prEN IEC 61800-5-3:2019

SLOVENSKI STANDARD
oSIST prEN IEC 61800-5-3:2020
01-marec-2020

Električni pogonski sistemi z nastavljivo hitrostjo - 5-3. del: Varnostne zahteve za

Adjustable speed electrical power drive systems - Part 5-3: Safety requirements for

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

IEC SC 22G : ADJUSTABLE SPEED ELECTRIC DRIVE SYSTEMS INCORPORATING SEMICONDUCTOR POWER CONVERTERS

SUBMITTED FOR CENELEC PARALLEL VOTING NOT SUBMITTED FOR CENELEC PARALLEL VOTING

This document is still under study and subject to change. It should not be used for reference purposes.

Recipients of this document are invited to submit, with their comments, notification of any relevant patent rights of which they

Adjustable speed electrical power drive systems - Part 5-3: Safety requirements for encoders - Functional,

Copyright © 2019 International Electrotechnical Commission, IEC. All rights reserved. It is permitted to download this

electronic file, to make a copy and to print out the content for the sole purpose of preparing National Committee positions.

You may not copy or "mirror" the file or printed version of the document, or any part of it, for any other purpose without

5 FOREWORD .......................................................................................................................... 7

6 INTRODUCTION .................................................................................................................... 9

7 1 Scope ............................................................................................................................. 9

8 2 Normative references .................................................................................................... 11

9 3 Terms and definitions .................................................................................................... 12

10 4 Safety sub-functions ..................................................................................................... 18

11 4.1 General ................................................................................................................ 18

12 4.2 Safe incremental position (SIP) ............................................................................ 18

13 4.3 Safe absolute position (SAP) ................................................................................ 19

14 4.4 Safe speed value (SSV) ....................................................................................... 19

15 4.5 Safe acceleration value (SAV) .............................................................................. 19

16 4.6 Safety sub-functions for evaluation and signalling ................................................ 19

17 5 Management of functional safety ................................................................................... 19

18 6 Requirements for design and development .................................................................... 19

19 6.1 General requirements ........................................................................................... 19

20 6.2 Design standards ................................................................................................. 22

21 6.3 Fault detection ..................................................................................................... 22

22 6.4 Design requirements for specific types of Encoder(SR) ........................................ 23

23 6.4.1 Design requirements for Encoder(SR) with sine and cosine output signal ...... 23

24 6.4.2 Design requirements for Encoder(SR) with incremental and absolute output

25 signals .......................................................................................................... 23

26 6.4.3 Design requirements for Encoder(SR) with square wave signal interface ...... 24

27 6.4.4 Design requirements for Resolver ................................................................. 24

28 6.5 Design requirements regarding Mechanics ........................................................... 25

29 6.5.1 General ......................................................................................................... 25

30 6.5.2 Design requirements for mechanical fastenings ............................................ 25

31 6.5.3 Design requirements for mechanical connecting elements............................. 25

32 6.5.4 Bearings ....................................................................................................... 25

33 6.6 Design requirements for signal generation ............................................................ 26

34 6.6.1 General ......................................................................................................... 26

35 6.6.2 Design requirements for signal generation of optical Encoder(SR) ................ 26

36 6.6.3 Design requirements for signal generation of magnetic Encoder(SR) ............ 26

37 6.7 Design requirements for signal processing ........................................................... 26

38 6.8 Design requirements for internal evaluation and signaling .................................... 26

39 6.9 Design requirements for software ......................................................................... 26

40 6.10 Pre-setting ........................................................................................................... 27

41 6.11 Parameterization .................................................................................................. 27

42 6.12 Design requirements for thermal immunity ............................................................ 27

43 6.13 Design requirements for mechanical immunity ...................................................... 27

44 6.14 Design requirements for integrated connection cables .......................................... 27

45 7 Information for use ........................................................................................................ 27

46 7.1 General ................................................................................................................ 27

47 7.2 Labels .................................................................................................................. 27

48 7.3 Information and instructions for safe application of an Encoder(SR) ..................... 27

49 8 Verification and validation ............................................................................................. 27

50 8.1 General ................................................................................................................ 27

51 8.2 Verification of hardware fault tolerance ................................................................ 28

52 8.3 Additional verification for Encoder(SR) with sine and cosine output signal ............ 28

53 8.3.1 Verification of diagnostic measures for Encoder(SR) with sine and cosine

54 output signal with HFT=0 .............................................................................. 28

55 8.3.2 Suitability for interpolation ............................................................................. 28

56 8.4 Qualitative FMEDA ............................................................................................... 28

57 8.5 Quantification ....................................................................................................... 29

58 9 Test requirements ......................................................................................................... 29

59 9.1 General ................................................................................................................ 29

60 9.2 Planning of tests .................................................................................................. 29

61 9.3 Functional testing ................................................................................................. 29

62 9.4 Electromagnetic (EM) and electrical immunity testing ........................................... 29

63 9.4.1 Electrical tests .............................................................................................. 29

64 9.4.2 Electromagnetic (EM) immunity testing ......................................................... 30

65 9.5 Thermal immunity testing ..................................................................................... 30

66 9.5.1 General ......................................................................................................... 30

67 9.5.2 Dry cold ........................................................................................................ 30

68 9.5.3 Dry heat ........................................................................................................ 30

69 9.5.4 Damp heat .................................................................................................... 30

70 9.5.5 Temperature rise test .................................................................................... 31

71 9.6 Mechanical immunity testing ................................................................................. 31

72 9.6.1 Clearances and creepage distances .............................................................. 31

73 9.6.2 Short-circuit testing of printed wiring boards ................................................. 31

74 9.6.3 Mechanical fastenings ................................................................................... 31

75 9.6.4 Mechanical connecting elements ................................................................... 31

76 9.6.5 Vibration and shock test ................................................................................ 32

77 9.6.6 Mechanical properties of electrical connections ............................................. 32

78 9.6.7 Testing the non-touchability .......................................................................... 32

79 9.6.8 Deformation testing ....................................................................................... 32

80 9.7 Material tests ....................................................................................................... 32

81 9.8 Suitability of the components and materials used ................................................. 33

82 9.9 Integrated connection cables ................................................................................ 33

83 9.10 Contamination of solid measure ........................................................................... 33

84 9.11 Labels .................................................................................................................. 33

85 9.12 Instructions .......................................................................................................... 34

86 9.13 Test documentation .............................................................................................. 34

87 10 Modification .................................................................................................................. 34

88 Annex A (informative) Types of Encoder(SR) ...................................................................... 35

89 Annex B (informative) Universal architecture of Encoder(SR) .............................................. 38

90 B.1 General ................................................................................................................ 38

91 B.2 The Universal Encoder(SR) architecture ............................................................... 38

92 Annex C (informative) Examples of suitable mechanical tests for rotary Encoder(SR) ......... 40

93 C.1 General ................................................................................................................ 40

94 C.2 Mechanical Fastening of the Encoder(SR) ............................................................ 40

95 C.2.1 Force-locked connection (e.g. by bolted joints) ............................................. 40

96 C.2.2 Form-locked connection (e.g. by feather key) ................................................ 40

97 C.3 Mechanical connecting elements of the Encoder (SR) - Stator coupling (torque

98 support) or shaft-rotor coupling ............................................................................ 40

99 C.3.1 General ......................................................................................................... 40

100 C.3.2 Axial loads .................................................................................................... 41

101 C.3.3 Radial loads .................................................................................................. 41

102 Annex D (informative) Extended shock testing for rotary Encoder(SR) mounted to motors... 42

103 D.1 General ................................................................................................................ 42

104 D.2 Pseudo-Velocity Shock-Response Spectrum (PVSRS) ......................................... 42

105 D.3 Verification of resilience ....................................................................................... 42

106 D.4 Testing machine ................................................................................................... 43

107 Annex E (informative) Dimensioning of clearances and creepage distances on printed wiring

108 boards - Example .......................................................................................................... 45

109 E.1 General ................................................................................................................ 45

110 E.2 Assumptions......................................................................................................... 45

111 E.3 Application of IEC 61800-5-1:2016 CSV, Clause 5.2.2.1 ....................................... 45

112 Annex F (normative) Information and instructions – detailed list .......................................... 46

113 Annex G (informative) Encoder(SR) fault lists and fault exclusions ...................................... 49

114 Annex H (informative) Quantification ................................................................................... 53

115 H.1 General ................................................................................................................ 53

116 H.2 Safety architecture and safety-related block diagram............................................ 53

117 H.3 Failure rates ......................................................................................................... 54

118 H.4 Failure rates at realistic working temperatures ..................................................... 55

119 H.5 Quantitative FMEDA and assessment of diagnostic measures .............................. 56

120 H.6 Estimation of the common cause factor β (only in case of redundancy) ................ 57

121 H.7 Estimation of the PFH .......................................................................................... 57

122 H.8 Safe failure fraction (SFF) .................................................................................... 57

123 H.9 Determination of the quantitative SIL capability .................................................... 58

124 H.9.1 SIL limit by architectural constraints .............................................................. 58

125 H.9.2 SIL limit by PFH ............................................................................................ 58

126 H.10 Additional considerations to comply with ISO 13849-1 .......................................... 59

127 H.10.1 General ......................................................................................................... 59

128 H.10.2 MTTF of a channel ...................................................................................... 59

129 H.10.3 Determination of the quantitative category capability ..................................... 59

130 H.10.4 Determination of the quantitative PL-capability .............................................. 59

131 Annex I (informative) Digital processing of sine/cosine signals ............................................ 60

132 I.1 General ................................................................................................................ 60

133 I.2 Sampling of sine and cosine signals ..................................................................... 60

134 I.3 Consequences ..................................................................................................... 61

135 I.4 Measures to improve DC ...................................................................................... 61

136 Annex J (informative) Single channel architecture with ideal fault detection ........................ 63

137 J.1 General ................................................................................................................ 63

138 J.2 Ideal fault detection for Encoder(SR) with sine and cosine output signal .............. 63

139 Annex K (informative) Quantification - Specifics for single channel incremental Encoder(SR)

140 with sine and cosine output signal ................................................................................. 65

141 K.1 General ................................................................................................................ 65

142 K.2 Single-fault tolerance ........................................................................................... 65

143 K.3 Undetectable faults .............................................................................................. 65

144 K.4 Fault detection (DC) ............................................................................................. 65

145 Annex L (normative) Static analysis of signal evaluation and fault detection ........................ 67

146 L.1 General ................................................................................................................ 67

147 L.2 Motivation for the analysis of signal evaluation and fault detection ....................... 67

148 L.3 What does “static analysis of signal processing” mean? ....................................... 67

149 L.4 Standard test signals ............................................................................................ 70

150 L.4.1 Make test signal available (Step 1) ................................................................ 70

151 L.5 Simulation of signal processing to specification .................................................... 75

152 L.5.1 General ......................................................................................................... 75

153 L.6 Assessment of the signal processing specification ............................................... 77

154 L.6.1 General ......................................................................................................... 77

155 L.6.2 Assessment concept for the signal processing specification .......................... 79

156 L.7 FMEDA Encoder(SR) for verification of the diagnostic coverage ........................... 81

157 L.7.1 General ......................................................................................................... 81

158 L.7.2 Explanation of the problem ............................................................................ 81

159 L.7.3 Procedure for FMEDA ................................................................................... 83

160 L.8 List of variables used for performing static analysis .............................................. 84

161 L.9 MS Excel tool for performance of static analysis ................................................... 86

163 Figure 1 – Context of Encoder(SR) ....................................................................................... 11

164 Figure 2 – Example of an hardware architecture of Encoder(SR) with incremental and

165 absolute output signal .......................................................................................................... 24

166 Figure B.1 – Universal Encoder(SR) architecture ................................................................. 38

167 Figure C.1 – Example of an additional ring for assembly with eccentricity x .......................... 41

168 Figure D. 1 –Sample shock (a) and corresponding PVSRS on 4CP (b) ................................. 42

169 Figure D.2 – Testing machine ............................................................................................... 43

170 Figure I.1 – Digital sampling of sine and cosine signals - hardware architecture, example .... 60

171 Figure I.2 – Lissajous figures of the sine and cosine signals A and B ................................... 61

172 Figure K.1 – Static analysis of signal evaluation and fault detection ..................................... 66

173 Figure L.1 – Static analysis concept ..................................................................................... 68

174 Figure L.2 – Static analysis procedure (for one test signal) with variable denominations ...... 70

175 Figure L.3 – Substitute circuit for Encoder(SR)’s outbound interface .................................... 71

176 Figure L.4 – Example of a circuit for evaluation of the output signals and diagnostics of

177 Encoder(SR) faults ............................................................................................................... 76

178 Figure L.5 – Lissajous diagrams (representation of signal B over signal A) in the fault free

179 case (a) and in the event of a critical Encoder(SR) fault (b) .................................................. 83

180 Figure L.6 – Examples of the dual effect of a single component fault a) Differential amplifier

181 with operating point setting b) Inverting amplifier with operating point setting ....................... 84

183 Table 1 – List of terms and definitions .................................................................................. 12

184 Table 2 – Applicable Clauses of IEC 61800-5-2:2016 for Encoder(SR) and respective

185 modifications ........................................................................................................................ 19

186 Table 3 – Applicable Clauses of IEC 61800-5-1:2016 CSV for Encoder(SR) and respective

187 modifications ........................................................................................................................ 21

188 Table A.1 – Types of Encoder(SR) ....................................................................................... 35

189 Table B.1 – Function blocks of the Universal Encoder(SR) architecture ................................ 38

190 Table G.1 – Encoder(SR) – mechanic fault list and fault exclusions ..................................... 50

191 Table G.2 – Faults and fault exclusions for the selection, mounting and operation of rolling

192 bearings ............................................................................................................................... 50

193 Table G.3 – Factors influencing the malfunctioning of rolling bearings – considerations for

194 selection, mounting and operation ........................................................................................ 51

195 Table H.1 – Components for Encoder(SR) and their inclusion in quantification ..................... 55

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