12_safety-chain-solution-Safe-Stop2-Servo-enhanced-safety.pdf

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Safety Chain Solution – Safe Stop 2 – Servo
enhanced safety
PL e, SIL 3
Improved accuracy through safety integrated devices
Function:
Safety-related stop function realized by a moveable guard that
help protects access to the hazardous area.
The hazardous movement is interrupted either if the stop button
(S2) or the emergency stop device (S3) is actuated, which initiates
the functional stopping of the servo-drive, i.e. by a deceleration
ramp.
The Safe Stop 2 safety function is used to achieve a category 2
safe stop in accordance with EN/IEC 61800-5-2, where the servo
motor is braked in a controlled manner, maintaining the power on
the actuators.
The safety function SS2 (Safe Stop 2), integrated in the enhanced
safety module (eSM) card, monitors the deceleration and the
standstill position.
When the SS2 function is triggered, a deceleration of movement is
monitored with the specified monitoring ramp up to standstill. The
motor is then immobilized by the ‘safe operating stop‘ (SOS)
function, which is used to monitor any deviation from the standstill
position.
If the monitored deceleration ramp is violated or the monitored
standstill position is not maintained, the drive is halted by the
‘safe torque off‘ (STO) function, which prevents the motor from
restarting unintentionally.
The eSM card also monitors the consistent actuation of the
redundant switch contacts from the magnetic switch to detect
possible failure, before restart of the machine movement is
permitted.
Typical applications:
Packaging, printing, or similar machines that use servo-drives in their movements
due to high speed and precision needed, on which non-braking stopping would
result in a impermissibly long run-down of the hazardous tool movements
SCS12/0311 - 17-03-2011
Safety Chain Solution – Safe Stop 2 – Servo
enhanced safety
Design:
The safety function employs well-tried safety principles and is robust in the event of a component failure by means of two
redundant contacts on the magnetic switch device and two redundant internal circuits for the servo-drive safety function.
The contact failure of the magnetic switch is detected by the enhanced safety module (eSM) integrated on the servo-drive at the
next demand upon the safety function.
The enhanced safety module (eSM) satisfies the requirements for performance level up to PL e in accordance with EN ISO
13849-1 and SILCL 3 in accordance with EN/IEC 62061.
The adjustable deceleration braking ramp must be selected so that under the most unfavorable operating conditions, the machine's
movement is stopped before the immobilization of the motor by SOS function is triggered.
Protection against over-current must be provided in accordance with EN/IEC 60947-4-1.
The servo-drive can be installed directly as part of the safety chain of the safety-related control system as it features an integrated
safety function (Safe Operating Stop - SOS), which is designed to monitor any deviation from the standstill position of the motor,
preventing restart.
The Safe Operating Stop (SOS) function meets the requirements of category 3 and PL e of EN ISO 13849-1, SIL 3 in accordance
with EN/IEC 61508 and the standard dealing with the functional safety requirements of power drive systems EN/IEC 61800-5-2.
Related products
Switches, pushbuttons, emergency
stop -
Harmony XB4
Guard switches -
Preventa XCSLE
Enhanced Safety Module (eSM) -
Lexium 32M
Servo drive -
Lexium 32M
Human machine interface -
Magelis
XBT GH
Modular beacon and tower lights -
Harmony XVB
Switch mode Power supply -
Phaseo
ABL8
SCS12/0311 - 17-03-2011
Safety Chain Solution – Safe Stop 2 – Servo
enhanced safety
Chain structure:
The circuit diagram SCS12/0311D 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,
input (I), logic (L) and output (O) blocks, per channel.
The unbroken lines for monitoring symbolize the higher DCavg
assumed for this category (see figure 1).
The functional channel is represented by the magnetic switch
device (B1) that correspond to the input block (see figure 2).
The enhanced safety module (eSM) 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 by the servo-drives (F1+F2+F3)
with two redundant internal circuits and connected in cascade.
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).
SCS12/0311 - 17-03-2011
Safety Chain Solution – Safe Stop 2 – Servo
enhanced safety
Safety level calculation:
A required performance level (PLr) 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 PLr.
Mean time to dangerous failure (MTTFd) values exceeding 100
years are 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.
If the protective guard device is assumed to be actuated every half
minute during 220 working days per year and 12 working hours,
the number of operations (nop) would be 316 800.
A B10d value of 50 000 000 cycles is stated for the coded
magnetic switch. In accordance with the assumed above nop
value, the MTTFd would be 1578.3 years for each channel. These
values are therefore limited to 100 years ("high").
A PFHd value of 7 x 10
-9
is stated for the enhanced safety module
(eSM). This value comes directly from the safety device data and
is certified by an accepted standards body. This value already
includes the servo drive PFHd value as it is using a safety function
integrated on it (Safe Stop 2).
A total value of 2.1 x 10
-8
is therefore stated for the logic and
output part as a results of using 3 servo-drives in cascade for the
same safety function.
Measures against common cause failures (Annex F of EN ISO
13849-1) must attain at least 65 points (i.e. separation of wiring
(15), overvoltage protection etc. (15) and environmental conditions
(25+10)).
Since this is the highest performance level, both the MTTFd of
each channel and the DCavg must be high.
The combination of channel 1 and channel 2 results in a DCavg >
99 % (high) as we are monitoring the coded magnetic switch input
contacts as well as the deceleration and the standstill position by
means of Safe Operating Stop (SOS) function.
The safety-related control system corresponds to category 3 with
high MTTFd (> 30). The complete functional safety chain results in
average probability of dangerous failure (PFHd) of 4.57 x 10-8.
This corresponds to PL e and SIL 3.
SCS12/0311 - 17-03-2011
ATTENTION
The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This
documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications.
It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific
application or use thereof. Neither Schneider Electric Industries SAS nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information
contained herein.
Schneider Electric Industries S.A.S
Head Office
35 rue Joseph Monier
CS 30323
92506 Rueil-Malmaison
www.schneider-electric.com
As standards, specifications and designs change from time to time,
please ask for confirmation of the information given in this publication.
Design : Schneider Electric
Photos : Schneider Electric

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