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Baumuller b maXX BMC-M-SAF-02 Operating Instructions Manual Download Page 15

15

of 118

 Operation Manual 

b maXX safe PLC

 BMC-M-SAF-02

Document no.: 5.07020.04

3

U

SE

 

OF

 

THIS

 

HANDBOOK

This safety handbook contains information on the intended use of the Baumüller b maXX 
safe PLC.

Knowledge of regulations and proper technical implementation of the safety instructions 
in this handbook by qualified personnel are prerequisites for the safe installation, commis-
sioning and safety during the operation and maintenance of the Baumüller b maXX safe 
PLC. Unqualified interventions in the devices, during shutdown or use of the safety func-
tions or failure to comply with the instructions of this handbook can lead to serious per-
sonal injury, property damage or environmental harm, for which Baumüller assumes no 
liability. 

Baumüller control devices are developed, manufactured and tested in compliance with 
the applicable safety standards. They may only be used under the specified environmen-
tal conductions and only in connection with approved external devices. 

The Operation Manual contains safety instructions, descriptions of the interfaces and in-
formation on the phases of the product’s life cycle:

n

Planning

n

Installation/Assembly

n

Commissioning

n

Validation

n

Operation

n

Modification/retrofitting

n

Troubleshooting

n

Maintenance/repair

n

Disassembly

Summary of Contents for b maXX BMC-M-SAF-02

Page 1: ...ing Instructions Read the Operating Instructions before beginning Language English Translation Document No 5 07020 04 Part No 422418 Status 07 02 2011 b maXX Systems b maXX safe PLC BMC M SAF 02 E 5 07020 04 ...

Page 2: ... Baumüller Nürnberg GmbH Ostendstr 80 90 90482 Nürnberg Germany Tel 49 9 11 54 32 0 Fax 49 9 11 54 32 1 30 E Mail mail baumueller de Internet www baumueller de ...

Page 3: ...Intended use 18 4 4 Operator responsibility 19 4 5 Protective equipment 19 4 6 Personnel training 20 4 7 Personnel protective equipment 21 4 8 Special dangers 22 4 9 Firefighting 23 4 10 Electric safety 24 4 10 1 Notice on power supply 24 4 11 Safety equipment 24 4 12 Conduct in the event of danger and accidents 25 4 13 Signage 26 5 Functional Safety 27 5 1 Safety related parameters for 20 years o...

Page 4: ...fety PLC 60 11 1 2 Combined operation of the safety PLC 61 11 2 General safety regulations 62 11 3 Requirements on the personnel conducting the work 63 11 4 Description inspection of the safety and monitoring equipment 63 11 5 Loading applications 63 11 5 1 Downloading projects from the PC 63 11 6 Setting the station number 63 11 7 Description and inspection of the operation and display elements 6...

Page 5: ...g out the work 94 17 3 Disassembly 94 17 4 Storage conditions 96 17 5 Recommissioning 96 18 Disposal 97 18 1 Safety regulation 97 18 2 Requirements for the personnel carrying out the work 97 18 3 Disposal instructions 97 18 4 Recycling collection center offices 98 Appendix A Abbreviations 99 Appendix B Accessories 101 B 1 List of all accessory items 101 Appendix C Checklists 103 C 1 Planning check...

Page 6: ...Operating Instructions b maXX safe PLC BMC M SAF 02 Document No 5 07020 04 Baumüller Nürnberg GmbH 6 of 118 Inhaltsverzeichnis Index 117 ...

Page 7: ... no 5 07020 04 1DOCUMENT HISTORY Revision level State Modifications 5 07020 01 18 10 2007 Initial document 5 07020 02 31 03 2009 Revision and CFI module extension 5 07020 03 25 08 2009 Editorially checked contents 5 07020 04 07 02 2011 New declaration of conformity ...

Page 8: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 8 of 118 ...

Page 9: ...ied is a prerequisite for work safety Furthermore it is also necessary to comply with the local accident prevention legislation and general safety regulations applying to the device s field of application Read the Operation Manual completely in particular the chapter on safety instructions before beginning any work on the device The Operation Manual is a component of the product and must be kept a...

Page 10: ...y and property damage Recommenda tions DANGER notifies of an imminent dangerous situation which will lead to death or serious in juries if not avoided WARNING notifies of a potentially dangerous situation which can lead to death or serious in juries if not avoided CAUTION notifies of a potentially dangerous situation which can lead to minor or slight inju ries if not avoided CAUTION notifies of a ...

Page 11: ...nformation 2 5 Copyright Treat the Operation Manual as confidential It is intended exclusively for those working with the device It is not permissible to transfer the Operation Manual to third parties with out the written approval of the manufacturer CAUTION The following shall apply if the document you are reading is designated as preliminary information This version pertains to preliminary techn...

Page 12: ... proper disassembly See also Z18 Disposal from page 97 onward 2 9 Warranty conditions The warranty conditions can be found as a separate document in the sales documenta tion The operation of the devices described here in accordance with the specified methods procedures requirements is permissible Everything else even the operation of devices in installation positions not depicted here for instance...

Page 13: ...System is also used for the product consisting of power supply for b maXX controller safe PLC b maXX safe PLC and further system components A list of the abbreviations used can be found in ZAppendix A Abbreviations from page 99 onward 2 12 Certification The programmable safety controller b maXX safe PLC from Baumüller Nürnberg GmbH has been developed in accordance with the standards specified in Z...

Page 14: ...tric electronic and programmable electronic sys tems Fulfilment of increased stability requirements in accordance with Appendix E Additional standards Area of application EN 61131 2 General device requirements and tests for control systems EN 50178 Equipping of high voltage equip ment with electronic utilities Use of ventilation and leakage paths EN 60204 Electrical machine equipment ...

Page 15: ...the safety func tions or failure to comply with the instructions of this handbook can lead to serious per sonal injury property damage or environmental harm for which Baumüller assumes no liability Baumüller control devices are developed manufactured and tested in compliance with the applicable safety standards They may only be used under the specified environmen tal conductions and only in connec...

Page 16: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 16 of 118 ...

Page 17: ...ssigned to work on or with the device must have read and understood that Operation Manual before beginning work with the device This also applies if the person concerned has already worked with such a device or similar device or has been trained by the manufacturer 4 2 Alterations and rebuilding of the device In order to avoid hazards and ensure optimum performance neither alterations additions no...

Page 18: ...e that the device is always used within its spec ifications m The device and or mounting rail is mounted on a wall which is sufficiently sturdy m Ensure that the power supply meets the required specifications m Only operate the device if it is in technically faultless condition m Only use the device in combination with components approved by Baumüller Nürn berg GmbH m Only operate the device in ty...

Page 19: ...the form of op eration instructions for the operation of the device m This Operation Manual must be kept in the immediate vicinity of the device and be ac cessible to persons working on and with the device at all times m The statements of the Operation Manual are to be followed completely and absolutely m The device may only be operated in technically faultless condition and must be safe for opera...

Page 20: ...qualified personnel m Qualified personnel Electrical engineers and specialist electricians of the customer or a third party who are authorized by Baumüller Nürnberg GmbH trained and certified in the installation and commissioning of Baumüller drive systems and commissioning grounding and desig nating electrical systems and devices in accordance with the safety engineering stan dards Qualified pers...

Page 21: ...ty in the work area To be worn during special work Protective work clothes denotes tight fitting work clothing with low tear resistance tight sleeves and no pro truding parts It primarily serves in protecting from Do not wear any rings and necklaces Protective helmet for protection from falling and flying parts Safety shoes for protection from heavy falling parts Safety gloves to protect the hands...

Page 22: ... if the insulation on the power supply is damaged m Only allow the work to be conducted on the electrical system by qualified person nel m Turn the current off when conducting any work on the electrical system and secure it before turning it back on DANGER Live threatening danger from electric current After the device has been disconnected from the mains live parts such as line con nectors may onl...

Page 23: ...s during operation m Do not open covers during operation m The mechanical residual energy depends on the application Powered parts will also keep rotating moving for a certain time after the power supply has been shut off Make sure to provide suitable safety equipment DANGER Live threatening danger from electric current Electric shock can occur if a conductive fire extinguishing medium is used The...

Page 24: ...g the system check that contamination degree 2 is not exceeded and ensure so by additional measures if necessary WARNING Risk of injury from electric current Only devices which have a safe disconnection to the 230 volt mains may be connect ed to the control The power supply for generation the 24 volt supply must meet the requirements for PELV in accordance with EN 50178 WARNING Live threatening da...

Page 25: ...rst aid kits blankets etc and fire extinguishers readily available m Instruct personnel in accident reporting first aid and rescue equipment In case of emer gency Act proper ly m Put the device out of operation immediately with the EMERGENCY STOP m Introduce first aid measures m Keep people out of the danger zone m Inform the supervisors at the site m Notify a doctor and or fire department m Clear...

Page 26: ...di tion at all times Electric current Only qualified personnel may work in work spaces with this marking Unauthorized persons may not touch work equipment bearing this marking DANGER Live threatening danger from electric current Discharge time 1 minute Saved electric charge Therefore m Keep the discharge time of the capacitors in mind and do not touch live parts be forehand m Follow the commensura...

Page 27: ... years Different safety characteristic values apply depending on this 5 1 Safety related parameters for 20 years of operation The safety related parameters of the b maXX safe PLC will be described in the following Safety related parameters of local I O terminals and decentral components can be found in the applicable documentation The values specified here relate exclusively to the PLC Parameters ...

Page 28: ...AUTION If the user calculates his safety application with 20 years for the specified values the safety control will have to be decommissioned and sent back to the manufacturer within not more than 20 years NOTICE If the PFDavg value of an application is too large the life cycle can be decreased to 10 years The controller must sent back to Baumueller to the proof test after 10 years For a proof tes...

Page 29: ...re assembly 6 2 Unpacking Upon receiving the still packaged module h Check to see if any shipping damages can be found If there are h Immediately file a complaint to the supplier Confirm the complaint in writing and imme diately contact the representative of Baumüller Nürnberg GmbH who is assigned to as sist you If no damage from shipping can be found CAUTION Danger from electrostatic discharge Th...

Page 30: ... complaint to the Baumüller representative assigned to you 6 3 Disposing of the packaging The packaging consists of cardboard and plastic h Follow local regulations on disposal if you dispose of the packaging 6 4 To be observed when shipping The module has been packaged at the factory for the initial shipping If you subsequently need to ship the module again please observe the following h use the ...

Page 31: ...in parallel to this The safety core used for this purposes is certified in accordance with SIL 3 IEC61508 The system can have both central and decentral I O terminals Standard data as well as safe data can be transmitted via network components and the local I O bus Safe drives which respond by means of safety protocols via bus systems are considered to be I O slaves in the system The implementatio...

Page 32: ...1 1 or higher in following pro gramming languages m Sequential Function Chart SFC m Structured Text ST m Instruction List AWL m Logic Diagram FUP m Ladder Diagram LD Safety program ming languages Safety programming is carried out in a modularized manner with the ProSafety program ming interface in the following programming languages m Logic Diagram FUP m Ladder Diagram LD Technology func tions Fur...

Page 33: ...X SAFEINT X SAFETIME X SAFEBYTE X Supported Functions and FBs Basic Level Supported Comment AND X OR X Type Conversion functions X SAFEWORD_TO_SAFEBOOLS SAFEBOOLS_TO_SAFEWORD SAFEBOOL_TO_BOOL SAFEBYTE_TO_BYTE SAFEDWORD_TO_DWORD SAFEINT_TO_INT SAFETIME_TO_TIME SAFEWORD_TO_WORD TON X TOF X TP X CTU X CTD X CTUD X Supported Functions and FBs Extended Level Supported Comment AND X OR X XOR X NOT X ADD...

Page 34: ...table FBs X SR RS Edge detection X F_TRIG R_TRIG Function Blocks Supported Comment SF_Equivalent X SF_Antivalent X SF_ModeSelector X SF_EmergencyStop X SF_ESPE X SF_SafeStop1 SF_SafeStop2 SF_GuardMonitoring X SF_SafelyLimitedSpeed SF_TwoHandControlTypeII X SF_TwoHandControlTypeIII X SF_GuardLocking X SF_TestableSafetySensor X SF_MutingSeq X SF_MutingPar X SF_MutingPar_2Sensors X SF_EnableSwitch X ...

Page 35: ... M BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1 BAUMULLER BAUMULLER A Jack for additional system components on the side B Plug for power supply or CF card if present on the side C Unlocking handle white bottom D Abbreviated designa tion E Type plate on the side F LEDs G RS232 interface H RS485 interface J Rotary switch K Switch button L ...

Page 36: ...hannel safety PLC as an example BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1 BAUMULLER BAUMULLER S1 H1 H4 BAUMULLER PSB 02 S5 S4 S3 S2 0 1 2 3 4 5 7 6 89A B C D E F 0 1 2 3 4 5 7 6 89A B C D E F 0 0 1 1 2 2 3 3 4 4 5 5 7 7 6 6 8 8 9 9 A A B B C C D D E E F F 24V PE PE 0V H5 H8 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F...

Page 37: ...inal interface visually separated from the b maXX safe PLC m up to 5 additional modules system components can be addressed n additional EtherCAT masters n additional CANopen masters n additional ethernet connections n additional ethernet connections with CANopen master m Motion control support m Power consumption of approx 5 W 7 5 Properties of the safety PLC The 32 bit RISC CPU 667 MHz of the sta...

Page 38: ...m x 36 4 mm x 3 3 mm compact Flash cards can be used as memory cards 7 7 1 Data on the memory card The memory card serves in downloading and uploading both security application projects as well as standard application projects including configuration data m Copy the data from the CFI card to the PLC m Copy the data from the PLC to the CFI card A E F C B D H G J K BAUMULLER CFI 01 H1 H4 S2 X1 0 1 2...

Page 39: ...5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1 BAUMULLER BAUMULLER BAUMULLER CFI 01 H1 H4 S2 X1 0 1 2 3 4 5 7 6 89A B C D E F H9 S1 H5 H8 BAUMULLER H1 H4 H5 S1 NOTICE This type code applies exclusively to the b maXX safe PLC module Other modules have their own type codes BMC M SAF XX YY ZZ Generation of device in which the module can be used BMC M SAF XX YY ZZ Module BMC M SAF XX YY ZZ Module type b ma...

Page 40: ...essential data A sum mary of all technical data can be found in ZAppendix D Technical data from page 109 onward NOTICE All modules in hardware version 1x are not compatible with modules in hardware version 0x since the knife edge contacts between the power supply PLC and po tential field bus modules have been changed Only modules in version 1x can be connected for that reason Example b maXX safe P...

Page 41: ...hich dangers a machine can present and which plant parts will have to be equipped with safety technology devices The residual risk is reduced to a justifiable level by means of safety technology measures DANGER Conducting the planning thoroughly aids in avoiding failures Failures in safety orient ed machines can lead to permanent injuries and death CAUTION The Planning checklist reproduced in the ...

Page 42: ...ISO 12100 1 and EN ISO 14121 Delineation of the system Determination of the system s boundaries and the intended use Hazard analysis Identification of hazards and the related hazardous situations Risk estimation Estimation of the risks for each hazard identified Risk assessment Assessment of the risks and establishment of risk reduction measures CAUTION It is absolutely necessary to conduct the ri...

Page 43: ...phase The system is planned according to the respective requirements of the plant or the ma chine The components available for the automation of the available components are de scribed in the Baumüller publication Automation Complete Catalog There you can find information on concepts PLC field buses motion control technology blocks HMIs IPCs and I Os The minimum version consists of a b maXX contro...

Page 44: ... right with the direct connection of I O modules such as digital input and output modules analog input and output modules thermal elements such as PT100 counter modules feed terminals as well as with digital input and output terminals The power consumption of the individual modules can be found in Appendix D of the op eration manual of the respective component assembly ...

Page 45: ...Conduct a visual inspection and check all system components for visible damage m Check the system for wiring errors m Inspect the tightening torque and make sure that the electrical connection is not interrupted by insulation material m Inspect the tensile load capacity of the electrical terminal and screw connections m Make sure that the installation and cable routing are carried out in accordanc...

Page 46: ... and knowledge of the relevant standards and provisions accident prevention regulations and operating conditions Example of the qualifications required for work with the unit include m Training or instruction in accordance with the safety technology standards in the main tenance and use of suitable safety equipment SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1...

Page 47: ... space The following diagrams show you the height and depth dimensions of the modules of the b maXX system Use these diagrams to determine the amount of space you will need in the electrical cabinet The width of the modules used varies In order to establish the weight of your b maXX system add the width of the individual modules which you want to use Take note of potential limitations to the numbe...

Page 48: ...2 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1 123456678 123456678 123456678 Minimum clearence 30 mm Minimum clearence 30 mm 65 mm BMC M SAF 02 57 mm 76 mm 84 mm SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 6 1 5 9 6 1 BAUMULLER BAUMULLER BAUMULLER CFI 01 H1 H4 S2 X1 0 1 2 3 4 5 7 6 89A B C D E F H9 S1 H5 H8 BAUMULLER H1 H4 H5 S1 Depth 91 mm 100 mm BMC M SAF 02...

Page 49: ...C DANGER Life threatening danger from electrical current The device and surrounding area in the electrical cabinet can carry life threatening voltages Therefore m Make sure that power to the device and surrounding area has been shut off before beginning work m Follow the applicable safety regulations when handling devices carrying high volt ages A Jack for additional system components on the side ...

Page 50: ...ft The handle will lock into place easily Repeat this step with the b maXX safe PLC 3 handles with the BMC M SAF 02 4 handles with the BMC M SAF 02 with memory card module Repeat this step with any further system components for the b maXX safe PLC which are plugged into the left side of the maXX safe PLC BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F X1 X2 5 9 ...

Page 51: ...H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F BAUMULLER S1 H1 H4 BAUMULLER PSB 02 S5 S4 S3 S2 0 1 2 3 4 5 7 6 89A B C D E F 0 1 2 3 4 5 7 6 89A B C D E F 0 0 1 1 2 2 3 3 4 4 5 5 7 7 6 6 8 8 9 9 A A B B C C D D E E F F H5 H8 PSB 01 0000 S_Nr 123456789 BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F BAUMULLER S1 H1 H4 BAUMULLER PSB 02 S5 S4 S...

Page 52: ...e the white handle to unlatch and the left part of the power supply to en gage with the 35 mm C rail Repeat this step with the b maXX safe PLC 3 handles with the BMC M SAF 02 4 handles with the BMC M SAF 02 with memory card module This will cause the fb maXX safe PLC to engage with the 35 mm C rail Repeat this step with additional system components for the b maXX safe PLC which are plugged into th...

Page 53: ...485 BAUMULLER H1 H4 H5 S1 CAUTION Danger from electrical current The module can be damaged or destroyed if the requirements for the electrical con nection of the module are not met Therefore m Make sure that the connection values specified in technical data are met and that the connections are carried out according to the specifications m Prevent a short circuit between inputs and outputs A short ...

Page 54: ...e connection cable Baumüller approves the following cables for use m RS485 interface Stranded cables in pairs with a recommended cross sectional area of 0 5 mm PVC outer jacked and overall shielding made of tin plated mesh may be used Such as Type LIYCY 6 x 2 x 0 14 mm m RS232 interface Shielded cable with a recommended cross sectional area of 0 5 mm Further information can be found in ZAppendix B...

Page 55: ...the left part of the b maXX safe PLC with the connection cable for a terminal or another device with the RS485 inter face for more on this see ZRequirements on the connection cable on page 54 and ZAppendix D Technical data from page 109 onward Figure 14 Cable routing h Route the connection lines according to the specifications in ZFigure 14 The cable shielding must be laid open first The length of...

Page 56: ...Installation Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 56 of 118 9 6 ...

Page 57: ...ETY Detailed instructions on programming the safety control can be found in the Application Handbook for the b maXX safe PLC or in ProSafety s online help system NOTICE Since the user administration is not initialized after the installation of ProSafety the installation of ProSafety should be limited to authorized persons by company policy ...

Page 58: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 58 of 118 ...

Page 59: ...ources between the standard and safe process will have to be adjusted WARNING Danger of injury from electric current The ZCommissioning and validation checklist from page 106 onward reproduced in the Appendix should be used during the commissioning phase Therefore m Make sure that the system is commissioned exclusively by qualified personnel m Make sure that there are no people in the danger zone ...

Page 60: ...y control at your disposal The operation mode is set when an IEC project is not transferred to the standard PLC or when an existing project is erased The safe parameter for the distribution of computing time between safety PLC and standard PC should be set on 90 for this operation mode see ZDetermination of the device parameters on page 43 Running the safety PLC in solitary operation will result i...

Page 61: ...h will only take effect on the respective piece being addressed standard PLC or safety PLC However every action will stop since the standard PLC also stops the safe communication The reason for this is that the communication is coupled to the status of the standard PLC and the safe communi cation cannot run if the standard communication is not running NOTICE If a bus configuration on the standard ...

Page 62: ... hand is of no concern In STOP status all original data will be set to 0 fail safe value If the safety PLC goes into error status the safe communication will no longer run The connected safety devices then detect a breakdown of the safe communication and automatically go into safe status CAUTION Danger due to non safe status Do not attempt to bring about the safe status of the system by using the ...

Page 63: ...button on channel 2 of the PLC and the S1 button on the BMC M PSB 02 power supply simultaneously 2 After pushing the buttons the LED on rotary switch S2 1st digit on the power supply will light up 3 The 7 segment display on channel 2 of the PLC will blink and show the value of rotary switch S2 on the power supply 4 The value of the 1st digit of the station number can now be set on the rotary switc...

Page 64: ...cognized at the turning of the decimal point for instance 1 2 2 4 means 1224 Initial digits which are zero are not displayed You can find additional information on the meaning of the station number and address ID allocation in the Application Manual b maXX safe PLC 11 7 Description and inspection of the operation and display elements 11 7 1 LEDs for displaying the operation statuses of the BMC M S...

Page 65: ... the sequence H1 green H2 red H6 red H5 green H1 green etc at an alternation of 500 ms If the I O bus is cannot be initialized within a maximum of 8 seconds or an error appears during the initialization of the I O bus H8 red will turn on Both of the above described procedures can be completed very quickly so that it is not absolutely crucial to observe the related operating displays Afterward a PR...

Page 66: ...tus INIT the control is in cold start or warm start phase only LED H5 green lights up m Project present status RUN LED H1 green and H5 green light up m Global ready message absent LED H4 red lights up PLC does not go into RUN m I O bus cannot be initialized LED H8 red lights up The twelve LEDs can be programmed freely by the user in the RUN status For infor mation on programming see the Applicatio...

Page 67: ...reset is conducted for the b maXX safe PLC mod ule for the power supply module for the b maXX controller safe PLC and for the fur ther system components modules which are plugged in to the left of the b maXX safe PLC or to the right of the power supply DANGER Danger from mechanical action The machine line or parts of the machine or line can be started during the commis sioning of the b maXX safe P...

Page 68: ...number is displayed per second Initial zeros are automatically omitted The new display of the station number always starts with one second of blank display Furthermore the status of the decimal points is inverted with each number so that identical numbers following one another in sequence can be differentiated from one another Error status The display will go into E status if an error appears It i...

Page 69: ... X X X Control in RUN X X X Control in STOP X X X Error in the control has occurred X X X Control status OK X X X BLINKING Inserted CF card detected during start up or safety code entry is running X X X BLINKING Copy code entry is running X X X STEADY Copying process from card to control running LED goes out once the copying process is complete X X X STEADY Copying process from control to card LED...

Page 70: ...s b maXX safe PLC and that the correct address has been set on the power supply if it is being eval uated in your project Further information on how you can ensure this or how you can conduct the Send a boot project to the b maXX safe PLC can be found in the Application Handbook b maXX con troller PLC 11 9 Startup and operation options with inserted memory card 11 9 1 Safety related instructions o...

Page 71: ... time the safety control is started to check whether the safe devices configured in the project are actually present in reality Only then with the safety application program be permitted to start A suitable measure would be labelling the memory cards with unique numbers which can be allocated by using a cross reference table for example The cross reference table is only accessible to authorized pe...

Page 72: ...ory cards are explained in detail in ZData transfer from the card to the control on page 74 and in ZData transfer from the control to the card on page 75 in the scope of commissioning CATION Memory cards of the b maXX safe PLC Systems may only contain the data of a b maXX safe PLC system and may not be used simultaneously for systems of other applications or for storing data not related to the app...

Page 73: ...try if pause 10 seconds Abort of the entry if pause 10 seconds Code entry copy code 2 digit green LED H4 blinks Yes First trying No Correct code entered Correct code entered No No Yes Yes Safety PLC runs up to error state without a project standard PLC runs up to STOP state Copying the project from the CF card to the controller yellow LED H3 lights up Copying the project from the controller to the...

Page 74: ... blink and the safety PLC will wait for the release code 3 digit to be entered The release code is the last 3 digits of the project check sum of the safety project which is displayed in the project information in ProSafety or if a connection to the internet is present in the resource control to the safety PLC under Info Code entry 1 The H5 7 segment display on channel 2 of the PLC shows a blinking...

Page 75: ...ty PLC will have to be in STOP status and the standard PLC will have to be in STOP or ON status The transfer is started by a short push and entering the release code 3 digit as de scribed above 11 9 4 Data transfer from the control to the card Once the user has pushed the S1 button on the CF module and the S1 button on channel 2 of the PLC simultaneously and held them down for a long time 3 s LED ...

Page 76: ...CF module is not used for entering codes with safety applications The procedure will be aborted if an incorrect code has been entered or the pause during the entire process was too long It will have to be restarted by holding down the S1 button on channel 2 and the S1 button on the CF module for a long 3 s time If the correct code has been entered the project will be copied from the control to the...

Page 77: ...ng process meaning that the online communication will also be running NOTICE Once the project has been copied to the memory card during only the residual time of the control the procedure can take considerably longer than in running up or when the control is in STOP status If you want to copy the project to the memory card in RUN status care must be taken that sufficient reserves still remain betw...

Page 78: ...rization with ProSafety Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 78 of 118 11 10 11 10Programming configuration and parameterization with ProSafety See Application Handbook b maXX safe PLC ...

Page 79: ...ing the project documentation can be found in the programming handbook Depending on the complexity of the logic circuit of the respective project it is recommend ed to conduct the function tests in steps WARNING Danger during commissioning The control system may only be put into commission after being tested successfully by a technical expert Therefore m Conduct a complete function test In doing s...

Page 80: ... results n the logical allocation of all system components is correct n the allocation of all system components is complete In deviation from the I O terminals the logical allocation of drives is determined by in spection the display of an LED see documentation on the safe drive For this purpose the bit xx see documentation on the safe drive of the bit string see Figure xy in the documentation on ...

Page 81: ...wer supply for the b maXX controller safe PLC Instructions on the operation of the system components connected to the b maXX safe PLC can be found in the respective operation manuals and application handbooks of those system components DANGER It is not permitted to make any changes to the system configuration during the oper ation of the safety control Therefore m Before expanding the system and r...

Page 82: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 82 of 118 ...

Page 83: ...d statuses in particular requires special knowledge which the operator must have In the following we will inform you of the various malfunc tions and the resulting error messages The malfunctions can be caused by either me chanical or electrical problems 14 3 Error diagnosis In order to achieve the degree of diagnostic coverage described in the chapter ZSafety related parameters for 20 years of op...

Page 84: ...he left of the b maXX safe PLC such as the eth ernet module with CANopen master The reason for this can be m There is a defect or connection error in a module Does the error also occur when only the b maXX safe PLC and its power supply are being used The modules may only be assembled and disassembled when the power has been disconnected See the respective operation manual of the modules for assemb...

Page 85: ...g the end module direct to the power supply i e operate without an I O module you always get an error message Check the contacts between the b maXX safe PLC and power supply for bent pins Exchange the b maXX safe PLC or the power supply if necessary No Assemble the other modules and always an end module sequentially until you can detect the defective module Are multiple I O modules and one end mod...

Page 86: ... control will go into safe status in the event of serious errors Error messages of the safety PLC can be read out with ProSafety Error messages of the standard PLC can be read out with ProProg wt The safety control has a red LED to indicate errors Diagnostic messages which support the localization of errors can be displayed with diagnostic flags in the safety PLC and standard PLC 14 5 Safe status ...

Page 87: ...so it must be ensured that the alloca tion of the project data is correct by means of organizational measures For the handling of defective component groups see the chapter ZRepairs from page 91 onward CAUTION m There is a memory card available with contents which guarantee a 1 1 copy of the applicable system by means of complying with organizational measures m No further changes in the configurat...

Page 88: ...e status Saved stopped is indicated by an F 14 7 2 Error indication of the LEDs on channel 2 H4 red on The status of the control is not in order Either an error has been entered in the SafeOS error memory or there is a problem with cross communication CAUTION It is necessary to label defective components to indicate that they are defective It is absolutely necessary to prevent defective components...

Page 89: ...hnical data page 115 then the b maXX safe PLC is maintenance free If you detect or suspect a defect in the b maXX safe PLC module contact Baumüller Nürnberg GmbH CAUTION Take organizational measures to make sure that the interval for the repeat testing of all system components proof test interval see ZSafety related parameters for 10 years of operation page 27 is complied with ...

Page 90: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 90 of 118 ...

Page 91: ...safe PLC BMC M SAF 02 Document no 5 07020 04 16REPAIRS You cannot repair a defective b maXX safe PLC module Please contact Baumüller Nürn berg GmbH for a replacement CAUTION Defective components may only be repaired by the manufacturer ...

Page 92: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 92 of 118 ...

Page 93: ...urrent before beginning work on the electrical connections m Only disassemble the connections and remove the connection once you are com pletely certain that the component assembly is not under power WARNING Danger of injury due to uncontrollable behavior of the machine line The behavior of the machine line can change as a result of removing the component assembly with the power source connected T...

Page 94: ... packaging if possible m Suitable packaging for further system components for the b maXX safe PLC if appli cable use the original packaging if possible m A suitable tool to open the spring clamps of the electrical connects such as a screw driver with a 2mm wide blade m A suitable tool for pulling out the white handles on the bottom of the module such as a pair of needlenose pliers for electronic w...

Page 95: ...ety PLC as an ex ample BAUMULLER BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C D E F BAUMULLER S1 H1 H4 BAUMULLER PSB 02 S5 S4 S3 S2 0 1 2 3 4 5 7 6 89A B C D E F 0 1 2 3 4 5 7 6 89A B C D E F 0 0 1 1 2 2 3 3 4 4 5 5 7 7 6 6 8 8 9 9 A A B B C C D D E E F F H5 H8 PSB 01 0000 S_Nr 123456789 BAUMULLER H1 H4 H5 S1 SAF 02 S1 H1 H5 H9 H4 H8 H12 S2 0 1 2 3 4 5 7 6 89A B C ...

Page 96: ...mponents if applicable into the prepared packaging for each component in question 11 If you want to exchange the b maXX safe PLC now mount the new b maXX safe PLC see ZAssembly and installation from page 45 onward 12 Close the electrical cabinet 13 Document the disassembly or exchange of the b maXX safe PLC module Document the disassembly or exchange of the power supply for the b maXX control ler ...

Page 97: ...assign to conduct the disposal disassembly must have the knowledge and training required to carry out this work properly The personnel selected must under stand and apply the safety instructions on the b maXX System and its components 18 3 Disposal instructions Prerequisites m The b maXX safe PLC module has already been disassembled properly m All of the tools and equipment necessary for the disas...

Page 98: ... 18 4 18 4 Recycling collection center offices Make sure that the disposal is carried out in compliance with your company s disposal guidelines as well as those of the competent recycling collection centers and offices In the event of uncertainty contact the industrial inspectorate responsible for your company or the environmental agency ...

Page 99: ...of the PLC and or power supply LED Light emitting diode MTTFd Mean Time To Failure NOVRAM Non volatile RAM OPC OLE for Process Control OLE Object Linking and Embedding PFD Probability of Failure on Demand PFH Probability of Failure per Hour PLC Process loop control stored Pro gram Control SPS ProProg wt III Tool for programming the b maXX PLC BMC M PLC 01 2 or BMC M SAF 02 RAM Random Access Memory...

Page 100: ...Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 100 of 118 A ...

Page 101: ...on HMI interfaces operator control panels touchscreens etc to the RS485 interface Since the pin configuration of a RS485 interface is not standardized Baumüller cannot offer a finished cable A cable stranded in pairs with a recommended cross sectional area of 0 5 mm PVC out er jacket and overall shielding made of tinned copper meshwork will have to be used The overall shielding will have to be app...

Page 102: ...List of all accessory items Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 102 of 118 B 1 ...

Page 103: ...cific plant C 1 Planning checklist Seria l no Requirement Fulfilled Remarks Yes No 1 Planning 1 1 Has a risk assessment been carried out and have the required SIL and performance levels in accordance with DIN EN ISO 13849 1 or IEC 62061 been determined 1 2 Are power supplies according to PELV specifications being used exclusively 1 3 Is the line routing carried out in accordance with the applicabl...

Page 104: ... complied with 1 10 Has the maximum permissible reaction time of the safety functions been estab lished by means of a risk analysis 1 11 Is the maximum permissible reaction time reached Has computational evidence been pro vided 1 12 Is the system protected from mechanical overloading 1 13 Is the system protected from corrosive sub stances 1 14 Are the specified electrical values of the output term...

Page 105: ... according to their allocation 2 5 Are the connection terminals loaded with the specified clamping torque 2 6 Has it been ensured that the insulation of the lines is not causing any faulty contacts 2 7 Has the reliability of all terminal connections been tested through mechanical tensile loading 2 8 Has a visual inspection of the installed com ponents been conducted 2 9 Have the required installat...

Page 106: ...cipants belonging to different safety controls if the controls are connected to one another via gateways such as ether net 3 2 Is the station number of this safety control set correctly 3 3 Has the safety cycle time been established and set in the safety control 3 4 Has the maximum reaction time with the set cycle time been demonstrated with compu tational evidence 3 5 Has the project data been co...

Page 107: ...e modification retrofitting of the system compatible Do all of the checklist s require ments on the planning installation and com missioning validating continue to be fulfilled 4 2 Are the calculated reaction times still com plied with after the modification retrofitting Proof is required 4 3 Has the project data been copied onto a memory card 4 4 Has a complete function test been con ducted and d...

Page 108: ...Modification and retrofitting check list Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 108 of 118 C 4 ...

Page 109: ... maXX safe PLC module from Baumüller Nürnberg GmbH D 1 Connection values D 1 1 BMC M SAF 02 D 1 2 BMC M CFI 01 Processor ARM Clock frequency Channel 1 667 MHz Channel 2 400 MHz Power supply 5 V DC internal Power consumption typ 1800 mA Potential separation 720 V DC Processor Micro32 Clock frequency 40 MHz Power supply 5 V DC internal Power consumption typ 300 mA ...

Page 110: ...ified in the table above may not be exceeded at any time Dimensions W x H x T BMC M SAF 02 BMC M CFI 01 76 mm x 100 mm x 91 mm Width 84 mm assembled 19 mm x 100 mm x 91 mm Width 27 mm assembled Weight BMC M SAF 02 BMC M CFI 01 approx 320 g approx 100 g Vibration test 1 g 9 150 Hz sinusoidal in accordance with DIN EN 60068 2 6 Shock resistance 15 g on the basis of DI EN 60068 2 27 Assembly On 35 mm...

Page 111: ...ata 3 RxD receive data 4 Connected to pin 6 5 GND signal ground 6 Connected to pin 4 7 CTS clear to send 8 RTS request to send 9 Not allocated NOTICE The signal grounds of the RS232 and RS485 interfaces are connected to one anoth er Pin no Configuration 9 way sub D socket 1 TxD transmit data negative 2 VCC 5 V output for supply of external RS485 RS232 converter 3 GND signal ground RS232 RS485 4 GN...

Page 112: ...mory cards can be used as memory cards NOTICE The signal grounds of the RS232 and RS485 interfaces are connected to one anoth er CAUTION Danger from electrical short circuit An electrical short circuit can damage the device Therefore m The 5 V on pin 2 of the X2 sub D socket of the b maXX safe PLC module are only intended for the supply of external Baumüller RS485 RS232 converters and may not be b...

Page 113: ...rking symbolizes conformity to all the obligations incumbent on manufac turers for the product by virtue of the Community directives providing for its affixing b The CE marking affixed to industrial products symbolizes the fact that the natural or legal person having affixed or been responsible for the affixing of the said marking has verified that the product conforms to all the Community total h...

Page 114: ...the requirements of 2004 108 EC EMC Directive by satisfying the requirements of the harmonized standard EN 61131 2 To enable you to market your machine within the EU you must be in possession of the following m Conformity mark CE mark m Declaration s of Conformity regarding the directive s relevant to the machine E 3 Definition of the term Declaration of Conformity A Declaration of Conformity as d...

Page 115: ...rdance with the machinery di rective mentioned above Name TÜV Rheinland Industrie Service GmbH Address Am Grauen Stein 51105 Köln Germany Notified body number 0035 Registration number 01 205 5093 11 The safety instructions in the manual must be observed This product is designed for integration in a machine The commissioning is not allowed until the entire machine in which this product is integrate...

Page 116: ...Declaration of Conformity Operation Manual b maXX safe PLC BMC M SAF 02 Document no 5 07020 04 Baumüller Nürnberg GmbH 116 of 118 ...

Page 117: ...gnosis 83 Exchanging devices 87 F Firefighting 23 Front plate 39 Function test 79 G Generation of device 39 H HMI Interface Connection 31 I Installation plan 43 Installation space 47 Intended use 18 Interfaces 36 L Limitation of liability 11 Low Voltage Directive 113 M Machinery directive 114 Mean Time To Failure MTTFd 27 Mechanical properties 110 Memory card 38 112 Memory card module Properties 3...

Page 118: ...tichwortverzeichnis Standard PLC Properties 37 STOP 66 69 Storage 96 Switch button 67 Switch Button S2 69 Switch button S2 74 Switching on 69 System components 32 T Technical Data 109 Technology functions 32 Terms Definition 13 Testing the functioning 70 Type code Module 39 W Waranty conditions 12 Wiring plan 43 ...

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Page 120: ...by our permanent change management system Note that all the data numbers information that are quoted are current values at the time of printing This information is not legally binding for dimensioning calculation and costing Before using the information listed in these Operating Instructions as the basis for your own calculations and or applications make sure that you have the latest most current ...

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