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1 B&R ACOPOS Motion control

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1 B&R ACOPOS Motion control ....................................................................................... 1

1.1 General Infromation .......................................................................................................... 5

1.1.1 Maximum Security ........................................................................................................... 5
1.1.2 Taking it to the limit.......................................................................................................... 6
1.1.3 Invididual I/O Configurations ............................................................................................ 6
1.1.4 Configuring Instead of Programming ................................................................................. 7
1.1.5 Easy Service................................................................................................................... 7
1.1.6 Soft and Hardware as a Unit ............................................................................................ 7
1.1.7 Plain Text for Functions ................................................................................................... 8
1.1.8 Simple Function Test ....................................................................................................... 9
1.1.9 Control Trigger ................................................................................................................ 9
1.1.10 Cam Profiles for Everyone ............................................................................................. 10
1.1.11 Configurations ............................................................................................................... 11
1.1.11.1 General Information.....................................................................................................................................11
1.1.11.2 Powerlink.......................................................................................................................................................12
1.1.11.3 Futher Literature ...........................................................................................................................................12

1.2 Servo Motors................................................................................................................... 14

1.2.1 Three-phase Synchronous Motors 8MS .......................................................................... 14
1.2.2 Feedback Systems Specified to meed Your Needs .......................................................... 15
1.2.3 Embedded Parameter Chip............................................................................................ 15
1.2.4 Smooth Surface ............................................................................................................ 16
1.2.5 Connection Technology ................................................................................................. 16
1.2.6 Custom Configurations .................................................................................................. 16

2 Servo Drive .......................................................................................................................17

2.1 Acopos............................................................................................................................ 17
2.1.1 General Information....................................................................................................... 17
2.1.2 Secure Restart Inhibit .................................................................................................... 18
2.1.3 24 VDC Supply during Power Failures ............................................................................ 18
2.1.4 Order Data.................................................................................................................... 19

2.2 Acopos1022,1045,1090.................................................................................................... 20
2.2.1 Order Data.................................................................................................................... 20
2.2.2 Technical Data .............................................................................................................. 20

2.3 ACOPOS 1180,1320......................................................................................................... 22

2.3.1 Order Data.................................................................................................................... 22
2.3.2 Technical Data .............................................................................................................. 22

2.4 ACOPOS 1640,128M ........................................................................................................ 24

2.4.1 Order Data.................................................................................................................... 24
2.4.2 Technical Data .............................................................................................................. 24

2.5 ACOPOS PLUG-in Moduls............................................................................................... 26

2.5.1 General Information....................................................................................................... 26
2.5.2 Order Data.................................................................................................................... 26
2.5.3 AC110 – CAN Interface.................................................................................................. 27
2.5.3.1 General Description..........................................................................................................................................27
2.5.3.2 Order Data..........................................................................................................................................................27
2.5.3.3 Technical Data...................................................................................................................................................28
2.5.4 AC121 Hypeface Encoder .............................................................................................. 29
2.5.4.1 General Description..........................................................................................................................................29
2.5.4.2 EnDat Entcoder.................................................................................................................................................29

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2.5.4.3 Incremental Encoder with sine formed output signal.................................................................................29
2.5.4.4 Order Data..........................................................................................................................................................30
2.5.4.5 Technical Data...................................................................................................................................................31
2.5.5 AC123 – Incremental Encoder and SSI Absolute Encoder Interface.................................. 32
2.5.5.1 General Description..........................................................................................................................................32
2.5.5.2 Order Data..........................................................................................................................................................32
2.5.5.3 Technical Data...................................................................................................................................................33

2.6 Servo Motors................................................................................................................... 35

2.6.1 Three Phase Synchronous Motors 8MS .......................................................................... 35
2.6.1.1 General Description..........................................................................................................................................35
2.6.1.2 Colling Types ....................................................................................................................................................36
2.6.1.3 Sizes ....................................................................................................................................................................36
2.6.1.4 Lengths ...............................................................................................................................................................37

2.7 Order Key........................................................................................................................ 38

2.7.1 General Description....................................................................................................... 38
2.7.2 Example Order.............................................................................................................. 39
2.7.3 General Motor Data ....................................................................................................... 40

2.8 Standarts, Definitions for Safety Techniques.................................................................. 41

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1.1 General Infromation

1.1.1 Maximum Security

EMC was given special attention in order to guarantee proper operation in an industrial
environment. Field tests have been carried out under difficult conditions in addition to the tests
defined in the standard. The results confirm the excellent values measured by the testing
laboratory and during operation. The filters required to meet the CE guidelines are also
integrated in the device. This simplifies installation considerably.

The embedded parameter chip on the motor is one factor used to guarantee maximum
security. It contains all mechanical and electronic data relevant to the functionality of the
motor. Parameters no longer have to be set manually and start-up times are substantially
reduced. Secure operation also means that relevant data can be requested during service
and the cause of the problem can be determined.

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1.1.2 Taking it to the limit

Operational security is also improved by monitoring high temperature components (IGBT

modules, brake resistor, motor windings). Computer-based simulation allows component
temperatures which cannot be measured directly to be calculated. One example is the junction
temperature. This is a decisive value for the maximum load of a semiconductor.
Using these models, a sufficiently precise value can be determined for each IGBT. Hot spots
can be ruled out and the full dynamic properties of the device can be used at low rpm values
and when stalled. The brake resistor and motor windings are monitored in the same way.
This form of monitoring allows better use of absolute limits on the drive and provides the user
with the advantages of higher performance at lower costs.

1.1.3 Invididual I/O Configurations

The I/O points needed to operate a servo axis are part of the standard equipment for
ACOPOS drives. The user is provided two trigger inputs for tasks requiring precise
measurements or print mark control. Sensor and actuator configurations are made using
modular plug-in modules. This modular concept allows the optimum configuration to be
selected to meet the requirements of the application.

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1.1.4 Configuring Instead of Programming

The I/O points needed to operate a servo axis are part of the standard equipment for
ACOPOS drives. The user is provided two trigger inputs for tasks requiring precise
measurements or print mark control. Sensor and actuator configurations are made using
modular plug-in modules. This modular concept allows the optimum configuration to be
selected to meet the requirements of the application.

1.1.5 Easy Service

All necessary data is placed in application memory on the controller so that service is
limited to simply exchanging the device. The program does not have to be changed. After
the system is started again, the controller installs the operating system that is used
automatically (or when requested by the user). After this procedure is complete, the
parameters are sent to the servo drive again. Problems resulting from different software
versions or parameters can be ruled out.

1.1.6 Soft and Hardware as a Unit

B&R integrates all relevant technologies in one tool - B&R Automation Studio™.
Adding a B&R ACOPOS servo drive is done in a Windows Look & Feel environment which
becomes routine after using the
program a few times. Wizards and selection boxes ease configuration of servo axis
parameters. The target system is shown
in a clear tree structure. Detailed information concerning the target system, with integrated
hardware documentation
ranging from software to terminal assignments, reduces project development times
considerably.

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1.1.7 Plain Text for Functions

NC Objects that can be accessed by the application program are also stored on the CPU
(like the application program).

Creating NC Objects (for axes, a CNC system or a cam profile) takes place using dialog
boxes and special data module editors. The individual hardware and software channels are
assigned symbolic names. This eases use and increases clarity. The initial parameters are
set in a separate editor in plain text.

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1.1.8 Simple Function Test

The built-in NC test allows an axis to be used without a line of program code being written.
As seen in the picture, several editors are grouped together as a single window. All
movements, ranging from point-to-point movements to gear functions, can be carried out
using an NC Action. The reaction of the axis can be seen online in the monitor window. If
the trace function is turned on, relevant data - from position to motor temperature - is
recorded on the drive. The multiple curve display in the trace window allows simple
evaluation of the movement results.

1.1.9 Control Trigger

The oscilloscope in the drive allows movements to be monitored in real time. Many trigger
possibilities allow data required for analysis to be easily obtained. The graphic display of
diagnosis data supports the user when making fine adjustments and when optimizing the
movement. Measurement cursor and reference points allow µs precision.

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1.1.10 Cam Profiles for Everyone

Modular technology plug-ins allow homogenous integration of high performance tools such
as the Cam Editor.

The mouse is used to define fixed points, synchronous sections or interpolations. Effects of
positioning behavior on speed, acceleration and jolt for the slaves axes connected can be
monitored directly.

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1.1.11 Configurations

1.1.11.1 General Information

The ACOPOS servo drives can be used in various configurations depending on the network
type (CAN, Powerlink) and the requirements of the application.

The following ACOPOS functions are possible with all ACOPOS configurations:

• Point-to-point

• Electronic gears

• Electronic compensation gears

• Cross cutter

• Electronic cam profiles

• Flying saw

• Line shaft

• CNC

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1.1.11.2 Powerlink

Recommended Topology

In the Powerlink network (seen from the manager), the tree structure should always come first
followed then by the line structure. Otherwise, the line structure delay affects the entire tree
beneath it.

1.1.11.3 Futher Literature

Unless otherwise stated, the recommendations in the following documents apply:

• "Industrial Ethernet Planning and Installation Guide", Draft 2.0, IAONA (www.iaona-
eu.com)

• "Guide to Understanding and Obtaining High Quality Generic Cabling", 3P Third Party
Testing (www.3ptest.dk)

Configuration 1

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Configuration 2

The functionality is the same as in configuration 1. The advantage compared to

configuration 1 is the low cabling expenditure.

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1.2 Servo Motors

1.2.1 Three-phase Synchronous Motors 8MS

B&R three-phase synchronous motors 8MS have been specially developed for use in high-
performance applications. They are now being used to produce consumer goods and
products in the plastic, packaging, metal, food and beverage industries and then pallet them
with material handling systems.

Complete solutions from one source, this requires the right components and also the right
configuration for the application environment. The large selection of available three-phase
synchronous motors makes it possible to easily meet conditions such as reducing the
variety of parts, guaranteeing ease of service and maintaining minimum requirements on
space.

An optimally configured drive rounds off a successful construction. To meet this goal,
specialists are available in B&R subsidiaries all over the world who are eager to share
their know-how in the area of mechatronics.

B&R automation components, the economical combination of mechanics, electronics,

technology and innovation.

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1.2.2 Feedback Systems Specified to meed Your Needs

The three-phase synchronous motors 8MS are available with different encoder systems. As
standard, they are equipped with Heidenhain encoders. Depending on the application, the
customer can select between normal and high-resolution encoders. Both types are also
available as multi-turn encoders. They allow operation without requiring homing procedures
or additional measurement systems on the work piece. The absolute encoder functions
without a battery and is therefore absolutely maintenance-free.

The three-phase synchronous motor are also available with resolvers for machines with lower
precision and speed
requirements.

1.2.3 Embedded Parameter Chip

All relevant mechanical and electrical information and data is stored in the encoder used for
the three-phase synchronous motors 8MS. That means the user doesn't have to make
settings on the servo drive in the field. As soon as the encoder is connected to the servo drive
and the power is applied to the electronics, the motor is automatically identified. The motor
sends the nominal and limit values to the servo drive. Then the drive automatically determines
the current limits and current control parameters required for secure operation of the motor.
The user only has to optimize the speed and position controller. The integrated start-up
environment in B&R Automation Studio™ provides assistance.

In addition to start-up assistance, routine service work is also made easier and motors can
be exchanged without having to take extra time to set parameters.

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1.2.4 Smooth Surface

The special construction of the surface of the three-phase synchronous motors 8MS allow
them to be used in applications for the food and beverage branch. Depressions where liquid
could collect were consciously avoided.

1.2.5 Connection Technology

The uniform connection technology, the prefabricated cables and the embedded parameter
chip described above allow plug and play operation of the power transmission system.

1.2.6 Custom Configurations

B&R has already developed successful projects where a custom drive configuration was
required. An example is direct attachment of a drive belt disk to the motor shaft. Using
bearings that withstand the high radial forces required by the construction allows the motor
and belt drive to be easily installed. High-alloy steel is used to keep the shaft diameter small
for trouble free mounting of small belt disks (in spite of enormous loads).
An enthusiastic customer hit the nail on the head: "We are killing two birds with one stone by
using this solution. Easier construction, smaller installation dimensions, exemplary friendly
service and all that with lower costs!".

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2 Servo Drive

2.1 Acopos

2.1.1 General Information

Controlling your power transmission system with B&R ACOPOS servo drives allows you to fully use
the advantages of an optimized system architecture. Applications that require additional positioning
tasks such as torque limitation or torque control can be created quickly and elegantly.

The flexible system concept for B&R servo drives is achieved using matched hardware and software
components. You can select the optimal system configuration for your application and increase your
competitiveness.
• Perfect integration in the B&R 2000 product family
• Object-oriented axis programming minimizes development time and increases reusability
• Integrated technology functions for branch specific tasks
• Operation of synchronous and asynchronous motors possible
• Current controller scan time up to 50 µs
• Reduced commissioning and service times using "embedded motor parameter chip"
• CAN and Powerlink network connection
• Input voltage range from 400 - 480 VAC (±10 %) for use worldwide
• Connection possibilities for all standard encoder systems
• 2 free slots for optional technology modules
• Electronic secure restart inhibit integrated

The ACOPOS servo drive series covers a current range from 2.2 - 128 A and a power range from 1
- 64 kW with 7 devices in 3 groups. The devices in a group are designed using the same basic
concept.

1) Integrated line filter in preparation.

2) External DC bus power supply 0PS320.1 (24V / 20A) can be used.
3) The braking resistor integrated in the ACOPOS servo drives 1640 and 128M is dimensioned
so that it is possible to brake to a

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ACOPOS servo drives are suitable for both synchronous and asynchronous servo motors
and have built-in line filters to meet the limit values for CISPR11, Group 2, Class A.
The ACOPOS servo drives also provide a modular fieldbus interface in addition to
connection possibilities for all standard encoder systems.

2.1.2 Secure Restart Inhibit

ACOPOS servo drives have a built-in secure restart inhibit to guarantee that the device is
stopped securely and to prevent it from restarting unexpectedly. It is designed to correspond
to safety category 3 according to EN 954-1. 1)

In addition to preventing the device from restarting unexpectedly according to EN 1037, this
safety function also meets the requirements of IEC 60204-1 regarding the stop function for
categories 0 and 1. Both stop functions require the supply to the machine drives to be
switched off (immediately for category 0 and after stopping for category 1).
The restart inhibit interrupts the supply to the motor by preventing the pulses to the IGBTs.
In this way, a rotating field can no longer be creating in synchronous and asynchronous
motors controlled by the ACOPOS servo drives. This fulfills the requirements of EN 1037
regarding preventing the device from starting unexpectedly and IEC 60204-1 regarding the
stop function for categories 0 and 1.

2.1.3 24 VDC Supply during Power Failures

In order to be able to provide the stop function for category 1 according to IEC 60204-1
during a power failure, the 24 VDC supply voltage for the servo drives as well as encoders,
sensors and the safety circuit must remain active during the entire stopping procedure.

The ACOPOS servo drives recognize a power failure and can immediately initiate active
braking of the motor. The brake energy that occurs when braking is returned to the DC bus
and the DC bus power supply can use it to create the 24 VDC supply voltage 2) . An external
DC bus power supply must be used for ACOPOS servo drives 8V1022 to 8V1090. A DC bus
power supply is integrated in ACOPOS servo drives 8V1180 to 8V128M.

The ACOPOS servo drives with an integrated DC bus power supply provide the 24 VDC
supply for the servo drive and also a 24 VDC output to supply encoders, sensors and the
safety circuit. In may cases, it is not necessary to use an uninterruptible power supply (UPS)
which is otherwise needed.

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2.1.4 Order Data

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2.2 Acopos1022,1045,1090

2.2.1 Order Data

2.2.2 Technical Data

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1) When using motor holding brakes, the valid input voltage range is reduced. The input
voltage range should be selected so that the proper supply voltage for the brake can be
maintained (also see section "Technical Data for the Standard Holding Brake", on page
97).

2) The current requirements depend on the configuration of the ACOPOS servo drive.

3) Additional requirements are to be arranged with B&R.

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2.3 ACOPOS 1180,1320

2.3.1 Order Data

2.3.2 Technical Data

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1) The current requirements depend on the configuration of the ACOPOS servo drive.

2) The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated
DC bus power supply, which reduces the 24 VDC current requirements (I24VDC ) to 0.
Mains Input Voltage: 3 x 400 VAC to 480 VAC ± 10 %.

3) Additional requirements are to be arranged with B&R.

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2.4 ACOPOS 1640,128M

2.4.1 Order Data

2.4.2 Technical Data

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1) Integrated line filter in preparation.

2) The current requirements depend on the configuration of the ACOPOS servo drive.

3) The 24 VDC supply voltage for the ACOPOS servo drive is created by the integrated DC
bus power supply, which reduces the 24 VDC current requirements (I24VDC ) to 0. Mains
Input Voltage: 3 x 400 VAC to 480 VAC ± 10 %.

4) Additional requirements are to be arranged with B&R.

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2.5 ACOPOS PLUG-in Moduls

2.5.1 General Information

The ACOPOS drives are equipped with four plug-in module slots. You can select the plug-in
modules required for your application and insert them into the ACOPOS servo drive.

2.5.2 Order Data

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2.5.3 AC110 – CAN Interface

2.5.3.1 General Description

The AC110 plug-in module can be used in an ACOPOS slot. The module is equipped with a
CAN interface. This fieldbus interface is used for communication and setting parameters on
the ACOPOS servo drive for standard applications.

2.5.3.2 Order Data

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2.5.3.3 Technical Data

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2.5.4 AC121 Hypeface Encoder

2.5.4.1 General Description

The AC120 plug-in module can be used in an ACOPOS slot. The module has an EnDat
encoder interface, but can also be used to evaluate simple incremental encoders with sine
formed output signal 1) .

This module can be used to evaluate encoders which are built into B&R servo motors and also
encoders for external axes (encoders that evaluate any machine movement). The input
signals are monitored. In this way, broken connections, shorted lines and encoder supply
failure can be recognized.

2.5.4.2 EnDat Entcoder

EnDat is a standard developed by Johannes Heidenhain GmbH (www.heidenhain.de),

incorporating the advantages of absolute and incremental position measurement and also
offers a read/write parameter memory in the encoder. With absolute position measurement
(absolute position is read in serially), the homing procedure is usually not required. When
necessary, a multi-turn encoder (4096 revolutions) should be installed. To save costs, a
single-turn encoder and a reference switch can also be used. In this case, a homing
procedure must be carried out.

The incremental process allows the short delay times necessary for position measurement on
drives with exceptional dynamic properties. With the sinusoidal incremental signal and the fine
resolution in the EnDat module, a very high positioning resolution is achieved in spite of the
moderate signal frequencies used.

The parameter memory in the EnDat encoder is used by B&R to store motor data (among
other things). In this way, the ACOPOS servo drives are always automatically provided the
correct motor parameters and limit values. This is referred to as the "embedded parameter
chip".

During start-up, the module is automatically identified, configured and its parameters set by
the ACOPOS servo drive operating system.

2.5.4.3 Incremental Encoder with sine formed output signal

When using the AC120 plug-in module to evaluate simple incremental encoders with sine
formed output signal, only the incremental transfer channel is now used. The "embedded
parameter chip" it not available in this case because this encoder does not have
parameter memory. The absolute position is also not available immediately after switching
the device on. In this situation, a homing procedure normally has to be carried out. The
module is equipped with a reference pulse input for this purpose.

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2.5.4.4 Order Data

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2.5.4.5 Technical Data

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2.5.5 AC123 – Incremental Encoder and SSI Absolute Encoder Interface

2.5.5.1 General Description

The ACOPOS plug-in module AC123 is used to connect standard industrial incremental or
absolute encoders with a synchronous serial interface (SSI) to ACOPOS servo drives. For
example, this allows electronic gears to be configured which read master movements
using external encoders. If the encoder resolution is high enough, motor feedback for
asynchronous motors is also possible.

With incremental encoders, the maximum counter frequency is 200 kHz. Single and multi-
turn encoders with a maximum of 31 bits at 200 kBaud can be read as absolute SSI
encoders.

The position is determined cyclically (initiated by the module) and is exactly synchronized
with the ACOPOS controller clock. The input signals are monitored for both encoder
types. In this way, broken connections, shorted lines and encoder supply failure can be
recognized.

With incremental encoders the count frequency and distance between edges is also
monitored. With absolute encoders, the parity bit is evaluated and a plausibility check
carried out.

2.5.5.2 Order Data

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2.5.5.3 Technical Data

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Technical data

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2.6 Servo Motors

2.6.1 Three Phase Synchronous Motors 8MS

2.6.1.1 General Description

The three-phase synchronous motors from the 8MSA and 8MSC series are permanently
excited, electronically commutated synchronous motors for applications that require
excellent dynamic properties and positioning precision as well as compact size and reduced
weight.

• NdFeB permanent magnets

• Sinusoidal commutation with EnDat encoder or resolver as feedback unit

• Three-phase winding with star connection

• Compact sizes result in low weight

,
• Minimum moment of inertia because of favorable rotor construction results in very good
dynamic properties

• High overload capability/maximum pulse torque

• Low torque ripple

• High dynamic torque at high speeds

• Long life-span, all motor parts except for bearings are free of wear

• Direct diversion of lost power generated in the stator over the housing to the flange

• Preloaded, grooved ball bearings which are sealed on both sides and greased

• Complete motor system with stall torque ranging from 0.2 Nm to 115 Nm

• Connection using two circular plugs

• Controlled by ACOPOS servo drives

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2.6.1.2 Colling Types

The three-phase synchronous motors are available with different cooling types.

Cooling Type A

Three-phase synchronous motors with cooling type A are self-cooling and have a long, slim
design. The motors must be installed on the cooling surface (= flange).

Cooling Type C

Three-phase synchronous motors with cooling type C are based on motors with cooling
type A. They are separately cooled and the only difference is a fan module mounted in the
area of the B-side bearing. The motors must be installed on the cooling surface (= flange).

The built-in fan module increases the rated torque (MN ), rated current (IN ), stall torque (M0)
and stall current (I0) by 30 % as compared to the respective motors with cooling type A.

2.6.1.3 Sizes

The three-phase synchronous motors are available in up to seven different sizes. They
are different regarding dimensions (especially flange dimensions) and power rating.

The various sizes can be differentiated by a number in the model number. The larger
the number, the larger the flange dimensions and power rating for the respective motor.

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2.6.1.4 Lengths

The three-phase synchronous motors are available in up to five different lengths. They
have different power ratings with identical flange dimensions.

The various lengths can be differentiated by a letter in the model number.

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2.7 Order Key

2.7.1 General Description

1) Option not available for size 8.

2) Option only available for size 2.

3) Special options must be arranged with B&R. If no special motor options are required,
enter nothing or 00 for ff.

4) If a motor version does not exist for the motor, nothing should be entered for g.

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2.7.2 Example Order

A three-phase synchronous motor of type 8MSA4L with a rated speed of 3000 min-1 was
selected for an application.

Because of the construction, the cables can only be connected on the top of the motor ("top"
connection direction). The motor should also be equipped with a holding brake, a keyed shaft
end and a 512 line EnDat single-turn encoder.

The code (dd) for the encoder system is E0 (see table 67 "Technical data for EnDat encoders",
on page 96).

The code (ee) for the other options (rated speed, oil seal, holding brake, keyed shaft and
connection direction) is 33 (see
table 81 "Order key code (ee) for the motor options", on page 103).

Therefore the model number for the motor required is: 8MSA4L.E0-33

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2.7.3 General Motor Data

1) Except sizes 2 and 7 as well as special option "reinforced A side bearing".

2) Centering diameter and hole pattern.
3) Continuous operation of the servo motors at environmental temperatures from +40 °C
to max. +55 °C is possible, but results in a shorter lifespan.
4) Additional requirements are to be arranged with B&R.

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2.8 Standarts, Definitions for Safety Techniques

Stop Functions according to IEC 60204-1/11.98 (electrical equipment for machines, part
1: general requirements)

The following three stop function categories exist:

The necessary stop functions must be determined based on a risk evaluation for the
machine. Stop functions in category 0 and category 1 must be able to function regardless of
the operating mode. A category 0 stop must have priority. Stop functions must have priority
over assigned start functions. Resetting the stop function is not allowed to cause a
dangerous state.

Emergency stops according to IEC 60204-1/11.98 (electrical equipment for machines,

part 1: general requirements)

The following requirements are valid for emergency stops in addition to the requirements for
the stop functions:

• It must have priority over all other functions and operations in all operating modes.

• The power to the machine drive elements which can cause a dangerous state must be
switched off as quickly as possible without creating other dangers.

• Resetting is not allowed to cause a restart.

Emergency stops must be category 0 or category 1 stop functions. The necessary stop
function must be determined based on a risk evaluation for the machine.

For emergency stop function in stop category 0, only hard wired, electromechanical
equipment can be used. Additionally, the function is not allowed to depend on electronic
switching logic (hardware or software) or the transfer of commands via a communication
network or data connection. 1)

When using a category 1 stop function for the emergency stop function, it must be
guaranteed that the power to the machine drive elements is completely switched off. These
elements must be switched off using electromechanical equipment . 1
)
Safety category according to EN 954-1/03.97 (safety of machines - safety related parts
of control systems, part 1: general design principles) 2
)
The safety related parts of control systems must meet one or more of the requirements for
five defined safety categories. The safety categories define the required behavior of safety
related controller parts regarding their resistance to errors.

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1) In accordance to the national foreword for the valid German version of IEC 60204-
1/11.98, it is determined that electronic equipment (and also especially for emergency stop
systems) can be used regardless of the stop category, if e.g. it provides the same safety
using the standards EN 954-1 and/or IEC 61508 as required by IEC 60204-1.

2) To prevent confusing EN 951-1 categories with IEC 60204-1 stop categories, the term
"safety categories" was used in the text shown above for EN 954-1 categories.

Selecting the suitable safety category must be done separately for each ACOPOS
servo drive (or for each shaft) based on a risk evaluation. This risk evaluation is a part
of the total risk evaluation for the machine.

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B&R Training

Servo Drive Seite 43

B&R Training

Restart inhibit according to EN 1037/04.96 (Safety of machinery - prevention of unexpected

start-up)

Keeping a machine in an idle state when people are working in the danger zone is one of the most
important requirements for safe operation of machines.

Starting refers to the transition of a machine or its parts from an idle state to moving state. Any
start is unexpected if it is caused by
:
• A start command sent because of a controller failure or because of external influences on the
controller.

• A start command sent because of incorrect operation of a start element or another part of the
machine.

• Restoration of power supply after an interruption.

• External/internal influences on parts of the machine.

To prevent unexpected starting of machines or parts of machines, power should be removed and
dissipated. If this is not practical (e.g. frequent, short work in danger zone), other measures must
be taken:

• Measures to prevent random start commands.

• Measures to prevent that random start commands cause unexpected starting.

• Measures to automatically stop dangerous parts of the machine before a dangerous situation
can be caused by unexpected starting.

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