EN50155 - LBFS - LFFS

Compliance report
EN 50155
Qualification of Baumer Level Switch LFFS and LBFS to
Railway applications according to BS EN 50155 –
Shock and Vibration Standard EN 61373
(Governing Standard BS EN 50155 Railway Applications
– Electronic equipment used on rolling stock)
Dated 2011-11-22
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Contents
1.0 Statement compliant to EN50155 ..................................................................................................................... 4
2.0 Evaluation of LFFS and LBFS according to EN50155 .................................................................................... 5
3.0 Product under test ............................................................................................................................................. 5
4.0 Environmental service condition of operation ................................................................................................. 5
4.1.1 Altitude ...................................................................................................................................... 5
4.1.2 Ambient temperature ................................................................................................................ 5
4.1.3 Shock and vibration ................................................................................................................... 8
4.1.4 Relative humidity ....................................................................................................................... 9
4.2 Special service conditions ........................................................................................................... 11
4.2.1 Atmospheric pollutants............................................................................................................ 11
5.0 Electric service conditions .............................................................................................................................. 11
5.1 Power supply............................................................................................................................... 11
5.1.1 Supply from accumulator......................................................................................................... 11
5.1.1.1 Variation of voltage supply ................................................................................................... 11
5.1.1.2 Interruption of voltage supplies ........................................................................................... 13
5.1.1.3 Variation of voltage supplies ................................................................................................ 13
5.1.1.4 D.C. ripple factor ................................................................................................................... 13
5.1.2 Supply by a static converter or a rotating set .......................................................................... 13
5.1.3 Supply change over .................................................................................................................. 13
5.1.4 Supply with overhead line or third rail .................................................................................... 13
5.1.5 Supply rated surges.................................................................................................................. 14
5.2 Supply overvoltage...................................................................................................................... 14
5.3 Installation .................................................................................................................................. 14
5.4 Surges and electrostatic discharge according to EN 50155 / EN50121 ...................................... 14
5.5 Electromagnetic compatibility according to EN 50155 / EN50121 ............................................. 14
6 Reliability, maintainability and expected useful life ........................................................................................ 14
6.1 Equipment reliability ................................................................................................................... 14
6.1.1 Predicted reliability .................................................................................................................. 14
6.1.2 Proof reliability......................................................................................................................... 15
6.2 Useful life .................................................................................................................................... 16
6.3 Maintainability ............................................................................................................................ 16
6.4 Maintenance levels ..................................................................................................................... 16
6.4.1 On-vehicle diagnosis and repair............................................................................................... 16
6.4.2 Off-vehicle diagnosis and repair .............................................................................................. 16
6.5 Built-in diagnostic ....................................................................................................................... 16
6.6 Automatic test equipment .......................................................................................................... 16
6.7 Alternative methods for fault diagnosis ..................................................................................... 16
6.8 Purpose built test equipment special tools ................................................................................ 17
7.0 Design ............................................................................................................................................................. 18
7.1 General ........................................................................................................................................ 18
7.1.1 Quality management ............................................................................................................... 18
7.1.2 Life Cycle .................................................................................................................................. 18
7.2 Detailed practices – Hardware.................................................................................................... 19
7.2.1 Interface ................................................................................................................................... 19
7.2.2 Fault protection ....................................................................................................................... 19
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7.2.3 Referring power supplies ......................................................................................................... 19
7.2.4 Interchangeability .................................................................................................................... 19
7.2.5 Reduction of power supply voltage ......................................................................................... 19
7.2.6 Polarity reversal ....................................................................................................................... 19
7.2.7 Inrush currents ......................................................................................................................... 19
7.2.8 Spare capacity .......................................................................................................................... 19
7.3 Detailed practices – Software ..................................................................................................... 19
7.3.1 General ..................................................................................................................................... 19
7.3.2 Software design measures ....................................................................................................... 20
7.3.2.1 Modular approach ................................................................................................................ 20
7.3.2.2 Translator proven in use ....................................................................................................... 20
7.3.2.3 Recording .............................................................................................................................. 20
7.3.2.4 Structured methodology ....................................................................................................... 20
7.3.2.5 Design and coding methods .................................................................................................. 20
7.3.2.6 Structured programming and analysis .................................................................................. 20
7.3.2.7 Programming language ......................................................................................................... 20
7.3.2.8 Proven techniques ................................................................................................................ 20
7.4 Equipment features .................................................................................................................... 20
7.4.1 Memory checking..................................................................................................................... 20
7.4.2 Self test .................................................................................................................................... 20
7.4.3 Watchdog ................................................................................................................................. 20
7.3.4 Error indication ........................................................................................................................ 20
7.4.5 Recovery................................................................................................................................... 20
8.0 Components .................................................................................................................................................... 21
8.1 Procurement ............................................................................................................................... 21
8.2 Application .................................................................................................................................. 21
9. Construction ..................................................................................................................................................... 21
8.1 Mechanical construction............................................................................................................. 21
10. Safty................................................................................................................................................................ 21
11. Documentation................................................................................................................................................ 21
12. Testing ............................................................................................................................................................ 21
Appendix A - EMC test report according to EN50121, EN61326, DNV 2.4:2006
Appendix B - Shock and Vibrations test according to EN50155, EN/IEC61373
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1.0 Statement compliant to EN50155
We,
Baumer A/S
Jacob Knudsens Vej 14
8230 Aabyhoej
Denmark
Tel: +45 89 31 76 11
confirm that the product Level Switch LBFS xxxx x (C) and LFFS xxxx x (C) are complying
with the Railway standard of EN50155. Copy of detailed test reports is available on request
from Baumer A/S.
Description of the evaluation and test are attach this statement. So are the declaration of
conformity for EMC according to EN50121 and accredited Vibrations test according to
EN61373.
Date: 2011-11-22
Sign:________________________
Kurt Møller Jensen, R&D Manager
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2.0 Evaluation of LFFS and LBFS according to EN50155
This document is made for proving the validation of the railway approval according to EN50155. All test
mentioned in the document are available on request from Baumer A/S. Most test reports are in the document
shown with two pages of the complete report.
3.0 Product under test
The evaluation is based on the Level Switches LBFS and LFFS series. For the LBFS series was test performed
on versions with plastic and metal M12 electrical connection where it is critical. On LFFS was test performed on
normal version and sliding connection where it is critical. Each group was tested as outlined below to
demonstrate compliance to EN 50155. Both product series was successfully tested without deterioration of
performance of the products as demonstrated in the test results.
4.0 Environmental service condition of operation
4.1.1 Altitude
The Level switches LFFS and LBFS are suitable for applications up to 1200m of altitude. There is no customer
for requirements exceeding 1200m of altitude.
4.1.2 Ambient temperature
Baumer internal extreme temperature test ranges from - 40°C to + 85°C and are preformed on all mentioned
instruments.
Extreme temperature test performed on LBFS
The LBFS are connected to a 100 Ω resistor on the output. This will ensure that the current limit circuit are
activated during the test and the maximum current are known. Measuring the output is done with a 10Kohm
resistor as mentioned in the datasheet.
All measurings are performed with supply voltage of 24VDC.
PNP (16556):
Vout_NC
Iout_NC
Vout_NO
Iout_NO
22,9 0C
22,44 VDC
0 VDC
22,80 mA
0 mA
22,40 VDC
0 VDC
22,80 mA
0 mA
85 0C
22,62 VDC
0,36 VDC
19,2 mA
0 mA
22,56 VDC
0,34 VDC
19,2 mA
0 mA
-40 0C
22,20 VDC
0 VDC
25,6 mA
0 mA
22,14 VDC
0 VDC
25,1 mA
0 mA
Active high PNP (VDC -1.5V) ± 0.5V ; Rload 10 kOhm, 20 mA output current.
PNP unit are within the specification of the datasheet. The leak current when the output is off is below 100uA as
described in the datasheet.
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NPN (16558):
22,9 0C
24,11 VDC
1,99 VDC
25,2 mA
0 mA
24,11 VDC
1,83 VDC
25,0 mA
0mA
Vout_NC
Iout_NC
Vout_NO
Iout_NO
85 0C
24,0 VDC
1,58 VDC
21,1 mA
0 mA
24,0 VDC
1,45 VDC
21,0 mA
0 mA
-40 0C
24,13 VDC
2,13 VDC
27,8 mA
0 mA
24,13 VDC
2,11 VDC
27,1 mA
0 mA
Active low NPN (-VDC +1.5V) ± 0.5V ; Rload 10 kOhm, 20 mA output current.
The NPN version of the LBFS is fulfilling specification within the ambient temperature area -40°C to 85°C.
Extreme temperature test performed on LFFS
The temperature test was carried out for LFFS where a function test is performed as a function of supply voltage
at different temperature levels for -40°C to 85°C.
Måleresultater
o
Vin (VDC)
+12
+36
-12
-36
-40 C (Medie: Sprit) (TRIGGER: 70%)
PNP output
trig↑ (mm): 31
trig↓ (mm): 33
trig↑ (mm): 31
trig↓ (mm): 33
trig↑ (mm): 31
trig↓ (mm): 33
trig↑ (mm): 31
trig↓ (mm): 33
+36
-12
-36
-40 C (Medie: Plexiglas klods) (TRIGGER: 82%)
PNP output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
+36
-12
-36
Digital output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
23,6 C (Medie: Rå linolie) (TRIGGER: 82%)
PNP output
trig↑ (mm): 26
trig↓ (mm): 29
trig↑ (mm): 27
trig↓ (mm): 29
trig↑ (mm): 25
trig↓ (mm): 28
trig↑ (mm): 27
trig↓ (mm): 29
NPN output
trig↑ (mm): 24
trig↓ (mm): 28
trig↑ (mm): 26
trig↓ (mm): 29
trig↑ (mm): 25
trig↓ (mm): 28
trig↑ (mm): 26
trig↓ (mm): 29
Digital output
trig↑ (mm): 25
trig↓ (mm): 28
trig↑ (mm): 27
trig↓ (mm): 29
trig↑ (mm): 25
trig↓ (mm): 28
trig↑ (mm): 27
trig↓ (mm): 29
o
Vin (VDC)
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NPN output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
o
Vin (VDC)
+12
Digital output
trig↑ (mm): 30
trig↓ (mm): 32
trig↑ (mm): 30
trig↓ (mm): 32
trig↑ (mm): 31
trig↓ (mm): 32
trig↑ (mm): 31
trig↓ (mm): 32
o
Vin (VDC)
+12
NPN output
trig↑ (mm): 31
trig↓ (mm): 33
trig↑ (mm): 31
trig↓ (mm): 32
trig↑ (mm): 31
trig↓ (mm): 33
trig↑ (mm): 31
trig↓ (mm): 33
85 C (Medie: Rå linolie) (TRIGGER: 82%)
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+12
+36
-12
-36
PNP output
trig↑ (mm): 12
trig↓ (mm): 16
trig↑ (mm): 14
trig↓ (mm): 17
trig↑ (mm): 11
trig↓ (mm): 16
trig↑ (mm): 13
trig↓ (mm): 17
+36
-12
-36
Digital output
trig↑ (mm): 11
trig↓ (mm): 15
trig↑ (mm): 13
trig↓ (mm): 17
trig↑ (mm): 11
trig↓ (mm): 15
trig↑ (mm): 13
trig↓ (mm): 17
o
Vin (VDC)
+12
NPN output
trig↑ (mm): 12
trig↓ (mm): 16
trig↑ (mm): 13
trig↓ (mm): 16
trig↑ (mm): 10
trig↓ (mm): 15
trig↑ (mm): 13
trig↓ (mm): 16
85 C (Medie: Plexiglas klods) (TRIGGER 82%)
PNP output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
NPN output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
Digital output
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
trig↑: OK
trig↓: OK
Supplementary temperature test
Tests for LFFS and LBFS according to IEC60945 are added as supplementary test. Test reports are made in
separated documents as show below.
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4.1.3 Shock and vibration
Tests of LFFS and LBFS according Requirements from IEC publication 600068-2-6 and EN 61373 were
verified. Test reports are made in separated documents two pages are shown below.
Total Accredited report for fulfilling vibration and shock requirements fromEN50155 and EN61373 can be seen
in appendix B.
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Both tests fulfill the specification from the standard and are therefore approved.
4.1.4 Relative humidity
Requirements according to IEC 60068-2-30 were verified.
Concerning LFFS:
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Concerning LBFS :
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4.2 Special service conditions
The products can be adjusted according to the customer needs within the limit of the product configuration
possibilities. This can be done with the Flexprogram software and the configuration unit Flexprogrammer9701.
Software og konfiguration enhed er ikke en del af LFFS og LBFS men tjener som service udstyr.
4.2.1 Atmospheric pollutants
Requirements according IEC 60068-2-30 Damp heat cyclic test were verified and accredited by Det Norske
Veritas (DNV). See point 4.1.4
Requirements according IEC 60068-2-52 Salt mist test were verified and accredited by Delta A/S
5.0 Electric service conditions
5.1 Power supply
5.1.1 Supply from accumulator
The specification of the power supple voltage for LFFS is 12,5Vdc to 36Vdc. Most of the tests are carried out at
24VDC.
5.1.1.1 Variation of voltage supply
The power supply range for LFFS is specified between 12,5VDC to 36VDC while LBFS is specified to a power
supply range from 12VDC and 30VDC.
For both products is the voltage supply range limited for the ATEX version.
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Requirements according Det Norske Veritas (DNV). were verified in below test reports.
LFFS:
LBFS:
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5.1.1.2 Interruption of voltage supplies
LFFS comply to Class S1, means no interruption of the supply voltage available according to EN50155. This is
only true in worst case
LFFS:
#
8. Power Supply interruption
Beskrivelse
Test according to IEC 770
At supply interruption must
the product shown correct
condition immediately after
the interruption. In case of
restart of the product must
the unstable condition be
equal to the starting up time.
Test
Output : short cut
Status
2 ms: OK
(Absolute worst case
is with a short cut of
the output)
4 ms: Restarts
only during
measuring.
Beskrivelse
Test according to IEC 770
At supply interruption must
the product shown correct
condition immediately after
the interruption. In case of
restart of the product must
the unstable condition be
equal to the starting up time.
Test
Output : short cut
>4 ms: restarts
LBFS:
#
8. Power Supply interruption
Status
2 ms: OK
4 ms: Restarts
only during
measuring.
>4 ms: restarts
5.1.1.3 Variation of voltage supplies
The requirement of this point concerns power supply units and therefore not applicable for the LFFS and LBFS
series.
5.1.1.4 D.C. ripple factor
The requirement of this point concerns power supply units and therefore not applicable for the LFFS and LBFS
series.
5.1.2 Supply by a static converter or a rotating set
See test performed in 5.1.1.1.
5.1.3 Supply change over
The LBFFS and LBFS comply to class C1, which means a power supply reduction to 0.6xUn during 100ms. A
class C2 of power supply changeover would generate a power restart of device T400 series. But no failure can
be generated in that case.
5.1.4 Supply with overhead line or third rail
The requirement of this point is not applicable for the LFFS and LBFS series.
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5.1.5 Supply rated surges
This requirement is part of voltage supply variation, see point 5.1.1.1
Requirements according to IEC EN 61000-4-2 DNV: 60068-2-30 was verified.
5.2 Supply overvoltage
This requirement is part of voltage supply variation, see point 5.1.1.1
5.3 Installation
The installation requirements are defined in manual for LFFS or LBFS.
For detailed description see operating manual for each product.
5.4 Surges and electrostatic discharge according to EN 50155 / EN50121
Requirements according EN50121 was verified. For test result see report in appendix A
5.5 Electromagnetic compatibility according to EN 50155 / EN50121
Requirements according EN50121 was verified. For test result see report in appendix A
6 Reliability, maintainability and expected useful life
6.1 Equipment reliability
6.1.1 Predicted reliability
MTTF calculations for LFFS and LBFS are carried out as show below:
Typ designation:
Operating temperature [°C]
40
Operating voltage range [VDC] 12,5 - 36
Calculation base:
Calculation method
MTTF(d)-Components (Worst Case)
50% hazardous failures
Environment temperature [°C] 40
Operating conditions
MTTF-base values (remaining parts)
Environmental conditions
Conditions
LFFS Level Switch
EN ISO 13849-1:2007
Part Count
Factor 10
Factor 0.5
Nominal load
MIL-HDBK 217F, Notice 2 / RDF 2000
Ground fixed, 40°C (Industry standard)
constant failure rate
Total
Mean time to dangerous failure MTTF(d) [year]
Mean time to dangerous failure MTTF(d) [hours, h]
Probability of a dangerous failure per hours [1/h]
Remarks:
-
Worst case
>100
876'000
< 1.14E-06
The values of applicable EN-ISO calculation method refers to worst case conditions, which are
improved by factor 2 compared to calculation according to MIL-HDBK-217.
Typical values by considering of effective applications can be improved up to factor 5.
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-
The resulting MTTF(d) values judges not the safety of the product. It is a calculation or
estimation of the random failures, which causing based on random hardware failures as a result
of limited reliability of components.
Typ designation:
Operating temperature [°C]
40
Operating voltage range [VDC] 12 - 30
Calculation base:
Calculation method
MTTF(d)-Components (Worst Case)
50% hazardous failures
Environment temperature [°C] 40
Operating conditions
MTTF-base values (remaining parts)
Environmental conditions
Conditions
LBFS Level Switch
EN ISO 13849-1:2007
Part Count
Factor 10
Factor 0.5
Nominal load
MIL-HDBK 217F, Notice 2 / RDF 2000
Ground fixed, 40°C (Industry standard)
constant failure rate
Total
Mean time to dangerous failure MTTF(d) [year]
Mean time to dangerous failure MTTF(d) [hours, h]
Probability of a dangerous failure per hours [1/h]
Remarks:
-
Worst case
>90
788'400
< 1.27E-06
The values of applicable EN-ISO calculation method refers to worst case conditions, which are
improved by factor 2 compared to calculation according to MIL-HDBK-217.
Typical values by considering of effective applications can be improved up to factor 5.
The resulting MTTF(d) values judges not the safety of the product. It is a calculation or
estimation of the random failures, which causing based on random hardware failures as a result
of limited reliability of components.
6.1.2 Proof reliability
MTBF calculations for LFFS and LBFS are carried out as show below:
LFFS:
The foundation of the used MTBF calculation method is “The Field Data Measurement”
The interpretation of registered failure has been evaluated with respect to the nature of the malfunction which
was discovered in the data gathering period. Some of the distinctively failures was, measurings gives rise to a
wrong output, wrong start up or an incorrect function during configuration. Inappropriate handling which could
cause fault has not been taken into consideration.
Conditions for the calculation:
It is assumed that the Level Switch LFFS works continually to perform level detection in the data gathering
period, the ambient temperature is 25°C.
In the MTBF calculation is a year corresponding to 8.760 hours in one year. The data gathering period during
this calculation has been 39 weeks.
Furthermore, following considerations have been taken in to account, 85% of sold transmitters are actually
installed and fully operation. 90% of failed products in the test period are returned for the factory for repair, the
rest have not been return or are still waiting for being returned.
Annual Failure Rate [%]
0,975
102
897.652
MTBF [years]
MTBF [Hour]
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LBFS:
The foundation of the used MTBF calculation method is “The Field Data Measurement”
The interpretation of registered failure has been evaluated with respect to the nature of the malfunction which
was discovered in the data gathering period. Some of the distinctively failures was, measurings gives rise to a
wrong output, wrong start up or an incorrect function during configuration. Inappropriate handling which could
cause fault has not been taken into consideration.
Conditions for the calculation:
It is assumed that the Level Switch LBFS works continually to perform level detection in the data gathering
period, the ambient temperature is 25°C.
In the MTBF calculation is a year corresponding to 8.760 hours in one year. The data gathering period during
this calculation has been 46 weeks.
Furthermore, following considerations have been taken in to account, 80% of sold transmitters are actually
installed and fully operation. 90% of failed products in the test period are returned for the factory for repair, the
rest have not been return or are still waiting for being returned.
Annual Failure Rate [%]
0,3595
278
2.436.823
MTBF [years]
MTBF [Hour]
6.2 Useful life
Baumer A/S confirms that 20 years as useful life duration. This expectation is made on background of
calculation made in 6.1.1.
6.3 Maintainability
The Level Switch LFFS and LBFS have no maintenance requirements as long as they are not exposed to medias
that PEEK and the used stainless steel cannot resist.
6.4 Maintenance levels
6.4.1 On-vehicle diagnosis and repair
For some versions of the Level Switch LFFS and LBFS there a blue indication light for showing if it is trigged.
Both product can be tested and configured with the Flexprogram and Flexprogrammer9701,. For details see
operation manual.
6.4.2 Off-vehicle diagnosis and repair
Both LFFS and LBFS can be tested and configured with the Flexprogram and Flexprogrammer9701. On extra
power are necessary. For details see operation manual.
6.5 Built-in diagnostic
There is no build-in option for diagnostic on the fly. When the product is power off the functionality can be
tested with the Flexprogram and Flexprogrammer9701. For details see operation manual.
6.6 Automatic test equipment
Both products can be tested and configured with the Flexprogram and Flexprogrammer9701. For details see
operation manual.
6.7 Alternative methods for fault diagnosis
Both products can be tested and configured by the Flexprogram and Flexprogrammer9701. For details see
operation manual.
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6.8 Purpose built test equipment special tools
The Flexprogram and Flexprogrammer9701 can be ordered at Baumer. The software can be downloaded free
from www.Baumer.com.
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7.0 Design
7.1 General
7.1.1 Quality management
Certificate DS/EN ISO 9001:2008:
7.1.2 Life Cycle
The product life cycle are described in the quality system which covers the process from design to scrap.
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7.2 Detailed practices – Hardware
7.2.1 Interface
All circuits are tested to meet requirements from actual norms regarding EMC immunity and emission. All tests
are documented as shown in appendix A. There are not galvanic isolation build in the electrical construction.
However there is not contact between the media and the electrical parts.
The principals used for level measurement do not involve moving part for measured the level of the media. This
ensures mechanical stability.
The allowed power supply voltage is below 60VDC/AC which means the European guideline 73/23/EWG is not
applicable for those instruments.
7.2.2 Fault protection
The LFFS and LBFS are protected against permanent reverse polarity of the power lines in the voltage domain
defined by the supply voltage range.
A change or restoring can be done by the configuration unit Flexprogrammer9701. Teach-in can also be
performed without configuration unit, see the manual.
7.2.3 Referring power supplies
Not applicable, this is a requirement for power supplies.
7.2.4 Interchangeability
Not applicable, these requirement concern modular systems which contain single replaceable elements.
7.2.5 Reduction of power supply voltage
The LFFS and LBFS will not be damage by reducing power supply voltage. If power supply voltage drops
below specified supply voltage will cause a reset of the microcontroller. The microcontroller wil A rise again in
the power supply will reset and started again if supply raises again.
7.2.6 Polarity reversal
LFFS and LBFS are protected against permanent reversed polarity.
7.2.7 Inrush currents
No inrush current occurs with LFFS and LBFS.
7.2.8 Spare capacity
Adaption of user demands can be implemented on request. Product Firmware can be change on user location.
7.3 Detailed practices – Software
7.3.1 General
The design phase is part of the company quality system according to ISO9001, which ensures a model where
each phase in the product development procedure from specification to integration is described. This procedure
covers hardware as well as software development and ensures a uniform development procedure where each
step is documented.
The two instruments LFFS and LBFS are both able to be firmware updated in case on maintenance. This also
ensures the possibility for adaption of user demands if needed on site. The firmware update can be carried out
by the customer them self with the Flexprogrammer9701. Newest firmware will always be available for
downloaded on Baumer WEB.
Side 19 af 21
QA: KMJ
Dato for sidste rev.: 2011-11-22
Dok. Nr.: 5506-124
Rev.: A1
7.3.2 Software design measures
7.3.2.1 Modular approach
The firmware is made in a modular way to ensure that the complexity doesn’t prevent systematic testing and
maintenance.
7.3.2.2 Translator proven in use
For the product isn’t a translator applicable.
For the configurations tools, Flexprogram, can be applied in several languages. For translations to the customers
language a translator can be applied.
7.3.2.3 Recording
All documentation from product design phase is made to meet demands of the quality system.
It is not applicable with a translator for LFFS and LFFS
7.3.2.4 Structured methodology
Checklists are worked out according to the procedure 5509-353 of Baumer A/S ISO9001 quality system.
7.3.2.5 Design and coding methods
Design of the code is done according to best practice and to ensure a test can be performed.
7.3.2.6 Structured programming and analysis
See point 7.3.2.5.
7.3.2.7 Programming language
High level language as C is used where it is possible. This ensures fast and sure maintenance.
7.3.2.8 Proven techniques
Proven techniques which has been used for software development and process are
- Function block diagrams
- sequence diagrams
- data flow diagrams
- decision tables
- process simulation
7.4 Equipment features
7.4.1 Memory checking
All memory are located onboard the microcontroller which helps to ensure full functionality.
7.4.2 Self test
There are not implemented self test routines to the products. However test can be performed by using the
diagnostic routine from the Flexprogam.
7.4.3 Watchdog
Watchdog is build-in the product. Additional will code processing outside defined code area initiate a reset of
the product. This is only applicable for Firmware version 11.
7.3.4 Error indication
Error indication is implemented by indicating an error by blinking with the LEDs.
7.4.5 Recovery
Recovery is ensured as described in point 7.4.3 Watchdog.
Side 20 af 21
QA: KMJ
Dato for sidste rev.: 2011-11-22
Dok. Nr.: 5506-124
Rev.: A1
8.0 Components
8.1 Procurement
All component used in the product are specified with details as supplier and product code number.
8.2 Application
The product will fulfill requirement as long as the products are used for dedicated applications as level
measurement and if all data have been taken into consideration.
9. Construction
8.1 Mechanical construction
The principal used in LFFS and LBFS ensure that no mechanical stress occurs as a consequence of no moving
parts. However, attention should be given to the specification of the PEEK tip and stainless steel in connection
with the media and environment where the product should work.
10. Safty
11. Documentation
These requirements are covered by the Baumer Quality Management System according to EN ISO
9001.
12. Testing
State of validation of Baumer Level Switch LFFS and LBFS series referring to the test list according to EN
50155:
Ref.
Test
type
Comment
1
2
Visual inspection
Performance test
Applied
Applied
3
4
5
6
Cooling test
Dry Heat test
Damp heat test, cycle
Supply overvoltage
Applied
Applied
Applied
Applied
7
Applied
8
Surges, electrostatic discharge
and transient burst
susceptibility
Radio interference test
Applied during daily work
Test procedure is performed on each
product during production
IEC 60068-2-1, approved by DNV
IEC 60068-2-2 approved by DNV
IEC 60068-2-3 approved by DNV
Performed according to specifications of
DNV, Approved by DNV
According to EN50121, EN 61326
Test is performed on Delta A/S test site
9
Insulation test
Applied
10
11
Salt mist test
Vibration, shock and bump test
Applied
Applied
12
13
14
Water tightness test
Equipment stress test
Low temperature storage test
Applied
According to DNV test spec. (156MHz to
165Mhz)
Performed according to specifications of
DNV, Approved by DNV
IEC 60068-2-52, accredit by Delta A/S
IEC 60068-2-6, GL test2
EN61373/EN50155, accredit by Delta A/S
IP67 accredit test performed by Delta A/S
Applied
-50°C, tested locally at Baumer
Side 21 af 21
QA: KMJ
Applied
Dato for sidste rev.: 2011-11-22
Dok. Nr.: 5506-124
Rev.: A1
Appendix A
EMC test for LFFS and LBFS
Side 23 af 24
QA: KMJ
Dato for sidste rev.: 2011-11-22
Dok. Nr.: 5505-103
Rev.: A1
First version: A1, 2009-06-11
EMC specification of product LFFS Level Switch
1.
Introduction
2.
The product
3.
Relevant standards
4.
Test plan
5.
Definition of error criterions
Side 1 af 5
QA: KHA
Date for last rev.: 2010-08-16
Dok. Nr.: 55 06-110
Rev.: C1
1.
Introduction
1.1
Aim:
To set up minimum requirements to meet the protection requirements in the EMC
directive 2004/108/EC
2.
The product
2.1
The product:
Level switch with a NPN, PNP or digital output.
2.2
Type:
Product type no. LFFS Level Switch
2.3
Environmental use:
Industry.
Side 2 af 5
QA: KHA
Date for last rev.: 2010-08-16
Dok. Nr.: 55 06-110
Rev.: C1
2.4
Description of the product:
Construction:
The product contains a circuit board, built into a round plastic cabinet mounted in a ø55
metal housing. The module contains analogue circuits and a low power CPU circuits.
The module has the following ports:
- Voltage supply input, 12-36 VDC and Flex programming (two terminals).
- Output (NPN, PNP or Digital out)
Adjustments:
The product has been adjusted from factory.
Accuracy:
Must be able to detect media with a DK value as low as 1,5.
3.
Relevant standards
3.1
Emission: EN 61326
The following tests are estimated to be relevant:
- CISPR 16 and 16-1: Emission.
3.2
Immunity: EN 61326
The following tests are estimated to be relevant:
- EN 61000-4-2:
ESD discharge 4/4 kV. Criterion B.
- EN 61000-4-3:
HF field, 80 - 1000 MHz, 80% AM (10 V/m) and 1,4 - 2GHz, 80% AM,
(3 V/m). Criterion A.
- EN 61000-4-4:
Burst transients 1 kV CM. Criterion B.
- EN 61000-4-5:
Surge transients 0,5 kV line to ground. Criterion B.
- EN 61000-4-6:
Conducted HF, 0.15 - 80 MHz, 80% AM, 3 VRMS. Criterion A.
(+), (-) and the output port are defined as: “I/O signal/control connected directly to mains
supply”. This definition is used because a power supply unit might be connected to these
ports. The teach in port is defined as an “I/O signal/control” port because it is not meant for
power supply connection. Teach-In is initiated by shorting the port to the (-) terminal.
Side 3 af 5
QA: KHA
Date for last rev.: 2010-08-16
Dok. Nr.: 55 06-110
Rev.: C1
4.
Test plan
4.1
The unit is programmed for PNP output to begin with. The unit output is changed to NPN and
Digital out when needed.
5.
Error criterions
5.1
Criterion A:
The product is unaffected during the test, within the specified levels.
5.2
Criterion B:
The output of the product varies beyond the specified range during test, but returns to
normal operation after disturbance is removed. No reset or crash is allowed.
5.3
Criterion C:
Not relevant.
Side 4 af 5
QA: KHA
Date for last rev.: 2010-08-16
Dok. Nr.: 55 06-110
Rev.: C1
First version: A1, 2010-04-21
EMC specification of product LBFS Level Switch
1.
Introduction
2.
The product
3.
Relevant standards
4.
Test plan
5.
Definition of error criterions
Side 1 af 5
QA: THH
Date for last rev.: 2011-11-07
Dok. Nr.: 55 06-115
Rev.: C1
1.
Introduction
1.1
Aim:
To set up minimum requirements to meet the protection requirements in the EMC
directive 2004/108/EC, as well as other directives that are determined to be relevant:
EN50121-3-2:2007
DNV 2.4:2006
2.
The product
2.1
The product:
A NPN or PNP level switch with normally open and normally closed outputs
2.2
Type:
Product type no. LBFS Level Switch
2.3
Environmental use:
Industry.
Side 2 af 5
QA: THH
Date for last rev.: 2011-11-07
Dok. Nr.: 55 06-115
Rev.: C1
2.4
Description of the product:
Construction:
The product contains a circuit board mounted in a “cylindrical” metal housing. The product is
electrically connected by either a M12 or a standard four wire cable. The module contains
analogue circuits and a low power CPU circuits.
The module has the following ports:
- Voltage supply input, 12-30 VDC and Flex programming (two terminals).
- Two outputs: NO and NC. The LBFS will be produced with either PNP or NPN output
configuration.
Adjustments:
The product has been adjusted from factory.
Accuracy:
Must be able to detect media with a DK value as low as 1,5.
3.
Relevant standards
3.1
Emission: EN 55011
The following tests are estimated to be relevant:
3.2
EN55011:2007:
Conducted and radiated emission.
DNV 2,4:2006:
Special requirement: 156 – 165 MHz Emergency frequency band
Immunity: EN 61326
The following tests are estimated to be relevant:
- EN 61000-4-2:
ESD discharge 8/8 kV. Criterion B.
- EN 61000-4-3:
HF field, 80 - 1000 MHz, 80% AM (20 V/m) and 1 – 2,5GHz, 80% AM,
(10 V/m). Criterion A.
- EN 61000-4-4:
Burst transients 2 kV CM. Criterion B.
- EN 61000-4-5:
Surge transients 1 kV line to line, 2 kV line to ground. Criterion B.
- EN 61000-4-6:
Conducted HF, 0.15 - 80 MHz, 80% AM, 10 VRMS. Criterion A.
(+), (-) and the output ports are defined as: “I/O signal/control connected directly to mains
supply”. This definition is used because a power supply unit might be connected to these
ports.
Side 3 af 5
QA: THH
Date for last rev.: 2011-11-07
Dok. Nr.: 55 06-115
Rev.: C1
3.3
DNV classification
This product is classified for use on open deck (Class B) as defined in the DNV 2.4:2006
directive Table 2-1.
4.
Test plan
4.1
A NPN and a PNP unit, mounted in a G½” stainless steel housing, will be tested. The units
will be electrical connected via a M12 cable
5.
Error criterions
5.1
Criterion A:
The product is unaffected during the test, within the specified levels.
5.2
Criterion B:
The output of the product varies beyond the specified range during test, but returns to
normal operation after disturbance is removed. No reset or crash is allowed.
5.3
Criterion C:
Not relevant.
Side 4 af 5
QA: THH
Date for last rev.: 2011-11-07
Dok. Nr.: 55 06-115
Rev.: C1
DECLARATION OF CONFORMITY
We,
Baumer A/S
Jacob Knudsens Vej 14
8230 Aabyhoj
Denmark
Tel: +45 89 31 76 11
declare under our sole responsibility that the product
Product Name:
LBFS Level Switch
Product Description: Level switch, PNP or NPN outputs, with LED indication.
Product Type:
Level Switch
to which this declaration relates is in conformity with
the following European Directives:
2004/108/EC
And related European Standards:
EN 61 326
Issue 1. 2006-11-03
We also declare conformity with the following specific Directives:
DNV 2.4: 2006
The Norwegian Veritas:
STANDARD FOR CERTIFICATION No. 2.4
ENVIRONMENTAL TEST SPECIFICATION FOR INSTRUMENTATION AND
AUTOMATION EQUIPMENT
EN50121: 2006
Railway applications – Electromagnetic compatibility – Part 3-2:
Rolling stock apparatus
Date:___________________ Sign:_____________________________
R&D Manager
Kurt Møller Jensen
Side 5 af 5
QA: THH
Date for last rev.: 2011-11-07
Dok. Nr.: 55 06-115
Rev.: C1
Appendix B
Vibrations test EN50155 / EN61373
Side 24 af 24
QA: KMJ
Dato for sidste rev.: 2011-11-22
Dok. Nr.: 5505-103
Rev.: A1
DELTA Test Report
TEST Reg. no. 19
Vibration and shock test of Level Switches
Performed for Baumer A/S
DANAK-1911632
Project no.: T201052
Page 1 of 18
including 4 annexes
24 October 2011
DELTA
Venlighedsvej 4
2970 Hørsholm
Denmark
Tel. (+45) 72 19 40 00
Fax (+45) 72 19 40 01
www.delta.dk
This report is issued under the rules of DANAK (Danish Accreditation) and ILAC
(International Laboratory Accreditation Cooperation) including its MRA (Mutual Recognition
Arrangement). Further information can be found at www.danak.dk and www.ilac.org.
The report must not be reproduced, except in full, without the written approval of DELTA.
Version m
DANAK-1911632
DELTA-T201052
Page 2 of 18
Title
Vibration and shock test of Level Switches
Test object
4 pcs. Level Switches
Detailed information is given in Chapter 2.
Report no.
DANAK-1911632
Project no.
T201052
Test period
6 – 12 October 2011
Client
Baumer A/S
Jakob Knudsensvej 14
8230 Åbyhøj
Danmark
Tel. +45 89 31 76 11
Contact person
Kurt Møller Jensen
E-mail: [email protected]
Manufacturer
Baumer A/S
Specifications
EN 50155: 2007 Railway applications –
Electronic equipment used on rolling stock.
EN/IEC 61373:1999 Railway applications –
Rolling stock equipment –
Shock and vibration tests.
Results
The performance of the test objects was OK before and
after the exposures.
No change in visual appearance and mechanical integrity
was observed after the exposures.
Test personnel
CLK/lko
René Toftdal
Torben Sibbern Larsen
DANAK-1911632
DELTA-T201052
Page 3 of 18
Date
24 October 2011
Project manager
Claus Kirk, B.Sc. ME, M.Sc. AVD
Specialist, Centre of Test Excellence
DELTA
Responsible
Andreas Wendelboe Højsgaard
Specialist, Centre of Test Excellence
DELTA
CLK/lko
DANAK-1911632
DELTA-T201052
Page 4 of 18
Table of contents
Page
1.
1.1
1.2
Summary of test
Test requirements
Conclusion
5
5
5
2.
2.1
2.2
Test objects
Test objects
Auxiliary equipment
6
6
6
3.
3.1
3.2
3.3
3.4
General test conditions
Test setup
Test sequence
Criteria for compliance
Functional test
7
7
7
7
7
4.
4.1
4.2
Test and results
Vibration – Endurance random
Shock
8
8
9
CLK/lko
Annex 1 List of instruments
10
Annex 2 Photos of test setup
12
Annex 3 Measurement curves - Vibration
15
Annex 4 Measurement curves – Shock
17
DANAK-1911632
DELTA-T201052
Page 5 of 18
1.
Summary of test
1.1
Test requirements
The following tests were carried out as agreed with the client.
1.2
Test
Test method
Random vibration
Shock
EN/IEC 60068-2-64:2008
EN/IEC 60068-2-27:2008
Conclusion
The test object mentioned in this report meets the relevant requirements of the standards
stated below.

EN 50155:2007

EN 61373:1999
The test results relate only to the objects tested.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 6 of 18
2.
Test objects
2.1
Test objects
EUT #1
Level Switch LFFS 011
S/N: 24641
EUT #2
Level Switch LFFS 014
S/N: 25610
EUT #3
Level Switch LBFS 0112 1
S/N: 24682
EUT #4
Level Switch LBFS 0312 1
S/N: 25615
EUT #3 was fitted with a plastic connector receptacle and EUT #4 was fitted with a steel
receptacle.
2.2
Auxiliary equipment
Power supplies delivered by the client were used for functional tests.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 7 of 18
3.
General test conditions
3.1
Test setup
Photos describing the test setup are enclosed in Annex 2.
3.2
Test sequence
The tests were performed in the following order:
Exposure
3.3
EUT #1 and #2
EUT #3 and #4
Shock
Y
X
Random vibration
Y
X
Random vibration
X
Z
Shock
X
Z
Random vibration
Z
Y
Shock
Z
Y
Criteria for compliance
Performance criterion A: Performance according to EN/IEC 61373 section 6.3.3 remains
within the defined limits.
Performance criterion B: Function according to EN/IEC 61373 6.3.2 remains within the
defined limits.
Performance criterion C: The visual appearance and mechanical integrity has not
changed.
3.4
Functional test
A functional test was performed before, during and after each test.
The test consisted of manually triggering the level switches and observing a blue LED
indicating that the switch had been triggered and that the EUT was working.
On EUT #3 with the steel receptacle observing the LED was not possible. Instead a
change in voltage between the output pins was measured using a voltmeter.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 8 of 18
4.
Test and results
4.1
Vibration – Endurance random
Specifications
EN 50155:2007
EN/IEC 61373:1999
Test method
IEC 60068-2-64: 2008, Test Fh: Vibration, broadband random and guidance.
Severity and procedure
Frequency range:
5 – 150 Hz
Acceleration spectral:
5 – 20 Hz: 0.019 g2/Hz
Density: 20 – 150 Hz:
-6 dB/octave
Total RMS level:
0.79 g
Duration:
300 minutes per axis
Number of axes:
3 mutually perpendicular
A functional test was performed before and after the exposure in each axis at a vibration
level of -18 dB (0.1 grms).
The test object is de-energised during the exposure to the endurance vibration levels.
A performance test is performed before and after the exposure.
A visual inspection is performed after the exposure.
Results
The function of the test objects was OK during the functional tests performed at 0.1grms
in each axis.
The performance of the test objects was OK before and after the exposure to 0.79 grms
in each axis.
No change in visual appearance and mechanical integrity was observed after the exposures.
Exposure curves and definition of axes are enclosed in Annex 3.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 9 of 18
4.2
Shock
Specifications
EN 50155:2007
EN/IEC 61373:1999
Test method
EN/IEC 60068-2-27: 2008, Test Ea and guidance: Shock.
Severity and procedure
Shock pulse:
Half sine, 5 g, 30 ms
Number of directions:
Each direction of 3 mutually perpendicular axes
Number of shocks:
3 per direction (18 in total)
The test object is de-energised during the exposure. A functional test is performed after
each axis.
Results:
The performance of the test objects was OK before and after the exposure to 5 g, 30 ms
in each axis.
No change in visual appearance and mechanical integrity was observed after the exposures.
Exposure curves are enclosed in Annex 4.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 10 of 18
Annex 1
List of instruments
CLK/lko
DANAK-1911632
DELTA-T201052
Page 11 of 18
List of instruments
V01020 Shaker
LDS
V850-440 LPT 750 Combo
V01027 Shaker control system
LDS Dactron
Laser USB LAS 200
V01024 Accelerometer
Kistler
8702B500M1
V01041 Accelerometer
Kistler
8778A500
CLK/lko
DANAK-1911632
DELTA-T201052
Page 12 of 18
Annex 2
Photos of test setup
CLK/lko
DANAK-1911632
DELTA-T201052
Page 13 of 18
Axis definition for EUT #1 and
#2.
X
Z
EUT #2
EUT #1
Y
Axis definition for EUT #3 and
#4.
EUT #4
Z
Y
EUT #3
X
Photo 1. Axis definition, Y-axis for EUT 1 & 2 and X-axis for EUT 3 & 4.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 14 of 18
Photo 2. X-axis for EUT 1 & 2, Z-axis for EUT 3 & 4.
Photo 3. Z-axis for EUT 1 & 2, Y-axis for EUT 3 & 4.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 15 of 18
Annex 3
Measurement curves - Vibration
CLK/lko
DANAK-1911632
DELTA-T201052
Page 16 of 18
Graph 1.
EUT #1 and #2
Y-axis
EUT #3 and #4
X-axis
Graphs in the 3 other axis are similar.
CLK/lko
DANAK-1911632
DELTA-T201052
Page 17 of 18
Annex 4
Measurement curves – Shock
CLK/lko
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Page 18 of 18
m/s²
69.0000
profile(t)
60.0000
high-abort(t)
50.0000
low-abort(t)
40.0000
control(t)
30.0000
20.0000
10.0000
0
-10.0000
-20.0000
-28.0000
-75
-60
-40
-20
0
20
40
60
80
105
Time (Milliseconds)
m/s²
28.0000
profile(t)
20.0000
high-abort(t)
10.0000
low-abort(t)
0
control(t)
-10.0000
-20.0000
-30.0000
-40.0000
-50.0000
-60.0000
-69.0000
-75
-60
-40
-20
0
20
Time (Milliseconds)
Graph 2 and3.
EUT #1 and #2
Y-axis
EUT #3 and #4
X-axis
Graphs in the 3 other axis are similar.
CLK/lko
40
60
80
105
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