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BONFIGLIOLI Agile Series User Manual

BONFIGLIOLI Agile Series
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26 AGL-STOV0-01SV0-05
06/12
10.1 STO according to Stop Category 0
10.1.1 STO Direct Stop
The Application example shows the minimum circuitry for Agile Frequency inverter for
realization of the safety function STO – “Safe Torque Off” with an emergency stop
device in a common electrical cabinet according to EN ISO 13849-1 PL d and Catego-
ry 3 or IEC 61508 SIL 2.
When operating the emergency stop device with two stop channels both release
paths paths STOA and STOB of the Agile frequency inverter are interrupted and the
integrated safety function is triggered by interrupting the inverter release. A (non-
safe) feedback to a process control can be done via a connected field bus. When STO
is requested, the process controller can no further influence the inverter release in-
side the frequency inverter.
Note: Terminal X11.1 can be used for DC 24 V supply of the safety control unit.
Please comply with chapter 7.3.1.

Table of Contents

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BONFIGLIOLI Agile Series Specifications

General IconGeneral
BrandBONFIGLIOLI
ModelAgile Series
CategoryDC Drives
LanguageEnglish

Summary

General Documentation Information

Quick Start Guide

Basic installation and commissioning steps.

Operating Instructions

Describes all functions and parameters.

Application Manual

Supplements documentation for installation and commissioning.

General Information about the Documentation

Instruction Manuals Overview

Overview of Quick Start, Operating, and Application Manuals.

Pictograms and Signal Words

Explains safety symbols and their meanings.

Application Examples

STO According to Stop Category 0

Examples of STO with Stop Category 0.

SS1 According to Stop Category 1

Examples of SS1 with Stop Category 1.

Internal DC 24 V Supply, SS1

Example of SS1 with internal DC supply.

Group Stop, SS 1

Example of Group Stop with SS1.

Pictograms and Signal Words Used

Danger and Warning Signals

Immediate/possible threats causing severe harm.

Caution and Attention Signals

Indirect threats or operational behaviors.

Notes for Handling

Information to facilitate use.

General Safety Instructions and Use

General Information

Risks of high voltage and improper use.

Designated Use

Intended use in industrial plants, compliance.

Transport and Storage

Guidelines for moving and storing devices.

Handling and Installation

Handling Precautions

Care against damage, electrostatic energy, seals.

Electrical Installation

Safety rules for electrical work.

Information on Use

Operation with Other Manufacturers' Products

Compatibility disclaimer for external products.

Maintenance and Service

Rules for repair and maintenance.

Disposal

Disposal rules according to laws and regulations.

Safety Instructions on Safe Torque Off (STO)

STO Functionality

Protects persons, does not disconnect power.

STO Application and Warnings

Used for Emergency Stop, includes critical warnings.

STO Function Limitations

Not for emergency switch-off, needs manual restart confirmation.

STO Fault Considerations

One-fault fail-safe, potential for jerky movement.

Approved Devices

Connection 3x AC 400/480 V

Approved device variants for 400/480V connections.

Connection 1x AC 230 V / 3x AC 230 V

Approved device variants for 230V connections.

Risk Analysis and Risk Assessment

Risk Assessment Criteria

Factors like injury degree, frequency, avoidance.

Standards for Risk Assessment

Applicable standards like EN ISO 13849-1.

Responsibility for Safety

Defines manufacturer and operator safety duties.

General Description of Safety Function

Integrated Safety Function

Replaces external components, reduces risk.

Functional Safety

Ensures safety in normal and error states.

Classification of Safety Requirements

SIL 2, PL d, Category 3 for STO.

Description of ACTIVE Cube Safety Function

Definitions According to EN 61800-5-2

Defines STO and SS1 c safety functions.

Definitions According to EN 60204-1

Defines Stop Category 0 and 1.

Definitions of AGL Safety Functions

Response Time

Time from triggering safety function to reaching safe state.

Fault Response Time

Time from fault occurrence to reaching safe state.

Specification of Safety Function 1 (SF1): STO

STO Specification Details

SIL, Redundancy, PL, Category, and Interface specs.

Response Time SF1

Specified response time for SF1.

Fault Reaction Time DF1

Specified fault reaction time for DF1.

Specification of Safety Function 2 (SF2): SS1

SS1 Specification Details

SIL, PL, Category, and Interface specs for SS1.

Response Time SF2

Specified response time for SF2.

Fault Reaction Time DF2

Specified fault reaction time for DF2.

Description of Safety Function

Safe Torque Off Functionality

Interrupted energy supply, motor coasts to standstill.

Traditional vs. Integrated System

Comparison diagram of system types.

Safety Function Description Details

STO Advantages and Triggering

No contactors, easy triggering by various means.

STO Application Example

Transport conveyor with light grid monitoring.

Two-Channel Monitoring

STO Function Redundancy

Two channels, redundant design for safety.

Triggering Mechanisms

Contactor control, sensors, emergency stop.

Error Detection

Self-monitoring, one error does not fail function.

STO Monitoring and Behavior

STO Input Truth Table

States of STOA/STOB for STO activation.

5-Second Monitoring Logic

Checks timely input switching for release.

Inverter Error Behavior

IGBT switch-off and error reporting.

Diagnosis Function and Enforced Dynamizing

Automated Stop Path Checking

Automatic tests for error detection in stop paths.

Requirements for Installation

Installation of Safety Equipment

General rules for safety equipment installation.

External Safety Control Equipment

Requirements for Safety Control Devices

PL d, SIL 2 classifications for safety control devices.

External DC 24 V Power Supply

DC 24 V Supply Voltage Requirements

SELV/PELV, voltage limits, and protection.

External DC 24 V Supply for Group Stop

DC 24 V Power Supply by AGL

Requirements for Operation

Requirements for Acceptance Inspection

STO According to Stop Category 0

STO Direct Stop

Minimum circuitry for STO direct stop application.

STO Direct Stop with Error Exclusion Short Circuit

STO with Error Exclusion Circuitry

Circuit with one enable path and error exclusion.

STO Direct Stop with Feedback to PLC

STO with PLC Feedback

PLC controls drive profiles and monitors switches.

STO Direct Stop with Feedback to PLC and Error Exclusion

STO with PLC Feedback and Error Exclusion

Circuit with PLC feedback and error exclusion.

SS1 According to Stop Category 1

SS1 Direct Stop

Minimum circuitry for SS1 direct stop application.

SS1 Direct Stop with Error Exclusion Short Circuit

SS1 with Error Exclusion Circuitry

Circuit with one enable path and error exclusion.

SS1 Direct Stop with Feedback to PLC

SS1 with PLC Feedback

PLC triggers function and decelerates motor.

SS1 Direct Stop with Feedback to PLC and Error Exclusion

SS1 with PLC Feedback and Error Exclusion

Circuit with PLC feedback and error exclusion.

Internal DC 24 V Supply, SS1

SS1 with Internal DC 24V Supply

Application circuitry with internal DC 24V supply.

Group Stop, SS 1

Group Stop SS1 Application

Application circuit for group stop with SS1.

Checklist

Risk Analysis Checklist

Requirements for performing risk analysis.

Installation Checklist

Checks for EMC, power supply, and wiring.

Commissioning Checklist

Checks for functional safety and acceptance.

Operation Checklist

Verification of operating limits and regular checks.

Safety Function Test Report

Test Assessment and Characteristics

TÜV assessment, SIL, PL, MTTFd, Diagnostic Coverage.

STO Status Diagnosis

STO Input Status Interpretation

Decoding of STOA/STOB input states.

Change Index

Document Revision History

Records changes made to the document.

Index

Alphabetical Index Entries

Cross-reference of topics and page numbers.

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