19_PerimeterGuarding_TM3_XUSL_ATV32_3d2_sc1.pdf

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Perimeter Guarding with Embedded Safety Module
Light curtain / Variable Speed Drive
Cat.3 PL d, SIL 2 / Stop Category 1
Function:
•
Safety-related stop function initiated by a safety light curtain
(ESPE Type 4 according to EN/IEC 61496-1 and EN/IEC 61496-
2). Controlled stopping with power maintained to the drive to
achieve stopping (i.e. braking), then cut-off of power when
standstill is reached (Safe Stop 1).
The hazardous movement is interrupted either if the stop button
(S2) or the emergency stop device (S3) is actuated. An
interruption of the detection field initiates the functional stopping
of the drive, i.e. by a braking ramp (stop category 1 in accordance
with EN/IEC 60204-1).
After the frequency monitored by the drive has elapsed, the drive
is halted, by the ‘safe torque off‘ (STO) safety function integrated
within it, which prevents the motor from restarting unintentionally.
The switching of the LIx inputs is monitored by the drive. The
power stage is disabled when the time offset is exceeded.
•
•
•
Typical applications:
Machines that use drives in their movements due to high speed and
precision needed (i.e. textile, wood-working or simple packaging
machines), when the delayed initiation of the stopping in the event of
a fault must not involve an unacceptably high residual risk.
Design:
•
The safety function employs well-tried safety principles and is
robust in the event of one channel failure by means of a SS1
inputs of ATV32
A light curtain fault is detected by the safety module at the next
demand upon the safety function by the restart interlock
pushbutton.
The start button (S) must be located outside the hazardous area
and at a point from which the potential danger is visible.
The light curtains (B1 and B2) have semiconductor outputs in
accordance with IEC 61496-1, 2 and EN 61496-1 and are
regarded as well-tried components.
The safety module satisfies the requirements for performance
level up to PL d according to EN ISO 13849-1 and SIL
CL
2
according to EN/IEC 62061.
•
•
•
•
SCS19/0514
2014-06-26
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Perimeter Guarding with Embedded Safety Module
meter
•
•
Protection against overcurrent must be provided in accordance
with EN/IEC 60947-4-1.
The mounting position of the light curtain has to follow the
requirements for safety distance according to ISO 13855.
Safety Chain Products:
•
•
•
Safety light curtain -
Preventa XUSL
USL
Safety Module -
Modicon TM3SAFL5R(G)
TM3SA
Variable Speed Drive -
Altivar 32
Related Products:
•
•
•
Switches, pushbuttons,
emergency stop -
Harmony XB4
Switch mode Power supply -
Phaseo ABL8
Modular beacon and tower light -
Harmony XVB
B1
B2
ATV32
LIx
LIy
P 24
SCS19/0514D
SCS19/0514
2014-06-26
-2-
Perimeter Guarding with Embedded Safety Module
Chain structure:
•
The circuit diagram SCS19/0514D is a conceptual schematic diagram
and is limited to present the safety function with only the relevant safety
components.
For the designated architecture of category 3, two redundant channels
are implemented.
The circuit arrangement can be divided into three function blocks per
channel with the input (I), logic (L) and output (O) blocks on each
channel.
The possibility of fault detection by monitoring the outputs is indicated by
the broken lines (see figure 1).
Since each light curtain forms part of a dedicated safety function, the
calculation of the performance level considers only one of them.
The functional channel can be represented by a single curtain actuating
two switches (i.e. B1 and B2) that would correspond to the input (see
figure 2).
The safety module (TM3SAFL5R(G)) corresponds to the logic block
(L1/L2), which maintains the internal redundancy of the safety circuits
required for this architecture.
The output block is represented not by STO but SS1. After reaching
almost zero speed ATV turns automatically to STO. SS1 to be connected
to two inputs of the ATV(please consult the Altivar 32 safety manual) that
are developed according IEC 61508 and are able to detect any drive
internal failure.
The complete wiring must be in accordance to EN 60204-1 and the
necessary means to avoid short circuits has to be provided (EN ISO
13849-2 Table D.4).
•
•
•
•
•
•
•
•
Safety level calculation:
Cycle time (s)
Number of hours' operation per day
Number of days' operation per year
Number of operations per year
60
12
220
158400
Values
Channel 1 Channel 2
Input device XUSL
PL
Category
PFH
d
resulting (1/h)
Logic TM3SAFL5R(G)
PL
Category
ATV32 STO
PFH
d
resulting (1/h)
PL
Category
PFH
d
resulting (1/h)
Safety function
PL attained
PFH
d
resulting (1/h)
e
4
4,90E-08
d
3
5,00E-09
d
3
8,20E-09
9,67E-08
d
6,22E-08
1,51E-07
•
•
•
•
A required performance level (PL
r
) must be specified for each
intended safety function following a risk evaluation. The
performance level (PL) attained by the control system must
be validated by verifying if it is greater than or equal to the
PL
r
.
At 220 working days per year, 12 working hours per day and
a cycle time of 1 minute, the number of operations (nop)
would be 158 400.
Mean time to dangerous failure (MTTF
d
) values exceeding
100 years will be limited to this value in order for the
component reliability not to be overstated in comparison with
the other main influencing variables such as the architecture
or tests.
These values are therefore limited to 100 years ("high").
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SCS19/0514
2014-06-26
Perimeter Guarding with Embedded Safety Module
ENVIRONM ENTA L
CONDITIONS
Light curtain P reventa
Safety mo dule
XUSL o utside o f a cabinet TM 3SA FL5R/G and
A ltivar 32 with STO inputs
•
General
Degree o f pro tectio n
acco rding to IEC/EN
60529
Terminals:
Enclo sure:
A mbient o perating
temperature (ho rizo ntal
installatio n)
Fo r use in max. height
abo ve sea o f
Sto rage temperature
Fo r sto rage in max.
relative humidity o f
Fo r sto rage in height
abo ve sea level o f
Overvo ltage catego ry
P o llutio n degree
Rated insulatio n vo ltage
acco rding to IEC/EN
60664-1
Supply
Supply vo ltage
M ax. pro tectio n
Rated po wer
B us 5 VDC
External Supply 24 VDC
Output circuit
M ax. current per o utput
path
The sum o f simultaneo us
currents o n all o f the
o utputs is limited to
P ro tectio n o f o utputs
M aximum switching
capacity o f o utputs
A C-1
5
DC-1
3
~ 230 V, 5 A
24 VDC, 4 A
6:00 A M
0.2 W
2.4 W
24 V DC
(+/- 20%)
SELV/P ELV c 24 V – 1
5/
+20 %
4 A fuse gG
-1 55 °C
0…
•
IP 65
IP 20
IP 20
–1
0...+ 55 °C (+ 1
4...+ 1 °F)
30
•
2000 m (6560 ft)
-25...75 °C
<= 95 % witho ut
co ndensatio n
- 40...+ 70 °C (- 40...1 °F)
58
95 %, no n co ndensing
0…
3000 m (0...9842 ft)
III (4 kV)
2
~ 300 V
•
A PFH
d
value of 5 x 10
-9
is stated for the safety module
(TM3SAFL5R(G)). This value comes directly from the safety
device data and it is certified by an accepted standards body.
Measures against common cause failures (Annex F of EN
ISO 13849-1) must attain at least 65 points (i.e. separation
(15), overvoltage protection etc. (15) and environmental
conditions (25+10)).
The safety-related control system corresponds to category 3
with high MTTF
d
. The complete functional safety chain
results in average probability of dangerous failure (PFH
d
) of
6.22 x 10
-8
.
The combination of all safety modules results in PL d and
SIL 2.
Σ
Ith
≤
1 A
8
max.: 4 A fuse gG o r 6 A
fast blo w
SCS19/0514
2014-06-26
-4-

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