................................................52
9.4 Result when using a 3WL circuit breaker ............................................................................53
9.5 Result when using a power contactor .................................................................................53
10 Evaluating the safety functions according to EN ISO 13849 when using two switching devices............. 55
10.1 Evaluation of "Detect" .........................................................................................................56
10.2 Evaluation of "Evaluate" .....................................................................................................57
10.3 Evaluation of "Respond" .....................................................................................................58
10.3.1 Evaluation of "Respond" with two power switching devices .................................................58
10.3.1.1 Evaluation of two 3WL circuit breakers connected in series ................................................58
10.3.1.2 Evaluation of two power contactors connected in series......................................................59
10.3.2 Result of "Respond" with two 3WL circuit breakers .............................................................60
10.3.3 Result of "Respond" with two power contactors ..................................................................60
10.4 Result when using two 3WL circuit breakers .......................................................................60
10.5 Result when using two power contactors ............................................................................61
11 Evaluation of the safety function according to EN 62061 .................................................................. 63
11.1 Evaluation of "Detect" .........................................................................................................64
11.2 Evaluation of "Evaluate" .....................................................................................................65
11.3 Evaluation of "Respond" .....................................................................................................66
11.3.1 Evaluation of "Respond" with two power switching devices .................................................66
11.3.1.1 Evaluation of two 3WL circuit breakers ...............................................................................66
11.3.1.2 Evaluation of two power contactors ....................................................................................67
11.3.2 Result "Respond" when using two 3WL circuit breakers ......................................................67
11.3.3 Result "Respond" when using two power contactors ...........................................................68
11.4 Result when using two 3WL circuit breakers .......................................................................68
11.5 Result when using two power contactors ............................................................................69
Table of contents
Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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12 Standards ................................................................................................................................... 71
13 Recommended safety relays ......................................................................................................... 73
14 Connection circuit diagrams for the switching devices ...................................................................... 75
15 Recommended circuit breakers and power contactors ..................................................................... 81
Table of contents
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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Supplement to liability exclusion
We accept no liability for any damage or loss caused by use of the safety functional examples, information, programs, planning data or performance data described in this document, irrespective of the legal basis for claims arising from such damage or loss, unless liability is mandatory, for example, according to the product liability law, in cases of malfeasance, gross negligence, due to endangerment of life, the body or health, due to assumption of a guarantee for a product's characteristics of state, due to malicious concealment of a defect or due to violation of basic contractual obligations. The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. Any change to the burden of proof to your disadvantage is not covered hereby.
Copyright
Copyright © 2016 Siemens AG. Reproduction or transmissions of these safety function examples or extracts thereof are forbidden without the express written authority of Siemens AG.
Manuals and application notes on the Internet
The manuals and application documents are available in the Internet: Manuals (https://support.industry.siemens.com/cs/ww/en/ps/13298) The list of general conditions available there include current supplements to the manuals. The notes included in the general condition lists have a higher priority than the statements made in the manuals.
Introduction
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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Introduction
1
1.1
Important note
The safety functional examples are non-binding and do not claim to be complete in respect of configuration, equipment or practical eventualities. The safety functional examples are not customer-specific solutions but are only intended to facilitate the performance of typical tasks. You are responsible for ensuring that the products described are used correctly.
These safety functional examples do not relieve you of the obligation to use the products safely during application, installation, operation and maintenance. By using these safety functional examples, you acknowledge the fact that Siemens cannot be held liable for any claims or damages above and beyond the liability described above. We reserve the right to make changes to these safety function examples at any time without prior notice. In the case of any differences between the suggestions made in these safety function examples and other publications from Siemens, such as catalogs, the contents of the other documentation have priority.
1.2
Preliminary remarks
In DIN EN 60204-1: 2007 a distinction is made between three stop categories to stop machines: Stop categories 0, 1 and 2 The stop category to be used must be defined based on the risk assessment of the particular machine.
The safety functions listed here are in conformance with:
● Safety Integrity Level (SIL) 2 according to DIN EN 61508
● Category 3 according to DIN EN ISO 13849-1
● Safety of machinery - functional safety according to EN 62061
● Performance Level (PL) d according to DIN EN ISO 13849-1
The safety functions correspond to the functions according to DIN EN 61800-5-2.
This application document explains stop categories 0 and 1.
Introduction
1.2 Preliminary remarks
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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1.2.1
Safe Torque Off (STO)
Safe Torque Off is a safety function to avoid unexpected starting in accordance with EN 60204-1. STO prevents the supply of energy to the motor, which can generate a torque and corresponds to Stop Category 0. The motor is stopped in an uncontrolled fashion.
Notes
● When a large DC smoothing reactor is used in the armature circuit the current decay time
of 0.05s before switching the firing pulses off may possibly not be sufficient for STO / stop category
0. If the armature current at this instant is not pulsating, inverter shoot-through
can occur. As a consequence, in this particular case we recommend that the output e
x-
pansion of the safety relay is shut down with a short delay of 0.5 s. Setting the output e
x-
pansion, see circuit example SS1.
● When the 2Q field
option that does not contain any free-wheeling diode for the field cur-
rent is used, the use of SS1 / stop category
1 is recommended to protect the field contac-
tor. This is necessary because the braking voltage of the opening contacts of a field contactor (
line side) does not suffice to activate the free-wheeling function of the 2Q thyri
s-
tor bridge.
1.2.2
Safe Stop 1 (SS1, time-controlled)
Safe Stop 1 is based on the "Safe Torque Off" function. This means that a Category 1 stop according to EN 60204-1 can be implemented. The drive is actively braked to a standstill. The energy feed is safely shut down after a time, which can be adjusted at the safety relay, after the motor should safely remain stationary (STO).
Introduction
1.3 Application overview
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1.2.3
Using EMERGENCY STOP
STO and SS1 are suitable for the EMERGENCY STOP function when the following preconditions are carefully taken into consideration:
The user must evaluate as to whether an immediate shutdown of the energy feed for STO does not result in dangerous states (uncontrolled stopping - STOP category 0 according to EN ISO 13850).
When using SS1, if the line supply fails, the drive can no longer be actively braked - and it must be taken into consideration that the drive only comes to an absolute standstill at a later point in time.
Although actuating the EMERGENCY STOP switch disconnects the energy feed to the drive, for a permanently excited DC motor that is still rotating, a voltage is still present at the armature terminals corresponding to the speed.
With an EMERGENCY OFF function the system is brought into a no voltage condition after switching off in an emergency according to IEC 60204-1. The motor must then come to a complete standstill and the field supply must have been switched off.
EMERGENCY STOP function according to EN ISO 13850: The function of the EMERGENCY STOP equipment must be designed so that after actuating the EMERGENCY STOP device, hazardous motion and operation of the machine are stopped in a suitable fashion without resulting in any additional risks and dangers.
1.3
Application overview
The following recommendations are described in this document:
Stop Category 0 (STO = Safe Torque OFF)
Stop Category 1 (SS1 = Safe Stop 1)
Overview of the various configurations
Switching device STO SS1 Achievable Performance
Level (PL)
Achievable Safety
Integrity Level (SIL)
1 3WL circuit breaker
Sec. 3.2
Sec. 4.2
d
X
1 power contactor Sec. 3.3 Sec. 4.3 d X
2x 3WL circuit breakers
Sec. 5.2
Sec. 6.2
d
2
2s power contactors Sec. 5.3 Sec. 6.3 e 3 2x power units with
3WL circuit breaker
Sec. 7.2 Sec. 8.2 d X
2x power units with
power contactor
Sec. 7.3 Sec. 8.3 d X
The safety relays used are listed in Recommended safety relays (Page 73).
Introduction
1.4 Armature circuit with one switching device
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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The power contactors and circuit breakers that have been tested are listed in Recommended circuit breakers and power contactors (Page 81).
Note
Circuit breakers
are, according to EN ISO 13849-2: 2013-02 considered as proven
components. As a consequence, two NC contacts of each circuit breaker are connected in series to provide a feedback signal, which must be integrated in the feedback circuit of the safety relay
.
Note
Power contactors
must have mirror contacts or positively-driven contacts to be considered
as proven component in compliance with EN
ISO 13849-2: 2013-02; these contacts must be
integrated in the feedback circuit of the safety relay.
1.4
Armature circuit with one switching device
The armature circuit power supply is realized with only one circuit breaker or one power contactor. The E-Stop for the power unit is controlled in parallel.
After STO has been selected, the E-Stop function of the drive is activated using the safety relay (supply at terminal 105 is disconnected). When setting p51616=0, using Alpha-W pulses, the SINAMICS DCM reduces the armature current - and then inhibits the firing pulses and also interrupts the main contactor control (terminals 109-110). The active E-Stop state is integrated in the feedback circuit of the safety relay using digital output (DO3) via a relay.
Via the expansion device, independent of the SINAMICS DCM state, a safety-related coupling relay is switched, which immediately opens the circuit breaker with the undervoltage coil - or for a power contactor, disconnects the solenoid.
If STO is not selected, then the circuit breaker or power contactor is switched with a positively-driven interface relay from the SINAMICS DCM.
1.5
Armature circuit with two switching devices
The armature circuit power supply is realized with two circuit breakers or power contactors connected in series. The E-Stop for the power unit is also controlled.
This solution essentially differs as a second switching device is installed in the amateur circuit.
After STO has been selected, the E-Stop function of the drive is activated using the safety relay (supply at terminal 105 is disconnected). When setting p51616=0, using Alpha-W pulses, the SINAMICS DCM reduces the armature current - and then inhibits the firing pulses and also interrupts the main contactor control (terminals 109-110). The active E-Stop state is integrated in the feedback circuit of the safety relay using digital output (DO3) via a relay.
Introduction
1.6 Field circuit description
Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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Via the expansion device, independent of the SINAMICS DCM state, a safety-related coupling relay is switched, which immediately opens the circuit breaker with the undervoltage coil - or for a power contactor, disconnects the solenoid.
If STO is not selected, then the circuit breakers or power contactors are switched with a positively-driven interface relay from the SINAMICS DCM.
Two switching devices are required to achieve SIL2 according to EN62061 and PL d according to DIN EN ISO 13849-1.
1.6
Field circuit description
If a power contactor is used in the field circuit, then this can be optionally switched with the safety function. If the field contactor is to be integrated in the safety function, then the field contactor must be opened and closed with the output expansion of the safety relay using a safety-related interface relay. The positively-driven NC contact of the coupling relay - as well as the mirror contact of the field contactor - must be integrated in the feedback circuit of the safety relay. This version is shown in the circuit examples.
Introduction
1.7 Safety shutdown (E-STOP)
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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1.7
Safety shutdown (E-STOP)
Note
The
E-STOP function alone does not represent a safety function.
The E-STOP function forces the "line contactor closed" relay to drop out, activating the relay contact (terminals XR1-109 and -110) for the main contactor control within approximately 20 ms, independent of the semiconductor components and Control Unit (CUD) functions. If the CUD is operating correctly, entering I = 0 via the control ensures that the main contactor switches in a no-current condition. The drive coasts down once E-STOP has been entered.
The E-STOP function is initiated when the switch between terminals XS1-105 and XS1-106 is opened.
The E-STOP function causes the drive to go into the "Switching on inhibited" operating state. This must be acknowledged by activating the "shutdown" function e.g. by opening terminal X177.12.
Sequence when initiating an E-STOP:
1.
The ramp-function generator, n controller, and I controller are disabled.
2.
The armature current is reduced to zero
3. a) p51616 = 0: E-STOP acts like OFF2 (firing pulses are inhibited as soon as I = 0).
b) p51616 = 1: E-STOP immediately stops firing pulses from being output (without waiting for I = 0).
4.
The "Close operating brake" signal is output (r53210.0 = 1, for p50080 = 2).
5.
Operating state o10.0 or higher is reached.
6. The field current is maintained at a fixed level
(i.e. there is no increase in the field current, even on exiting the field-weakening range).
7. The "Close line contactor" relay (terminals XR1-109 and -110) drops out.
8
The drive coasts down (or is decelerated by the operational brake).
9
The wait time (to be set at p50258) elapses.
10.
The field is reduced to a parameterizable value (p50257).
11.
Once n < nmin (p50370, p50371), the "Close holding brake" signal is output (r53210.0 = 1, for p50080 = 1).
Note
20 ms after an E-STOP has been initiated (even if point 7 in this sequence has not yet been reached), the "Close line contactor" relay (terminal XR1-109 and XR1-110) is opened (drops out), initiated by the hardware.
Introduction
1.8 Parameterizing the digital outputs
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1.8
Parameterizing the digital outputs
In order to signal to the safety relay that the drive E-STOP function has been activated, the following parameters must be set at the SINAMICS DC MASTER:
Digital output DO3 at connector X177.22 controls relay K
EP
. This serves as feedback signal contact for the E-STOP path. The function of DO3 (connector X177.22) is defined using parameter p50774: p50774 = (63) r53100.0
Digital output DO2 at connector X177.21 controls, via relay K
DO2F
, the field contactor. The function of DO2 (connector X177.21) is defined using parameter p50773. The setting of p50773 is dependent on the setting of parameter p50082:
p50082 = 0
(no field)
p50773 = 0
p50082 = 1
(field is also switched with the armature contactor)
p50773 = (63) r53082.0
p50082 = 2
(standstill field at ≥ o7.0)
p50773 = 1
p50082 = 3
(field is permanently switched on)
p50773 = 1
p50082 = 4
(field is also switched with the auxiliaries ON si
g-
nal)
p50773 = (63) r53
210.2
p50082 = 21
(external field power unit, otherwise, as for setting
1)
p50773 = (63) r53082.0
p50082 = 22
(external field power unit, otherwise, as for setting
3)
p50773 = 1
p50082 = 23
(external field power unit, otherwise, as for setting
3)
p50773
= 1
p50082 = 24
(external field power unit, otherwise, as for setting
4)
p50773 = (63) r53210.2
Note (63) signifies: "from own drive object"
r53100.0 is E
-Stop state (1 = no E-Stop, 0 = E-Stop)
r53082.0 is CLOSE armature contactor r53210.2 is
auxiliaries ON
Note The maximum 100 mA current rating of the digital outputs must be carefully observed.
Introduction
1.9 Parameterizing the digital input for SS1 OFF3
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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1.9
Parameterizing the digital input for SS1 OFF3
Digital input DI/DO 4 (terminal X177.15 on the CUD electronics module) of the SINAMICS DC MASTER must be used for the SS1 function. This digital input must be parameterized so that signal OFF3 (fast stop) is controlled in all of the command data sets (CDS) used
Setting p849 (OFF3) p53010[8] (DI/DO 4)
Setting p50296 (OFF3 down ramp) e.g. 5 seconds
Note For setting p50269=0 (OFF3 ramp down time), the drive brakes at the current limit. The
actual ramp
-down time is influenced by the driving forces of the mechanical system. The
safety relay delay should be set longer than the actual ramp
-down time
.
Introduction
1.10 Abbreviations and circuit diagram symbols
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1.10
Abbreviations and circuit diagram symbols
K
A[n]
Armature contactor
KF
Field contactor
K
AH[n]
Safety-related interface relay to control the armature contactor
K
FH1
Safety-related interface relay to control the field contactor
K
EP[n]
Relay, feedback signal E-Stop
DO2
Programmable digital output 2 2 = X177.21 (field contactor control)
DO3
Programmable digital output 3 = X177.22 (feedback signal E-Stop active)
DI/DO4
Programmable digital input 4, X177.15 (to select OFF3 = fast stop)
K
FH1 KAH1 KAH[n]
Phoenix Contact, PSR-SPP-24DC/FSP/1X1/1X2 - 2981981
K
DOKop
; K
EP[n]
Phoenix Contact, PR1-RSC3-LDP-24DC/2X21AU - 2834520
P24
24 V supply via X177.9 or X177.10
M24
24 V ground via X177.23 or X177.24
L, N
Maximum supply voltage, 250 VAC
L
AH1
, N
AH1
Maximum armature contactor supply voltage 250V AC/DC 5A
Observe the load curve and derating of the K
AH
LFH, NFH Maximum field contactor supply voltage 250V AC/DC 5A
Observe the load curve and derating of the KFH
L
AH[n]
, N
AH[n]
Maximum armature contactor supply voltage 250V AC/DC 5A
Observe the load curve and derating of the K
AH[n]
Positively-driven contacts = combination of NO and NC contacts is designed so that they can never be simultaneously closed
Mirror contact = auxiliary NC contact that cannot be closed simultaneously with a main NO contact.
Switch position = black
Introduction
1.10 Abbreviations and circuit diagram symbols
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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Application doc ument for functional safety STO, SS1 (ISO 13849-1) Compact User Manual, 09/2016, A5E34871844AM
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2
The following two block diagrams show the two-channel architecture of the safety system, so that after the first two faults – each in one of the two channels – the system can fail.
Safety block diagram of a drive without field excitation
Safety block diagram of a drive with field excitation
Path 3 is not considered to be a safety-related switch-off signal path as the field remanence of the DC motor – for a high armature current – can result in the motor developing a torque.
On the following page, as in 4.2, the function blocks are colored the same as in the previous block diagram as example.
Principle of the dual channel architecture
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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Dual channel architecture, color-coded using the application of SS1 as example
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3
3.1
Description
When selecting the safety function (actuating the Emergency Stop pushbutton), the instantaneous NO contacts are immediately opened in the 3SK1122-2CB41 safety relay. As a consequence, the E-Stop function is initiated at the SINAMICS DCM. The SINAMICS DCM reduces the armature current, inhibits the firing pulses and opens the armature contactor. The "E-Stop active" signal must be integrated in the feedback circuit of the safety relay via a coupling relay at digital output DO3 (X177.22). At the same time when the NO contacts of the safety relay open, the safety-related output expansion 3SK1211-2BB40 is shut down via the internal communication of the 3SK safety relay; as a consequence, the safety-related coupling relays to control the armature and field circuits are opened.
The motor current therefore goes to zero and in turn, the motor torque also goes to zero. The motor coasts down.
In the circuit examples, the energy feed to the field power units as well as to the armature circuit is interrupted. Controlling the field contactor is optional. However, in this case, the motor cannot be considered to be in a no-voltage condition.
STO stop Category 0 with one switching device
3.2 STO circuit example with one 3WL circuit breaker
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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3.2
STO circuit example with one 3WL circuit breaker
STO stop Category 0 with one switching device
3.3 STO circuit example with one power contactor
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3.3
STO circuit example with one power contactor
STO stop Category 0 with one switching device
3.3 STO circuit example with one power contactor
Application doc ument for functional safety STO, SS1 (ISO 13849-1)
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