WEG SCA06 User manual

Motors | Automation | Energy | Transmission & Distribution | Coatings

Servo Drive

Servoconvertidor

Servoconversor

SCA06 - STO Option Board

User’s Manual

Manual del Usuario

Manual do Usuário

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Safety Manual

Series: SCA06

Document: 10004016577 / 01

Models: 4 A / 220 ... 230 V single-phase

5 A / 220 ... 230 V three-phase

8 A / 220 ... 230 V three-phase

16 A / 220 ... 230 V three-phase

24 A / 220 ... 230 V three-phase

5.3 A / 380 ... 480 V three-phase

14 A / 380 ... 480 V three-phase

Date: 07/2016

English

4 | SCA06

Summary of Revisions

Version Revision Description

- R00 First edition

- R01 General review

Summary

English

1 APPROVALS ......................................................................................... 7

2 GENERAL INFORMATION ................................................................ 10

2.1 ABOUT THE MANUAL ............................................................................. 10

2.2 PRELIMINARY RECOMMENDATIONS ................................................. 10

2.3 SAFE TORQUE OFF ................................................................................ 11

3 INSTALLATION .................................................................................. 13

3.1 TYPES OF INSTALLATION ...................................................................... 16

4 COMMISSIONING ............................................................................. 18

5 MAINTENANCE ................................................................................. 19

6 DECOMMISSIONING ........................................................................ 21

7 SAFETY DATA ....................................................................................22

English

SCA06 | 7

Approvals

English

1 APPROVALS

EC DECLARATION OF CONFORMITY

Manufacturer’s name:

WEG Drives & Controls - Automação Ltda.

Manufacturer’s address:

Avenida Prefeito Waldemar Grubba, 3000

Jaraguá do Sul - SC - Brazil

89256-900

And our representative established within the European Community:

WEG Germany GmbH

Industriegebiet Türnich 3, Geigerstraße 7, 50169

Kerpen Türnich - North Rhine-Westphalia

Germany

We hereby declare that the safety functions of the following product

Product Name:

SSC 1.00 option board to be used with WEG SCA06 family products

Product Identification:

10859533 - CARTÃO ELETRÔNICO SSC1.00

Product Safety Functions:

Safe Torque Off according to EN 61800-5-2 standard

fulfills all of the relevant safety component requirements of Machinery Directive,

2006/42/EC.

Notified body that carried out the EC type examination:

01/205/5493.00/16

NB-No.: 0035

TÜV Rheinland Industrie Service GmbH

Alboinstr. 56

12103 Berlin / Germany

The following standards and/or technical specifications referenced below were used:

IEC 61508 - 1 to 7: 2010

Functional safety of electrical/electronic/programmable electronic safety-related

systems

EN 61800-3:2004+A1:2011

Adjustable speed electrical power drive systems

Part 3: EMC requirements and specific test methods

EN 61800-5-1: 2007

Adjustable speed electrical power drive systems

Part 5: Safety requirements / Section 1: Electrical, thermal and energy

8 | SCA06

Approvals

English

EN 61800-5-2: 2007

Adjustable speed electrical power drive systems

Part 5: Safety Requirements / Section 2: Functional

EN ISO 13849-1: 2008 + AC:2009

Safety of machinery – Safety-related parts of control systems

Part 1: General principles for design

EN ISO 13849-2:2012

Safety of machinery – Safety related parts of control systems

Part 2: Validation

EN 60204-1: 2006 + A1:2009 + AC:2010

Safety of machinery – Electrical equipment of machines

Part 1: General requirements

EN 62061: 2005 + AC:2010 + A1:2013

Safety of machinery – Functional safety of safety-related electrical, electronic and

programmable control systems

IEC 61326-3-1

Electrical equipment for measurement, control and laboratory use – EMC requirements

Part 3-1: Immunity requirements for safety-related systems and for equipment intended

to perform safety-related functions (functional safety) – General industrial applications

EN 50178: 1997

Electronic equipment for use in power installations

UL 508C: 2004

Power Conversion Equipment

Signature

In Jaraguá do Sul, 29

th

of January, 2016.

Norton Petry

R&D Manager

SCA06 | 9

Approvals

English

10 | SCA06

General Information

English

2 GENERAL INFORMATION

NOTE!

These are the original instructions.

2.1 ABOUT THE MANUAL

This manual provides the necessary information to install and configure the Safety

Function Safe Torque Off of the SCA06 servodrive. This manual must be used together

with the User’s Manual and the Programming Manual of the SCA06 servodrive.

For further details about the installation, how to perform commissioning, technical

characteristics and how to identify and fix the most common problems of the SCA06

servodrive, refer to the User’s Manual.

For information about programming the SCA06, refer to the Programming Manual.

All manuals are available for download on WEG website – www.weg.net.

2.2 PRELIMINARY RECOMMENDATIONS

DANGER!

 Only duly qualified personnel, familiar with Functional Safety, with

the SCA06 servodrive and related equipment must plan or perform

the installation, commissioning, operation and maintenance of this

equipment.

 The personnel must follow the safety instructions described in this

manual and/or defined by local standards.

 The noncompliance with the safety instructions may result in

deathrisk and/or equipment damage.

NOTE!

For the purposes of this manual, qualified personnel are those trained

in order to be able to:

1. Install, ground, power up and operate the SCA06 in accordance with

this manual and the safety legal procedures in force;

2. Use the protective equipment according to the relevant standards;

3. Give first aid.

SCA06 | 11

General Information

English

DANGER!

 Always disconnect the general power supply before touching any

electrical component associated to the servodrive.

 Many components may remain charged with high voltages and/or

moving (fans), even after the AC power supply input is disconnected

or turned off.

 Wait for at least ten minutes so as to guarantee the full discharge

of the capacitors.

 Always connect the frame of the equipment to the protection

grounding (PE) at the proper point.

ATTENTION!

The electronic boards have components sensitive to electrostatic

discharges. Do not touch directly the components or connectors.

If necessary, first touch the grounded metallic frame or use proper

grounding strap.

2.3 SAFE TORQUE OFF

The SCA06 servodrive can be equipped with a redundant dual channel Safe Torque

Off (STO) function.

The STO function acts on the removal of torque from the motor, i.e., no power that can

cause torque is present on the motor after enabling the Safe Torque Off function. The

difference of the Safe Torque Off function from a normal way to disable the motor is

that the first one does it with very high levels of reliability against unexpected motor

starts, even under a fault condition. For this reason, it is allowed to be used where safety

must be guaranteed. See safety specifications presented at the end of this chapter.

Once activated, the STO function removes the power from the electronics, causing

the motor to coast due to the load inertia. See Figure 2.1 on page 12.

ATTENTION!

While the Safe Torque Off mode is activated, hazardous voltages may

still be present on the motor. Before any intervention on electrical parts,

the whole system must be deenergized.

ATTENTION!

In circumstances where external influences, e.g., falling of suspended

loads are present, additional measures like mechanical brakes, for

example, may be necessary to prevent any hazard.

A risk analysis must be performed by the end user in order to identify

and cover all possible risks and hazards.

12 | SCA06

General Information

English

t

STO

Motor

speed

Figure 2.1: Safe Torque Off behavior

NOTE!

The Safety of whole system depends on the final certification of

the equipment/safety function where the servodrive is applied. This

certification is responsibility of the final equipment manufacturer. WEG

is not liable for damage and/or losses due to the use or application of

the servodrive. For the same reasons, WEG is not liable for applications

based on figures and examples described in this manual, which are

presented for illustrative purposes only.

NOTE!

This function should not be used as a control for starting and/or

stopping the motor.

NOTE!

The Safe Torque Off function takes priority over all other functions of

the servodrive.

SCA06 | 13

Installation

English

3 INSTALLATION

The servodrive must be installed according to the instructions of the SCA06 User’s

Manual.

If pollution degree 2 cannot be guaranteed, IP54 protection class must be used.

The connections of the Safety signals are made at connector X7, located at the bottom

of the servodrive, according to Figure 3.1 on page 13 and Figure 3.2 on page 14.

Additionally, the type of safety signals coming from the installation must be chosen at

a Dip Switch. See location at Figure 3.1 on page 13. The Dip Switch must be set

before energization, according to the description below:

 “D” for Dry Contact devices, i.e., all devices that have electromechanical output

contacts, like relays.

 “O” for OSSD (Output Signal Switching Device), i.e., devices that have outputs

containing test pulses.

NOTE!

The 24 Vdc power supply must attend Low Voltage Directive (2006/95/

EC), applying the specifications of IEC 61131-2:2007, Programmable

controllers - Part 2: Equipment requirements and tests and must attend

one of the following specifications:

 Safety extra-low voltage (SELV) type, according to EN60950.

 Protected extra-low voltage (PELV) type, according to EN60204.

The minimum installation necessary to operate the safety function is shown at Figure

3.3 on page 15.

Figure 3.1: X7 connector and OSSD selector

14 | SCA06

Installation

English

Tabl e 3.1: Dry Contact / OSSD selector

Dip Switch Configuration Description

Both switches set to Dry Contact. This conﬁguration must

be chosen when the safety signals are commanded by dry

contacts, for example, relay contacts, as shown on Figure 3.4

on page 16

One switch set to “D” (Dry contact) and another set to “O”

(OSSD). This is a not valid combination and results on a Fault

state (F0160) shown by the servodrive after energization. The

servodrive will not work

One switch set to “D” (Dry contact) and another set to “O”

(OSSD). This is a not valid combination and results on a Fault

state (F0160) shown by the servodrive after energization. The

servodrive will not work

Both switches set to OSSD. This conﬁguration must be chosen

when the safety signals are commanded by OSSD (Output

Signal Switching Device), for example, safety relays, as shown

on Figure 3.5 on page 17

X7

1

3

5

2

4

6

Pin Name Description

1 GND Reference for +24Vdc PELV/SELV supply

2 STO2 Safety input n°2

3 SP2 Safety signal for STO2 input

4 STO1 Safety input n°1

5 SP1 Safety signal for STO1 input

6 +24Vdc

+24Vdc PELV/SELV supply, provided by the

customer.

Provided by the customer

Figure 3.2: X7 connector description

SCA06 | 15

Installation

English

For X7 control cabling consider the following:

 Wire stripping length: 6.0 mm (0.236 in).

 Wire gauge from 0.5 mm² (20 AWG) to 1.0 mm² (16 AWG).

 Screw M2, maximum tightening torque of 0.20 N.m (1.8 lbf.in).

 Run the cables separated from the remaining circuits (power, 110V / 220Vac

control, etc.).

AC input

3Ø

24 Vdc

PELV /

SELV

STO 1

X5

X7

STO 2

R

S

T

PE

Figure 3.3: Basic Installation

16 | SCA06

Installation

English

3.1 TYPES OF INSTALLATION

+24 Vdc

6

4

2

5

3

Safety Board

X7

1

STO1

STO2

GND

Figure 3.4: Installation using Dry Contacts

Table 3.2: Truth table for Dry contacts operation

STO1

(Contact

Between

X7:4-5

Terminals)

STO2

(Contact

Between

X7:2-3

Terminals)

Safety Stop

Function

Servodrive Behavior

Open Open

Activated

(enabled)

Servodrive remains in STO state and does

not accept commands. The servodrive

indicates “STO” on the keypad

Open Closed

Fault

Servodrive trips to Fault “F0160” if this status

lasts longer than 1 s

To reset the fault, both contacts must be at

the same status and the +24Vdc supply must

be deenergized and reenergized

Closed Open

Closed Closed Disabled Servodrive accepts commands normally

SCA06 | 17

Installation

English

Safety Board

X7

6

4

2

5

3

1

STO1

STO2

GND

Figure 3.5: Installation using OSSD signals

Table 3.3: Truth table for OSSD signals

STO1

(Voltage

Between

X7:1-4

Terminals)

STO2

(Voltage

Between

X7:1-2

Terminals)

Safety Stop

Function

Servodrive Behavior

0 V 0 V

Activated

(enabled)

Servodrive remains in STO state and does

not accept commands. The servodrive

indicates “STO” on the keypad

0 V 24 V

Fault

Servodrive trips to Fault “F0160” if this status

lasts longer than 1 s

To reset the fault, both contacts must be at

the same status and the +24Vdc supply must

be deenergized and reenergized

24 V 0 V

24 V 24 V Disabled Servodrive accepts commands normally

18 | SCA06

Commissioning

English

4 COMMISSIONING

The sequence to of commissioning is:

1) The installation is completed and according to the servodrive’s manual.

2) The Dip Switch is set according to the type of safety signals.

3) The safety signals are not present, i.e., the contacts are open or, for OSSD type

signals, 24V is not present.

4) The motor is not coupled to the machine or, if coupled, it can run in any direction

without any risk of human harm or machine damages.

5) Turn on the power stage (Three-phase input). The led “power on” is set.

6) Turn on the electronics power supply (24Vdc power supply). The Human-machine

interface of the SCA06 turns on.

7) Program the servodrive according to the product programming manual and the

application necessity. At the end, enable the motor, via P0099 parameter, digital

input or communication network and check if the motor is running.

8) Enter the Safe State by opening STO1 and STO2 contacts or removing STO1 and

STO2 signals simultaneously. See Figure 3.4 on page 16 and Figure 3.5 on

page 17.

9) Check if the motor coasts to stop.

10) Check if the message “STO” is shown at the servodrive’s display.

11) Stop the Safe State by closing STO1 and STO2 contacts or replacing STO1 and

STO2 signals simultaneously. See Figure 3.4 on page 16 and Figure 3.5 on

page 17.

12) Check if the motor restarts. Depending on the programmed parameters, maybe

necessary to enable the motor again.

13) Check all other machine functionalities in order to verify the correct working and

safety parameters of the machine.

NOTE!

In order to verify the complete machine or system working and safety,

other steps may be necessary. The presented steps are the minimum

necessary to verify the integrity of the servodrive’s safety function.

The machine manufacturer is responsible for the final verification and

certification of the safety of the machine or system where the servodrive

is applied.

NOTE!

Simultaneously activation of the STO inputs means that the time between

the activation or deactivation of the inputs must be less than 1 s. This

time is also known as discrepancy time. If the time is longer than 1 s,

a fault code “F0160” will be shown on the display of the product. To

reset the fault code, it is necessary to set the STO switches to the same

state and then turn off the 24 Vdc power supply of the servodrive and

turn it on again.

NOTE!

Test pulses present at OSSD outputs are tolerated and do not trigger

the STO function since they do not last more than 1 ms.

SCA06 | 19

Maintenance

English

5 MAINTENANCE

The servodrive is equipped with several self-diagnosis functions and messages on

it display to help the user to identify abnormalities and problems with the servodrive

or it installation.

The Safe Torque Off function, in special, is equipped with a very accurate self-diagnosis

circuit, which guarantees that even under a fault, the safety is not affected. Faults

in the safety installation are reported as “F0160”. This includes also some external

misconnections of the safety signals.

Examples of external faults that may cause the Fault “F0160”:

 Discrepancy time between STO inputs higher than 1 s.

 One of the STO inputs is not operating, i.e., closing or opening when commanded.

 One of the STO signals has a Stuck-at fault.

 The STO signals are short-circuited.

 There is a misconnection at the connector X7. See Figure 3.4 on page 16 and

Figure 3.5 on page 17.

If the Fault “F0160” is shown at the servodrive’s display and no external faults can be

identified, than is possible that there is an internal fault on the Safety Board. In this

case, the servodrive must be submitted to Service. Contact your local WEG supplier

to get information on how to proceed.

NOTE!

If a fault on the servodrive is identified, it shall be submitted only to a

WEG Service center. Never try to fix or allow a person non authorized

by WEG to fix the servodrive. In the same way, do not use spare parts

to repair the product. The safety of the product depends not only on

values of components but also on type and quality of the components

used. The safety guarantee of the product is automatically lost if any

violation of the product occurs.

NOTE!

The Functional Safety circuits of the SCA06 were designed in such a

way that no maintenance or regular tests are necessary. The circuit

checks itself at determined intervals and the servodrive informs if any

problem is detected. Additionally, if a malfunction occurs, the safety

circuits are designed in such a way that it fails in a safe way.

20 | SCA06

Maintenance

English

NOTE!

In case of maintenance of the machine or system, the complete safety

of the machine must be retested in order to check the integrity of safety

of the machine or system.

Additionally, in case of a change or modification, the validation of the

safety function must be repeated and documented.

ATTENTION!

If, during the activation of the Safe Torque Off, occurs a simultaneous

fault on two or more IGBTs of the servodrive, the servodrive can deliver

sufficient energy to cause a magnetic alignment of the rotor and the

internal magnetic poles of the motor. This movement can be up to a

maximum of 180° of the motor shaft, depending on the number of

poles of the motor. Be sure that this movement cannot cause harm to

people or damages to machinery.

SCA06 | 21

Decommissioning

English

6 DECOMMISSIONING

For decommissioning, the machine or system shall preferably be switched off from

any type of energy supply. If this is not possible, all electrical connections, i.e, power

connections and the control connections of the servodrive must be switched off

before any decommissioning activities on the servodrive.

DANGER!

After switching off the power connections of the servodrive, it may

remain loaded with high voltages and/or moving (fans), even after the

mains power supply and the 24 Vdc power supply are disconnected

or turned off. Wait for at least 10 minutes in order to guarantee the

full discharge of internal components. Additionally, the “POWER” led,

located on the front part of the servodrive, can be monitored visually

to certify that the DC Link capacitors are discharged.

DANGER!

Before decommissioning, it is necessary to make an analysis of the

safety of the machine or system during decommissioning. Hanging

loads, brakes or rotating parts may require energy to stay in safe state

and the power removal can lead to unsafe conditions. Be sure that

power removal can be realized in a safe way.

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