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 Side 1 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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 Side 2 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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 Side 3 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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 Side 4 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 5 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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) Side 6 af 21 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%) QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 +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. Side 7 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 8 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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: Side 9 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 Concerning LBFS : Side 10 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 11 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 Requirements according Det Norske Veritas (DNV). were verified in below test reports. LFFS: LBFS: Side 12 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 13 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 14 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 - 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] Side 15 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 16 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 17 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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. Side 18 af 21 QA: KMJ Dato for sidste rev.: 2011-11-22 Dok. Nr.: 5506-124 Rev.: A1 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 DANAK-1911632 DELTA-T201052 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