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Operation Manual

Safety Module for b maXX 5000

BM5-O-SAF-002/3

Document no.: 5.11016.03

Baumüller Nürnberg GmbH

of 180

Inhaltsverzeichnis

18 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

19 Troubleshooting and Error Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

19.1

Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

19.2

Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 137

19.3

Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

19.4

Detecting errors in the periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

19.5

Operating states and error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

21 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

21.1

List of all accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

21.1.1

Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

21.1.2

Ferrite ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

22 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

23 Disassembly, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

23.1

Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

23.2

Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 152

23.3

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

23.4

Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

23.5

Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

24 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

24.1

Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

24.2

Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 155

24.3

Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

24.4

Recycling collection center/offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Appendix B - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

B.1

Planning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

B.2

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

B.3

Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

B.4

Modification and retrofitting check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Appendix C - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

C.1

Connection values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

C.2

Technical Data safe inputs, STO-Inputs and Daisy-Chain-Inputs . . . . . . . . . . . . . . . . 163

C.3

Operational conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

C.4

Pin assignment of Safety Module connector X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

C.5

Examples for connecting the Safety Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Appendix D - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Summary of Contents for BM5-O-SAF-002

Page 1: ...ation Manual Read the Operating Instructions before beginning Language English Translation Document No 5 11016 03 Part No 00440935 Date 19 11 2018 BM5 O SAF 002 3 Safety Module for b maXX 5000 E 5 11016 03 ...

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

Page 4: ...function SS1 62 10 5 Safe Stop 2 SS2 63 10 5 1 Error reaction with function specific SS1 time for the safety function SS2 and its follow ing function SOS 64 10 6 Safe Operating Stop SOS 65 10 6 1 Error reaction with function specific SS1 time for the safety function SOS 66 10 7 Safely Limited Speed SLS 68 10 7 1 Error reaction with a function specific SS1 time for the safety function SLS 69 10 8 S...

Page 5: ...y function 106 12 6 Status word S_StatusWord1 Display of activated safety function and of the last active parameter switchover 106 12 7 Status word S_StatusWord2 Reading of digital inputs and outputs for a quicker diagnosis 108 13 Parameterization and Configuration 111 13 1 Safe Module Address 111 13 2 Setting of the Safe Module Address 112 13 3 Standard Configuration 113 14 Planning of a safety o...

Page 6: ...he personnel conducting the work 152 23 3 Disassembly 152 23 4 Storage conditions 152 23 5 Recommissioning 153 24 Disposal 155 24 1 Safety regulations 155 24 2 Requirements on the personnel conducting the work 155 24 3 Disposal instructions 155 24 4 Recycling collection center offices 156 Appendix A Abbreviations 157 Appendix B Checklists 159 B 1 Planning checklist 159 B 2 Installation checklist 1...

Page 7: ... 8 type code extended Chapter 10 1 and chapter 10 2 para 2 deleted Chapter 10 3 1 figure and note new Chapter 10 4 para 2 new figure changed and note new Chapter 10 4 1 and chapter 10 4 2 new Chapter 10 5 Abs 2 new and figure changed Chapter 10 5 1 new Chapter 10 6 note 2 new and figure changed Chapter 10 6 1 new Chapter 7 figure changed Chapter 10 7 1 new Chapter 10 8 figure new Chapter 10 8 1 ne...

Page 8: ... Chapter 12 6 status word S_StatusWord1 bits 5 7 new and 2 notes after table new Chapter 19 5 operating states added encoder fail and text before error list inserted Chapter 19 5 error list extended row SS1 time general and error 31 77 78 109 113 and additional information at error 48 extended error no 6 192 194 196 Chapter C 2 5 reaction times extended ...

Page 9: ...s operation manual are prerequisites for the safe work Furthermore the local accident prevention legislation and general safety regulations applying to the Safety Module s field of application must also complied with Read the operation manual completely in particular the chapter on safety instructions before beginning any work on the Safety Module The operation manual is a component of the product...

Page 10: ...onal injury and property damage DANGER notifies of an imminent dangerous situation which will lead to death or serious injuries if not avoided WARNING notifies of a potentially dangerous situation which can lead to death or serious injuries if not avoided CAUTION notifies of a potentially dangerous situation which can lead to minor or slight injuries if not avoided NOTICE notifies of a potentially...

Page 11: ...ervoltage protection etc The person who conducted the assembly or installation shall be accountable for damages occurring during assembly or connection 2 4 Preliminary information NOTICE The following shall apply if the document you are reading is designated as preliminary information This version pertains to preliminary technical information which the user of the described Safety Modules and func...

Page 12: ...s from other manufacturers Components from other manufacturers are built into the Safety Module Hazard evaluations for these bought in parts have been conducted by the applicable manufacturers The conformity of the designs with the applicable European and national legislation has been declared by the respective component manufacturers 2 7 Replacement parts WARNING Improper or defective replacement...

Page 13: ...id if the Safety Modules are operated differently than described here 2 10 Customer service Our customer service is available for technical support Information on the competent contact person can be found at any time via telephone fax E mail or over the Internet 2 11 Terms used A list of the abbreviations used can be found in ZAppendix A Abbreviations from page 157 onward 2 12 Certification The Sa...

Page 14: ...e level e IEC 62061 Functional safety of safety related electric electronic and programmable electronic systems Fulfillment of increased stability requirements in accordance with EN 61326 3 1 Additional standards Area of application IEC 61800 3 Adjustable speed electrical power drive systems Part 3 EMC requirements IEC 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requi...

Page 15: ...f the safety functions or failure to comply with the instructions of this manual can lead to serious personal injury property damage or environmental harm for which Baumüller assumes no liability Baumüller safety components and systems are developed manufactured and tested in compliance with the applicable safety standards They may only be used under the specified environmental conditions and only...

Page 16: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 16 of 180 ...

Page 17: ... 4 1 Contents of the operation manual All persons assigned to work on or with the Safety Module must have read and understood that operation manual before beginning work with the Safety Module This also applies if the person concerned has already worked with such a Safety Module or a similar Safety Module or has been trained by the manufacturer 4 2 Alterations and rebuilding of the Safety Module I...

Page 18: ... the intended use can lead to dangerous situations Therefore m Only use the Safety Module as intended m Only use the Safety Module in combination with compatible controllers see ZCompatibility list on page 31 m Follow all specifications of this operation manual m Ensure that exclusively qualified personnel work on or with the Safety Module m Take care in project planning to see that the Safety Mod...

Page 19: ... The statements of the operation manual are to be followed completely and absolutely m The Safety Module may only be operated in technically faultless condition and must be safe for operation 4 5 Protective category When installed in the controller the Safety Module complies with the protective category IP20 4 6 Personnel training WARNING Risk of injury if operated by insufficiently qualified pers...

Page 20: ...orking is required in order to minimize hazards to the health m Always wear the respective protective equipment required for the respective task when working m Observe signs on personal safety in the work area Protective work clothes consists of close fitting workwear of low tear strength without loose sleeves or projecting parts Intended mainly to protect the wearer from moving machine parts Do n...

Page 21: ... Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 21 of 180 4 4 8 Special dangers The residual risks arising as a result of the hazard analysis will be specified in the following section Observe the safety instructions described here and the warning notices in the following chapters in order to reduce health hazards and avoid dangerous situations Electrical current Moving parts WARNIN...

Page 22: ...nd commissioning the system check if the contamination degree 2 is not exceeded do this also by optical inspections if it is necessary 4 9 1 Notice on power supply WARNING Risk of injury from electric current Only safety devices which have a safe disconnection to the 230 volt mains may be connected to the Safety Module The power supply unit for generating the 24 Volt supply must meet the requireme...

Page 23: ...Y STOP until the machine stops Additionally EMERCENCY OFF m Keep people out of the danger zone m Introduce first aid measures m Inform the supervisors at the site m Notify a doctor and or fire department m Clear access routes for rescue vehicles 4 12 Signs The following symbols and notification signs are found in the work area They relate to their immediate installation environment WARNING Injury ...

Page 24: ...Signs Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 24 of 180 4 12 ...

Page 25: ...ation of 20 years The following table lists the safety related parameters of the Safety Module for an operation of 20 years with an average environmental temperature of 70 C Safety related parameters of local I O terminals and decentralized components can be found in the applicable documentation The values in the following table relate exclusively to the Safety Module In the identification values ...

Page 26: ...or an environmental temperature of 70 C at the components Parameters in accordance with IEC 61508 Safety Module configuration PFH Probability of dangerous Failure per Hour Single axis minimum configuration PFH 1 29 10 9 h Single axis maximum configuration PFH 1 95 10 9 h Double axis minimum configuration PFH 2 10 10 9 h Double axis maximum configuration PFH 3 16 10 9 h Safety Module configuration ...

Page 27: ...uration Safe Failure Fraction fraction of failures which lead to a safe status Single axis minimum configuration SFF according to SIL 3 Single axis maximum configuration SFF according to SIL 3 Double axis minimum configuration SFF according to SIL 3 Double axis maximum configuration SFF according to SIL 3 Parameters in accordance with DIN EN ISO 13849 1 Safety Module configuration MTTFD Mean Time ...

Page 28: ...issioning the Safety Module The maintenance and cleaning of the fan must be made at least once a year Safety related parameters for an operation of 20 years Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 28 of 180 5 1 ...

Page 29: ...tective packaging immediately before assembly 6 2 Unpacking Upon receiving the still packaged module h Check to see if any shipping damages can be found If so h Immediately file a complaint to the supplier Confirm the complaint in writing and immediately contact the representative of Baumüller Nürnberg GmbH who is assigned to assist you CAUTION Danger due to electrostatic discharge The Safety Modu...

Page 30: ...ound or any items are missing from the delivery file a 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 th...

Page 31: ... are enabled either by a safety function or by a safety relevant error This puts the drive into the status STO Safe Torque Off refer to the description of the interface of the safe pulse inhibit in chapter ZSTO Inputs from page 94 Precondition at STO is a brake which can be connected optionally For this the brake supply voltage is led internal via the Safety Module and the controller to the connec...

Page 32: ...ive IGBT also in status STO may occur The angular movement thus traveled is dependent of the inductor s position and of the motor s pole pair number It can reach a maximum of 180 pole pair number DANGER Danger due to moving parts An immediate driver stage supply is caused by the input supply due to a connected safety element emergency stop device safety light grid A fail of the controller can caus...

Page 33: ...the controller Figure 2 Operating mode The encoder signals of the used rotary encoders from the controller s signal paths are decoupled and are provided for the parallel evaluation to the Safety Module for the motion detection of the input end The requirement for the rotary encoder is described in chapter ZRequirements for the use of rotary encoders for the safety related monitoring on page 34 If ...

Page 34: ... D 16 m Encoders must have the possibility of a safe connection between encoder cabinet and motor chassis according to EN61800 5 2 table D 16 m The safety relevant parameters must be common to the encoders m Category m MTTFD per channel Mean Time to Failure dangerous m DC average Diagnostic Coverage m PL Performance Level m PFH Probability of Failure per Hour m HFT Hardware fault tolerance m PFD P...

Page 35: ... is switched off and on again or the voltage supply of the drive is interrupted for a short time Figure 3 Encoder monitoring Diagnosis time of 12 h expired Fail safe Switch off voltage supply Instead of that in the module version Software extension refer to ZIdentification of the Safety Module Type Key from page 46 for the definition the Encoder Fail is reported after 12 hours which can be acknowl...

Page 36: ...e anymore The electrical angle PHI Electrical controller parameter P019 018 is read and evaluated by the SAF module in order to check the plausibility if the controller recognizes a standstill as well If the electrical angle changes and a change of the mechanical angle was recognized at the rotary encoder within 3 seconds then the SAF module changes in the safe status and reports an encoder error ...

Page 37: ...encoder based safety functions the diagnostic interval is exceeded because there is no movement the module changes into the safe status Encoder Fail Figure 5 Encoder monitoring of the SINCOS encoder with asynchronous motor Expiration diagnostic time during the encoder based safety function Encoder fail The Encoder Fail status can be exited by deactivating all of the safety functions of the module ...

Page 38: ...e monitoring of the encoder in the Software Extension is evaluated only if there is actually a safety function with the speed or the position information activated or is demanded However the diagnostic time is running Independently of this as long as no movement is detected or the automatic encoder monitoring is reset such as of the encoder type Resolver In case of the encoder monitoring of the SI...

Page 39: ...ried out in the group Parameter of the drive NOTE During the activated Parameter check ProSafePara parameter P207 002 On of axis 1 and P207 010 On for axis 2 the set SAF module parameters Motor Type Encoder Type and Encoder PPR count are automatically checked with the actually set values of the controller controller parameter P107 038 P106 001 and P137 001 during the set up of the SAF module In ex...

Page 40: ...rate a movement at the drive so that the module can reset the internal diagnostic time leading to the encoder fail m If position dependent safety functions were defined homing must be executed once more Optionally to the controller the message Encoder fail can be acknowledged by the S1 key of the SAF module The key must be pressed approximately 500 ms The green LED H2 lights up if the key is press...

Page 41: ...ute position is required for the safety functions SLP and SCA Therefore the safe position must be referenced with each new switch on Description of the Safety Module Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 41 of 180 7 7 6 The Structure of the Safety Module Figure 9 Safety Module SAF 002 ...

Page 42: ...r the display of the operating status the Safety Module has two LEDs on the front side LED H1 red LED H2 green m LED H1 red Display of errors or incompatibility to the controller m LED H2 green Display of an error free operation Figure 10 LEDs Safety Module In the following table the possible display combinations of the status LEDs and its meaning are listed LEDs H1 red H2 green Meaning Off Off No...

Page 43: ...cknowledge the message Encoder fail refer to ZAcknowledgment encoder fail status on page 40 Figure 11 Button S1 Safety Module Off Flashing 50 ms on 50 ms off The configuration file was not loaded Standard configuration active see ZStandard Configuration from page 113 Flashing Off Device error or unpermitted module change commissioning not possible see ZTroubleshooting and Error Correction from pag...

Page 44: ...y functions which confirm errors and reset the diagnostic time on the module back to 0 by a generated movement at the encoder again Then the encoder based safety function can be activated again Homing must be carried out again if the safety functions SLP or SCA are used because a safe absolute positioning is required m Saving the gray data set on the SAF module Saving is possible if the module is ...

Page 45: ...meterization of the error reaction and SS1 Stop Time on Zpage 60 The error types which support the SS1 error reaction were marked in the error list from Zpage 140 as SS1 General m Function specific SS1 times There are no configuration options for specific error procedures within the safety func tion such as the reaction behavior of a limit value noncompliance or the switching via FSoE to a data se...

Page 46: ...ser in ProSafePara project such as at the Open Loop without encoder if the STO function is used only In the earlier ProSafePara version 1 0 0 20 the parameter check automatically is switched off The printed type key shows the SAF 002 3 module type definition refer to chapter 7 8 The described software extension is coded directly in the type key and receives another part number than the Standard so...

Page 47: ...y Chain 001 Separated grounds for operation with SO4000 BM5 O SAF 002 xxx xxx 01 Software type of the Safety Module 000 Standard type 002 Software extension BM5 O SAF 002 xxx xxx 01 Safety level Identification for the compatibility between the module and the controller Description of the Safety Module Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 47 of 180 7...

Page 48: ...peration Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 48 of 180 7 9 These states can be read either in ProDrive by the parameter list or in the navigation tree by the page Diagnosis SAF Module ...

Page 49: ... reset command see ZResetting of the safety level by the controller on page 53 8 2 Compatibility list The Reset Module BM5 O SAF 100 can only be used in the combination with controllers of the type b maXX 5000 which where released by Baumüller Nürnberg GmbH 8 3 Operating mode of the Reset Module BM5 O SAF 100 In order to reset the module ID of the controller the slot A of the device must be equipp...

Page 50: ...ith its corresponding type code is found on the right side of the module see the example below Reset Modul BM5 O SAF 100 000 00 000 000 S310345678 00500204 123456678 O Figure 14 Example type code BM O SAF 100 Reset Module NOTICE m The exchange of the module must only be performed by authorized and qualified personnel m Prior to the exchange of the module ensure that the Safety Module and the contr...

Page 51: ...O SAF 002 3 Document no 5 11016 03 51 of 180 8 8 6 Mode of operation module replacement Deleting of safe parameter file and of protocol file of b maXX 5000 by reset module Command processing Switch on Error message error number 2423 Drive status Failure P108 006 15 Reset last module version P200 008 0 by b maXX 5000 Setting of module identification by reset module Module version P200 001 1 Figure ...

Page 52: ...Mode of operation module replacement Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 52 of 180 8 6 ...

Page 53: ... controller can be reset without a reset module with a controller command also 9 2 Operation of mode of the reset command The safety level of the controller is reset to the value zero by the command The parameter files remain in the controller The following mode of operation for resetting must be followed 1 Writing of the value 4096 into parameter 139 023 0 0 system command 2 On the 7 segment disp...

Page 54: ...Operation of mode of the reset command Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 54 of 180 9 2 ...

Page 55: ...5 O SAF 002 supports the safety functions shown in the following table Safety Functions Description see Chapter Safe Torque Off STO ZSafe Torque Off STO from page 57 Safe Stop 1 SS1 ZSafe Stop 1 SS1 from page 59 Safe Stop 2 SS2 ZSafe Stop 2 SS2 from page 63 Safe Operating Stop SOS ZSafe Operating Stop SOS from page 65 Safely Limited Speed SLS ZSafely Limited Speed SLS from page 68 Safe Direction S...

Page 56: ... Stop 1 SS1 from page 59 Safe Stop 2 SS2 ZSafe Stop 2 SS2 from page 63 Safe Operating Stop SOS ZSafe Operating Stop SOS from page 65 Safely Limited Speed SLS ZSafely Limited Speed SLS from page 68 Safe Direction SDI ZSafe Direction SDI from page 70 Safe Brake Control SBC ZSafe Brake Control SBC from page 72 Safely Limited Position SLP ZSafely Limited Position SLP from page 75 Safely Limited Increm...

Page 57: ...res that the controller s voltage supply is switched off safe in the driver stage and that the pulse inhibit is therefore activated The generation of a rotating field for motor control is prevented thereby This switch off function does not disconnect the energy supply from the motor Safe torque off STO m The control of the power output stage is safely interrupted at the safety function The motor s...

Page 58: ...ion STO is also active at error detection as well as at the fail of voltage supply This can cause safety limits in dependence of the application Therefore in this case additional actions must be made as e g installing an appropriate holding brake DANGER Danger due to moving parts An immediate driver stage supply is caused by the input supply due to a connected safety element emergency stop device ...

Page 59: ...e Stop 1 SS1 the drive is braked to an operating stop by the drive control After elapse of the parameterized delay time SS1 time the drive is set to the state STO Safe Torque Off Thereby the braking ramp is not monitored m The safety function corresponds to the stop category 1 in accordance with EN 60204 1 Figure 17 Safety function SS1 without monitoring the braking ramp NOTE If STO is activated t...

Page 60: ...ntly down a steep brake ramp Thereby in certain cases no higher level controller is required By the immediate active braking to the standstill of the drive it is avoided that the drive coasts to a stop In order to achieve an efficient solution the brake ramp of the controller must be set so that the drive comes to a standstill before the SS1 time in the SAF module is processed and the STO module i...

Page 61: ...urrent limit Figure 21 SS1 stop time P110 029 in controller in the Error reaction SS1 setting After the completion of the error reaction the drive changes to the fault state and inhibits the pulses It must be considered that the SS1 stop time in the controller in the example 3000 ms is lower than the set SS1 time on the SAF module in the example above 4500 ms After the parameterized delay time in ...

Page 62: ...time gap can result of this in which the pulses of the controller have been inhibited in the failure status already and the brake has not been applied yet safely Safe Stop 1 SS1 Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 62 of 180 10 4 10 4 2 Error reaction for the safety function SS1 The following individual error can occur at the...

Page 63: ...e Stop 2 SS2 the drive is braked to an operating stop by the drive control After the pre parameterized delay time SS2 time the drive is set to the state SOS Safe Operating Stop Thereby the braking ramp is not monitored m The safety function complies with the stop category 2 as per EN 60204 1 Figure 22 Safety function SS2 without monitoring of the brake ramp During noncompliance with the following ...

Page 64: ...uring the SS2 function and its following function SOS the following individual errors can occur m Switchover to a data set which was not set m There is no encoder connected m Encoder standstill time extended m Exceeding the tolerance window If a value in P212 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time ...

Page 65: ... stop is monitored via a parameterized tolerance window position window NOTE The ProSafePara parameter tolerance for standstill s_Zero_SOS was limited from ProSafePara V1 1 0 0 to a value of 1073676287 to avoid the exceeding of the number range by differential generation and in dependence of the encoder triggering which theoretically is possible prior limit value 4294967295 This new limit applies ...

Page 66: ...ue is existent which is able to display a danger in case of an error STO then the drive must be equipped with a mechanical brake Observe chapter ZSafety notes for the Function STO Safe Torque Off on page 58 10 6 1 Error reaction with function specific SS1 time for the safety function SOS With the software extension SAF 002 3 and the SAF module configuration software ProSafePara a function specific...

Page 67: ...arameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalization to the controller is connected if the error occurs Thereby the drive error 1066 SS1 stop forced by SAF module is initiated In the controller an accordant error reaction is parameterized refer to Parameterization...

Page 68: ...ely Limited Speed SLS NOTE The safety function SLS is supported by the Safety Modules SAF 002 and SAF 003 The safety function Safely Limited Speed SLS monitors the compliance of a limited drive speed after lapse of parameterizable delay time t Delta t Figure 26 Safety function SLS During noncompliance of SLS after a parameterizable SS1 time STO is initiated ...

Page 69: ... set which was not set m There is no encoder connected m Encoder standstill time extended m Exceeding the speed limits If a value was parameterized in P214 005 that is greater than zero then not immediately a STO is carried out if an individual error occurs but the parameterized time at first is processed for this function An automated signalization to the controller is initiated during the occurr...

Page 70: ...s supported by the Safety Modules SAF 002 and SAF 003 The safety function Safe Direction SDI assures drive movement of the principal drive mode in one defined rotational direction only If there is no compliance with the rotational direction then the function STO Safe Torque Off is triggered Figure 28 Safety function SDI During noncompliance of SDI after a parameterizable SS1 time STO is initiated ...

Page 71: ...ver to a data set which was not set m There is no encoder connected m Encoder standstill time extended m Incorrect rotational direction If a value in P213 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalization to the controller is connected if the error occu...

Page 72: ...he application of the brake This is executed by switching off the brake supply to the drive axis safely via the internal power output in the Safety Module At an input which has closed input contacts and which was configured for the safety function SBC the brake s application can be requested still by the controller s standard part inputs on 24V brake opened This request is not safety related Figur...

Page 73: ...utputs physical I O Bit 4 brake axis 1 status and bit 12 axis 2 brake refer to the following figure m By FSoE Bit 7 in the FSoE status word 2 refer to Zchapter 12 7 Coding of S_Sta tusWord for axis 1 and axis 2 In both cases a bit value shows 0 that a motor holding brake which is connected to the drive is independently of the status of the drive free of voltage and therefore activated by the SAF m...

Page 74: ...d Figure 32 P220 005 SS1 time for the safety function SBC This time always acts as a delay if an individual error occurs This is supposed to allow the drive to drive down a brake ramp before the STO is activated The following individual error can occur at the function SBC m Switchover to a data set which was not set m There is no encoder connected m Encoder standstill time extended m Homing was no...

Page 75: ...ition limit 1 and Position limit 2 Figure 33 Safety function SLP During noncompliance with SLP after a parameterizable SS1 time STO is initiated The Safety Module must know the safe absolute position in order to execute the safety function SLP Upon first request of the safety function homing must be executed The Safety Module requests an execution of homing at the controller via the communication ...

Page 76: ...he user The benefit is that the user can approach the home position anywhere on the route and can take over the default value Furthermore the user can carry out a fine adjustment of the accessed home position because it can happen that the zero point is moved by a few increments due to the different installations of the home switch regarding the mechanics By the setting of a low offset this deviat...

Page 77: ...ata set which was not set m There is no encoder connected m Encoder standstill time extended m Homing was not carried out m Exceeding the tolerance window If a value in P215 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalization to the controller is connecte...

Page 78: ...le which was configured with SLI causes the stop of the drive and going into the function SOS By pressing a button which is placed at an input of the Safety Module triggers a safely limited increment This triggering via the button is made edge controlled That means that the button must be pressed once per limited increment The operation of the button during execution of a limited increment is not ...

Page 79: ...tolerance window If a value in P216 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalization to the controller is connected if the error occurs Thereby the drive error 1066 SS1 stop forced by SAF module is initiated The related error reaction must be parameter...

Page 80: ...dered that the switch is debounced during the release of the next incremental jog This can be reached by the parameterization in ProSafePara of accordant high filter times at the safe input of the switch Figure 38 SLI digital inputs If it shall be avoided that the next incremental jog is released by a short pressing on the switch then the filter time must be increased accordantly to the demands of...

Page 81: ...ction SLA is supported by the Safety Module SAF 003 The safety function Safely Limited Acceleration SLA monitors the compliance of a limited and parameterized acceleration The function STO Safe Torque Off is triggered when exceeding the parameterized acceleration Figure 39 Safety function SLA During noncompliance with SLA after a parameterizable SS1 time STO is initiated ...

Page 82: ...al errors can occur m Switchover to a data set which was not set m There is no encoder connected m Encoder standstill time extended m Exceeding the acceleration If a value in P218 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalization to the controller is co...

Page 83: ...r SSM supplies a safety output signal as long as the speed does not leave a v 0 symmetric tolerance band If the value of the parameterized speed limit is exceeded in positive or negative direction with regard to a parameterizable hysteresis then the safe output signal is switched off Figure 41 Safety function SSM NOTE The safety function SSM operates the safe output which is assigned to the safety...

Page 84: ... is supposed to allow the drive to drive down a brake ramp before the STO is activated The following individual errors can occur at the function SSM m Switchover to a data set which was not set m There is no encoder connected m Encoder standstill time extended If a value in P221 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the...

Page 85: ...afe output signal if the position of the cam is in a defined range around an absolute position defined by Position limit 1 Position limit 2 Before that homing must be executed Figure 43 Safety function SCA With regard to the homing point P 207 019 for axis 1 and P 207 022 for axis 2 refer to explanations in SLP NOTE The safety function SCA operates the safe output which is assigned to the safety f...

Page 86: ...SCA the following individual errors can occur m Switchover to a data set which was not set m There is no encoder connected m Encoder standstill time extended m Homing was not carried out If a value in P222 005 is parameterized greater than zero STO is not immediately carried out if an individual error occurs but at first the parameterized time of this function is processed An automatic signalizati...

Page 87: ...encoder to the axis has a PPR count of 1024 For the above mentioned formula a deviation of 16 increments to the bottom and to the top of the limit value 65536 4 1024 16 must be taken into account With the setting of 1000 increments a switch off can be made by a noncompliance of a limit at 984 increments or alternatively after 1016 increments Example of a speed based function SLS The user sets maxi...

Page 88: ...Inc limit value noncompliance between 607 Inc and 1393 Inc Example SLS limit value 1000 Inc ms limit value noncompliance between 803 Inc ms and 1197 Inc ms NOTE Due to the arctan calculation at the resolver the deviations during the calculation of the standardized increments are very great compared to the SINCOS encoder This is why SINCOS encoders including a preferably large encoder PPR count are...

Page 89: ...s which is determined by the terminals GND group1 and GND group 2 The signal names of the terminals the meaning and the physical assignment in its standard configuration are listed in the tables in ZChapter 11 1 1 m Optional configuration Separate Grounds e g for operation with SO4000 For each input on two channels an own ground terminal is implemented in an optional configuration This configurati...

Page 90: ...gnal names and meaning Terminal no Assignment Signal name 1 24V2 24V group2 2 STO_IN_2A STO input A group2 3 CHAIN_IN_2A Daisy Chain input A group2 4 DIG1_IN_2A input 1 A group2 5 DIG2_IN_2A input 2 A group2 6 CHAIN_OUT_2A Daisy Chain output A group2 7 DIG3_IN_2A input 3 A group2 8 CLK_OUT_2A cycle output A group2 9 DIG_OUT_2A output A group2 10 DIG_OUT_1A output A group1 11 CLK_OUT_1A cycle outpu...

Page 91: ...IN_IN_2B Daisy Chain input B group2 22 DIG1_IN_2B input 1 B group2 23 DIG2_IN_2B input 2 B group2 24 CHAIN_OUT_2B Daisy Chain output B group2 25 DIG3_IN_2B input 3 B group2 26 CLK_OUT_2B cycle output B group2 27 DIG_OUT_2B output B group2 28 DIG_OUT_1B output B group1 29 CLK_OUT_1B cycle output B group1 30 DIG3_IN_1B input 3 B group1 31 CHAIN_OUT_1B Daisy Chain output B group1 32 DIG2_IN_1B input ...

Page 92: ... input 2 group1 14 DIG2_IN_1A input 2 A group1 15 DIG1_IN_1A input 1 A group1 16 GND_STO_IN_1 Ground STO input group1 17 STO_IN_1A STO input A group1 18 24V1 24V group1 19 GND24V2 GND group2 20 STO_IN_2B STO input B group2 21 GND_DIG1_IN_2 Ground input 1 group2 22 DIG1_IN_2B input 1 B group2 23 DIG2_IN_2B input 2 B group2 24 GND_DIG3_IN_2 Ground input 3 group2 25 DIG3_IN_2B input 3 B group2 26 CLK...

Page 93: ...of safety relevant controller signals as e g encoder signals A description of external interfaces are in chapter ZExternal Interfaces from page 93 Figure 46 Interfaces SAF 002 003 The different signal connection are described in the following 11 3 External Interfaces NOTE The physical inputs at the SAF module work on the closed current principle That means that a missing voltage at a safe input is...

Page 94: ...ction of external input sided short circuits between two inputs and for the detection of short circuits of the inputs against electrical power supplies external clock signals are supplied with current via the cycle outputs of the Safety Module when using electro mechanical safety switches e g emergency stop see chapter ZCycle Outputs from page 97 m Detection of internal errors of the parts and of ...

Page 95: ...osed ring structure existing of several drive axes can be made with the Daisy chain inputs and outputs The Daisy chain consists of two control cables which are wired as shown in ZFigure 47 on page 95 Daisy Chain Example Open Chain An open chain is shown in the following figure The safe inputs of the module axis 1 are configured in such a way that they enable the safety functions STO Safe Torque Of...

Page 96: ...ovides that the activated safety functions on the Safety Module are safely transmitted to the following modules The configuration of the Daisy chain output is made with the parameterization tools ProSafePara It specifies on which active safety function on the Safety Module the Daisy chain output is activated output is on 0 V potential With an OR function these different safety functions can be ass...

Page 97: ...Crossfault detection Short circuit detection A crossfault detection to other outputs or to the operating supply voltage potentials for the cables is assured by diagnostic functions and the construction of the hardware So that the crossfault detection does not generate wrong error messages the capacitive load of the safe input which is connected to the output may be 15 nF at maximum Technical Data ...

Page 98: ...ng tool ProSafePara a switch on delay and a switch off delay can be configured for the brakes The brakes are connected at the basic unit see Instruction handbook of the basic unit 5 09021 Both connecting cables of the brake must be routed through a ferrite ring This ferrite ring is available as accessory article no 00453308 NOTE The cables for brake control at the controller must be installed safe...

Page 99: ...STO missing pulse enable and supply voltage to the brake is interrupted Generally must be considered that a b maXX 5000 device of the type double axis contains one EtherCAT slave only but each SAF module can be operated with up to two FSoE drive slaves Therefore the FSoE master e g safePLC of Baumüller must be able to generate two FSoE telegrams which are separated from one another and can be send...

Page 100: ...is 1 and axis 2 is different see description in the following The following functions are implemented via the FSoE protocol m Connection of the FSoE slave axes at the FSoE master when starting FSoE communication m Selection and deselection of parameterized safety function of the SAF module m Request of status Fail Safe which identifies the safety functions which released the set error reaction m S...

Page 101: ...ber Example of a version of a valid version number 1 0 Major 1 Minor 0 The adjustment of the version number between master and slave is an organizational measure which is made by the user in order to assure that there are no incompatiblities between the versions of the configured application parameters which were made over ProSafePara and the SAF module The rule is as follows Evaluation Major Mino...

Page 102: ...Thereby is to be regarded that at the physical input the safe function with a low active input value 0 volt is activated the activation via FSoE however must be made by a logic 1 when the parameterized bit is set by the FSoE master A mixed operation with physical inputs at the SAF module and the FSoE inputs is accepted as well The safe function is activated if either the connected physical input i...

Page 103: ...5 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 activated S_ControlWord0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 STO Axis 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Yes SS1 Axis 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 No SS2 Axis 1 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 No SOS Axis 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 No SLS Axis 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 Yes WARNING The assignment of the control word must be adapted to the configur...

Page 104: ... the index 1 This assignment to the index 1 can be re configured to another index in ProSafePara At operation of the SAF module at a double axis the control word S_ControlWord1 is available at each axis If a safety function is activated the axis moves into the safe state The controller generates an error message 1013 Switch off by safety functions The activation of a safety function is displayed t...

Page 105: ... 1 0 Bit 0 0 0 0 1 STO 0 0 0 1 0 SS1 0 0 0 1 1 SS2 0 0 1 0 0 SOS 0 0 1 0 1 SLS 0 0 1 1 0 SDI 0 0 1 1 1 SBC 0 1 0 0 0 SLP 0 1 0 0 1 SLI 0 1 0 1 0 SLA 0 1 0 1 1 SSM 0 1 1 0 0 SCA 0 1 1 0 1 SLT 0 0 1 Data set 1 0 1 0 Data set 2 0 1 1 Data set 3 1 0 0 Data set 4 1 0 1 Data set 5 1 1 0 Data set 6 1 1 1 Data set 7 0 Acknowledge bit to reset an activated safety function rising edge 0 1 0 0 0 0 0 0 0 rese...

Page 106: ... 0 0 0 0 0 1 0 STO 1 Yes SLS 1 Yes 12 6 Status word S_StatusWord1 Display of activated safety function and of the last active parameter switchover The status and error messages are displayed in the S_StatusWord1 Which kind of active safety function was activated due to an error reaction and was set to status Fail Safe bit 0 4 is mainly related to this In order to check the parameter switchover whi...

Page 107: ...it violation 0 1 0 Triggering caused by an incorrect parameter set 0 1 1 Triggering caused by a missing absolute position 1 0 0 Triggering caused by a missing rotary encoder 1 0 1 Triggering caused by time out of the rotary encoder 1 1 0 0 0 0 0 0 No FSoE connection X X X X X X X X Specification for S_ControlWord1 Bit 0 7 a NOTE At the standard version of STO bit 0 is not set as there is neither a...

Page 108: ...axis 1 and on axis 2 However if only one axis is configured in a single or double axis there is no FSoE telegram generated for axis 2 and no FSoE slave response of axis two takes place The evaluation of S_StatusWord2 of axis 2 in the FSoE master is omitted Therefore all relevant digital inputs were completely mapped into S_StatusWord2 of axis 1 The status word for axis 1 is structured as shown in ...

Page 109: ...oup axis 2 Bit 1 DIG1_IN_2 4 22 Input 1 group axis 2 Bit 2 DIG2_IN_2 5 23 Input 2 group axis 2 Bit 3 DIG3_IN_2 7 25 Input 3 group axis 2 Bit 4 CHAIN_IN_2 3 21 Daisy Chain input group axis 2 Bit 5 DIG_OUT_2A 9 Output group axis 2 A Bit 6 DIG_OUT_2B 27 Output group axis 2 B Bit 7 Brake axis 2 Internal output axis 2 to the controller Bit 8 CHAIN_OUT_2 6 24 Daisy Chain output axis 2 Bit 9 Bit 15 reser...

Page 110: ... word S_StatusWord2 Reading of digital inputs and outputs for a quicker diagnosis Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 110 of 180 12 7 ...

Page 111: ...ameterization of safety functions and questions concerning validation of the parameter container which was generated with ProSafePara NOTE If the operator configures one axis in ProSafePara only axis 1 then axis 2 remains in STO no pulse inhibit supply voltage to the brake is interrupted 13 1 Safe Module Address The Safety Module is provided with a safe module address slave address which serves as...

Page 112: ... to set the slave address The address range from 1 to 65534 is available for the user The two slave addresses 0 FSoE master is fixed and 65535 provided as a error address is ignored referring to FSoE addressing are reserved and may not be set Therefore the address below ZFigure 50 is the following 20 21 23 24 28 29 211 212 1 2 8 16 256 512 2048 4096 6939 m Parity even odd In order to detect an inc...

Page 113: ...eleted then the basic behavior of the Safety Module is determined via the two binary switches STO SS1 and the STO inputs after it was started As the selected STO SS1 setting is valid for the total module either STO or SS1 can be operated A mixed operation where STO is executed on one axis and SS1 is executed on the other axis is not implemented in the standard configuration The binary switch STO S...

Page 114: ... on the input 3 of the respective group DIG3_IN_1 for axis 1 and DIG3_IN_2 for axis 2 Now STO inputs which are linked with safe switches can be connected to 24V directly A cross connection identification is not possible in this case Safety category 3 is valid In order to recognize if the configuration data is on the Safety Module or if the standard configuration is active two different flashing se...

Page 115: ...ds in avoiding failures Failures in safety oriented machines can lead to permanent injuries and death CAUTION The Planning checklist reproduced in the appendix must be used in the planning phase 14 1 Risk assessment The risk assessment establishes which 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 just...

Page 116: ...hould be conducted according to the procedure described in the following Figure 51 Risk assessment procedure in accordance with DIN EN ISO 12100 1 and EN ISO 14121 Delineation of the system Determination of the limits 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...

Page 117: ...le standards and guidelines on laying electrical lines must be observed when developing the wiring plan 14 3 Course of the planning phase The system is planned according to the requirements of the installation or the machine The components which are available for the automation of the available components are described in the Automation Catalog of the company Baumüller Nürnberg GmbH Here informati...

Page 118: ...Course of the planning phase Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 118 of 180 14 3 ...

Page 119: ...nspection and check all system components for visible damage m Check the system for wiring errors m Check the tightening torque and make sure that the electrical connection is not interrupted by insulation material m Check the tensile load capacity of the electrical terminal and screw connections m Make sure that the installation and the cable routing are carried out in accordance with applicable ...

Page 120: ... page 19 Personnel training 15 3 Assembly instructions The assembly of the controller is described in the operation manual for the controller DANGER Perilous danger from electrical current The device and surrounding area in the electrical cabinet can carry perilous voltages Therefore m The described danger and warning notes must be observed see chapter Z4 8 on page 21 The following tools are requi...

Page 121: ...Assembly and installation Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 121 of 180 15 Figure 52 Assembly of Safety Module ...

Page 122: ...nment for the type with Daisy Chain and for the type with Grounds is in Appendix ZC 4 Pin assignment of Safety Module connector X1 from page 167 15 4 1 Requirements for the electrical connection CAUTION Danger due to voltage The module can be damaged or destroyed if the requirements for the electrical connection of the module are not met Therefore m Make sure that the connection values specified i...

Page 123: ...ust be selected in accordance with the EN 60204 1 standard The Safety Module is equipped with plugged connectors at delivery 2 pieces with 18 poles respectively part number 00351525 per connector for the connection of the conductors These connectors must be plugged always in operation even if a conductor is not connected Connectable conductors must observe to the following characteristics Terminal...

Page 124: ...Installation Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 124 of 180 15 4 ...

Page 125: ...for an error free operation Before beginning the commissioning procedure make sure that the following prerequisites have been fulfilled 1 The Safety Module is installed correctly 2 Safety Module is connected to the safety component e g safe sensors 3 No individuals or parts are in the danger zone 4 The controller is ready for use NOTICE The commissioning of the Safety Module is permitted only afte...

Page 126: ... that the system is commissioned exclusively by qualified personnel m Make sure that there are no people in the danger zone during the initial commissioning Always anticipate that a machine system or safety device might react differently to what is inspected m If changes or expansions are conducted during the commissioning procedure the effects on system reaction must be checked To do this it is n...

Page 127: ... data by the Safety Module The Safety Module contains a micro controller with communication interface If the controller is switched on the Safety Module initiates a request for the controller ID and the parameter data to the controller 2 Checking of data sets of controller and the Safety Module The saved data sets on the controller and on the Safety Module are compared m Data sets of the Safety Mo...

Page 128: ...00 P200 008 0 0 P200 001 0 0 YES upgrade even NO downgrade Setting last module version P200 008 4 5 by b maXX 5000 Error message controller error number 2420 Command processing Drive status Failure P108 006 15 Erro error number 2419 r message controller Command processing Drive status Failure P108 006 15 Trouble shooting by safety module and by b maXX 5000 see block C Replacement of the module Ope...

Page 129: ...ory RAM Functional parameters in b maXX 5000 available NO YES Functional parameters in safety module available YES NO Data backup of b maXX 5000 to safety module Block A Automatic loading of safety module P105 010 1 Commissioning and replacement of the module Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 129 of 180 16 Figure 55 Process of the module change p...

Page 130: ... whether safe parameter in b maXX 5000 available Await confirmation by button at safety module Red LED is on at safety module Fehlermeldung Regler Fehlernummer 2411 YES Checking by safety module whether valid and safe parameters in b maXX 5000 available NO YES Take over the safe default parameter set into the object dictionary by safety module Read in the safe parameters into the object dictionary...

Page 131: ...O SAF 002 3 Document no 5 11016 03 131 of 180 16 Figure 57 Process of the module change procedure block C Error number Short description 2411 No valid safety parameter file on SAF module 2419 Module change from SAF 003 to SAF 002 2420 No valid controller for SAF module 2422 No FSoE communication active at SAF 002 or SAF 003 2423 Pulse inhibit because of SAF 100 NOTE m If the data sets on the Safet...

Page 132: ...necessary to prevent defective components from being reused by taking measures in the scope of quality management on the user s side see the chapter ZRepair from page 149 onward NOTE If the controller was equipped with a module of a higher safety level previously SAF 002 and another module with a lower safety level shall be plugged e g SAF 001 the parameter storage of the controller must be reset ...

Page 133: ...hecklist from page 162 onward Conduct the validation of the system in accordance with this checklist and document the procedure accordingly m Make sure that operating personnel has been instructed in the handling of the Safety Module 17 1 Function test The function test is a major part of the validation of the entire system The function test is used to determine the trouble free allocation of the ...

Page 134: ... 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 134 of 180 17 1 To conduct the function tests trigger all safety functions sequentially and document the system s reaction Check whether the reaction corresponds with the expected behavior ...

Page 135: ...sponding operation manuals and application manuals for these components DANGER It is not permitted to make any changes to the system configuration during the operation of the Safety Module Therefore m Before expanding the system and removing individual system components and making changes in the wiring the Safety Module must as a rule be disconnected from the power source and put into safe conditi...

Page 136: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 136 of 180 ...

Page 137: ...dge which the operator must have 19 3 Error diagnosis Fail safe principle The Safety Module is based on the fail safe principle This means that each error automatically causes the module to switch into the safe status STO Safe Torque Off However external errors which are detected cause a safe status STO These errors can be caused by interferences of the FSoE communication or from the diagnostic po...

Page 138: ...page 93 m Electronic sensors must have an own error detection regarding short circuits on the output CAUTION An elimination of errors for short circuits on line must be made for safe outputs which are used separately in order to safely switch off an actuator Measures must be taken in accordance with EN ISO 13849 2 19 5 Operating states and error messages Description of operating states in paramete...

Page 139: ...alues 10 Waiting for FSoE connection 11 Waiting for GDP to complete transmission 12 Waiting for the end of SS1 time for the safety function 13 Parameter check Comparison of Motor type Encoder type Encoder PPR count of the drive and SAF module 3 Parameteri zation Bit 0 Saving the FU file on FU Bit 1 Saving of the parameter container on FU Bit 2 Deleting the FU file on FU Bit 3 Deleting the paramete...

Page 140: ...t 1 STO due to limit exceeded at axis 2 8 Encoder failure At the asynchronous motor no movement was detected the last 12 hours at the encoder occurs at SAF modules with software extension only This encoder fail status can be acknowledged by the user refer to the chapter ZAcknowledgment encoder fail status on page 40 Error number Description SS1time general 0 No error 1 Nullpointer access no 2 Acce...

Page 141: ...ready active 42 Error at online test yes 48 No data exchange at FSE communication 49 No new FSoE data from the master 56 Incorrect identification for GDP real time telegram yes 57 Incorrect command for GDP real time telegram yes 58 Incorrect telegram length for GDP real time telegram yes 59 Incorrect list parameter for GDP real time telegram yes 60 Incorrect checksum for GDP real time telegram yes...

Page 142: ...s 1 yes 103 Differences in the detected analog cosine values for axis 1 yes 104 Differences in the detected analog sine values for axis 2 yes 105 Differences in the detected analog cosine values for axis 2 yes 106 Error when checking the DIP switch yes 107 Test manager is activated already 108 Error at the hardware test yes 109 No movement detected at the encoder for 12 hours occurs at SAF modules...

Page 143: ...s 1 17 Inputs with clock control CPU 1 axis 1 18 Enable output High Side CPU 1 axis 2 A 19 Enable output High Side CPU 1 axis 2 B 20 Output 1 and output 2 CPU 1 axis 2 21 Output brake CPU 1 axis 2 set 22 Output brake CPU 1 axis 2 read 23 Output Daisy Chain CPU 1 axis 2 24 Inputs with clock control CPU 1 axis 2 25 DIP switch check 1 26 DIP switch check 2 65 STO input 1 CPU 2 axis 1 66 Input 2 CPU 2...

Page 144: ...g overflow 6 Invalid FSoE address requested by FSoE master 7 Invalid process data 128 Invalid FSoE parameter 129 Invalid user parameter 130 Invalid command sequence 192 Invalid FSoE address 65535 at DIP switch 193 Invalid session ID 0 received 194 CRC error 196 No new data from FSoE master FailSafe 83 Enable output Low Side CPU 2 axis 2 A 84 Enable output Low Side CPU 2 axis 2 B 85 Output 1 CPU 2 ...

Page 145: ...ward then the Safety Module is maintenance free A defective device cannot be repaired see the accordant notes in ZRepair on page 149 CAUTION The Safety Module does not require a proof test within its service life of 20 years After this time it must be put out of operation and must be disposed of properly It is forbidden to perform a proof test see ZSafety related parameters for an operation of 20 ...

Page 146: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 146 of 180 ...

Page 147: ...000 If you have any queries about accessories or suggestions for improvements Baumüller s Product Management will be pleased to hear from you 21 1 List of all accessories 21 1 1 Supplement Type Article number Supplement group 1 00443825 Supplement group 2 00443826 See examples for connecting the Safety Modules ZC 5 5 BM5 O SAF 00x 001 000 separate grounds with SO4000 on page 173 21 1 2 Ferrite rin...

Page 148: ...List of all accessories Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 148 of 180 21 1 ...

Page 149: ...Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 22REPAIR You cannot repair a defective Safety Module Please contact Baumüller Nürnberg GmbH for a replacement NOTICE Defective components must be repaired by the manufacturer ...

Page 150: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 150 of 180 ...

Page 151: ...onent assembly can be destroyed by electricity if it is removed when the power is turned on Therefore m Make sure that the power to all electrical connections is shut off and secured to prevent from being turned back on m Using suitable measuring equipment check to make sure that none of the connections are carrying live current before beginning work on the electrical connections m Only disassembl...

Page 152: ... of 180 23 2 23 2 Requirements on the personnel conducting the work The personnel who is assigned to carry out the disassembly must have the knowledge and training which is necessary to perform this work properly The personnel must be able to understand and use the safety instructions attached to the device and its components as well as the connections 23 3 Disassembly The personnel carrying out t...

Page 153: ...M5 O SAF 002 3 Document no 5 11016 03 153 of 180 23 23 5 Recommissioning If you want to put the Safety Module back into operation observe the specifications under Storage conditions Then conduct the ZCommissioning and replacement of the module from page 125 onward again ...

Page 154: ...Recommissioning Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 154 of 180 23 5 ...

Page 155: ... assign to carry out the disposal disassembly must have the knowledge and training necessary to perform this work properly The personnel must be able to understand and use the safety instructions attached to the controller and its components 24 3 Disposal instructions Prerequisites Safety Module has already been disassembled properly All devices which are necessary for the disassembly are applicab...

Page 156: ...of 180 24 4 24 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 who is responsible for your company or the environmental agency ...

Page 157: ... for Stan dardization LED Light emitting diode MTTFd Mean Time To Failure dangerous PFD Probability of dangerous Failure on Demand PFH Probability of dangerous Failure per Hour SAF Safety module SCA Safe Cam SBC Safe Brake Control SDI Safe Direction SFF Safe Failure Fraction SIL Safety integrity level SLA Safely Limited Acceleration SLI Safely Limited Increment SLP Safely Limited Position SLS Safe...

Page 158: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 158 of 180 A ...

Page 159: ...1 Planning checklist Serial No Requirement Fulfilled Remarks Yes No 1 Planning 1 1 Was a risk assessment carried out and were the required SIL and performance levels in accordance with DIN EN ISO 13849 1 or IEC 62061 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 applicable standards and guideline...

Page 160: ...h If required minimize contamination level by installation or encapsulation Installation in IP54 according to EN 61800 5 2 D 2 and EN ISO 13849 2 D 5 is required 1 10 Has the maximum permissible reaction time of the safety functions been established by means of a risk analysis Reaction times of the safety module see ZC 2 5 Technical data reaction times on page 165 1 11 Is the maximum permissible r...

Page 161: ...ction plugs labeled 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 Is it ensured that the insulation of the cables is not damaged 2 7 Has the reliability of all terminal connections been tested through mechanical tensile loading 2 8 Has a visual insp...

Page 162: ...ders used exclusively which have been certified and or released by Baumüller Date Name Signature B 4 Modification and retrofitting check list Serial no Requirement Fulfilled Remarks Yes No 4 Modification and retrofitting 4 1 Is the modification retrofitting of the system compatible Are all requirements which are listed in the check lists on planning installation and commissioning validation of thi...

Page 163: ...ange is UB 24V 15 20 Potential separation Separated potentials for group 1 group 2 Connection cables at connector X1 Safety Module 30 m C 2 Technical Data safe inputs STO Inputs and Daisy Chain Inputs Input sided switch thresholds for voltage and current Voltage Current Switching Threshold U high max 30 V U high min 11 V U low max 5 V U low min 3 V I high max 15 mA I high min 2 mA I low max 15 mA ...

Page 164: ...Rated output current 500 mA Required minimum current 50 mA Proof voltage 60 V Output type protected output according to EN 61131 2 Test pulse length 800 µs always active C 2 3 Technical data cycle outputs Rated output voltage 24 V Rated output current 50 mA Output type protected output according to EN 61131 2 Test pulse length 800 µs active if at least one input was parameterized as Sensor type pa...

Page 165: ... in the controller and the power unit of the drive of 15 1 ms must be regarded that can occur between the SAF module and the IGBT level Therefore the total reaction time of the event such as limit violation due to accelerated safety function until to the switch off of the IGBT level of the drive is 10 ms 15 1 ms 25 1 ms at the maximum The maximum reaction time of the safety module to STO Safe Torq...

Page 166: ...tion height Up to 2000 m above sea level WARNING The operating conditions specified in the table above may not be exceeded at any time C 3 2 Mechanical properties Dimensions W x H x D 24 mm x 89 mm x 136 mm Weight ca 122 g Assembly In frequency controller of the type b maXX 5000 see chapter ZCompatibility list on page 31 Installation position Vertical parallel to the vertically installed frequency...

Page 167: ...11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 24V2 19 GND24V2 2 STO_IN_2A 20 STO_IN_2B 3 CHAIN_IN_2A 21 CHAIN_IN_2B 4 DIG1_IN_2A 22 DIG1_IN_2B 5 DIG2_IN_2A 23 DIG2_IN_2B 6 CHAIN_OUT_2A 24 CHAIN_OUT_2B 7 DIG3_IN_2A 25 DIG3_IN_2B 8 CLK_OUT_2A 26 CLK_OUT_2B 9 DIG_OUT_2A 27 DIG_OUT_2B 10 DIG_OUT_1A 28 DIG_OUT_1B 11 CLK_OUT_1A 29 CLK_OUT_1B 12 DIG3_IN_1A 30 DIG3_IN_1B ...

Page 168: ... 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 24V2 19 GND24V2 2 STO_IN_2A 20 STO_IN_2B 3 GND_STO_IN_2 21 GND_DIG1_IN_2 4 DIG1_IN_2A 22 DIG1_IN_2B 5 DIG2_IN_2A 23 DIG2_IN_2B 6 GND_DIG2_IN_2 24 GND_DIG3_IN_2 7 DIG3_IN_2A 25 DIG3_IN_2B 8 CLK_OUT_2A 26 CLK_OUT_2B 9 DIG_OUT_2A 27 DIG_OUT_2B 10 DIG_OUT_1A 28 DIG_OUT_1B 11 CLK_OUT_1A 29 CLK_OUT_1B 12 DIG3_I...

Page 169: ...DIG_OUT_2A 24V2 24V DC 0V GND24V2 DIG1_IN_1B DIG3_IN_1B CLK_OUT_1B DIG_OUT_1B DIG1_IN_2B DIG3_IN_2B CLK_OUT_2B DIG_OUT_2B DIG2_IN_1A STO_IN_2A DIG2_IN_2A 24V1 GND24V1 STO_IN_1B DIG2_IN_1B STO_IN_2B DIG2_IN_2B CHAIN_IN_1A CHAIN_OUT_1A CHAIN_IN_2A CHAIN_OUT_2A CHAIN_IN_1B CHAIN_OUT_1B CHAIN_IN_2B CHAIN_OUT_2B BM5 O SAF 00x 000 yyy x 2 3 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5...

Page 170: ...DIG2_IN_1A STO_IN_2A DIG2_IN_2A 24V1 n OSSD1 OSSD2 GND CHAIN_IN_1A CHAIN_OUT_1A CHAIN_IN_2A CHAIN_OUT_2A GND24V2 DIG1_IN_1B DIG3_IN_1B CLK_OUT_1B DIG_OUT_1B DIG1_IN_2B DIG3_IN_2B CLK_OUT_2B DIG_OUT_2B GND24V1 STO_IN_1B DIG2_IN_1B STO_IN_2B DIG2_IN_2B CHAIN_IN_1B CHAIN_OUT_1B CHAIN_IN_2B CHAIN_OUT_2B BM5 O SAF 00x 000 yyy x 2 3 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5 6 7 8 9...

Page 171: ...ND24V2 DIG1_IN_1B DIG3_IN_1B CLK_OUT_1B DIG_OUT_1B DIG1_IN_2B DIG3_IN_2B CLK_OUT_2B DIG_OUT_2B DIG2_IN_1A STO_IN_2A DIG2_IN_2A 24V1 GND24V1 STO_IN_1B DIG2_IN_1B STO_IN_2B DIG2_IN_2B BM5 O SAF 00x 001 yyy x 2 3 GND_STO_IN_2 GND_STO_IN_1 GND_DIG2_IN_2 GND_DIG1_IN_2 GND_DIG1_IN_1 GND_DIG3_IN_2 GND_DIG3_IN_1 GND_DIG2_IN_1 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5 6 7 8 9 10 11 12...

Page 172: ...IN_1A STO_IN_2A DIG2_IN_2A 24V1 n OSSD1 OSSD2 GND GND24V2 DIG1_IN_1B DIG3_IN_1B CLK_OUT_1B DIG_OUT_1B DIG1_IN_2B DIG3_IN_2B CLK_OUT_2B DIG_OUT_2B GND24V1 STO_IN_1B DIG2_IN_1B STO_IN_2B DIG2_IN_2B BM5 O SAF 00x 001 yyy x 2 3 GND_STO_IN_2 GND_STO_IN_1 GND_DIG2_IN_2 GND_DIG1_IN_2 GND_DIG1_IN_1 GND_DIG3_IN_2 GND_DIG3_IN_1 GND_DIG2_IN_1 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5 6 ...

Page 173: ...B GND_STO_IN_2 GND_STO_IN_1 GND_DIG2_IN_2 GND_DIG1_IN_2 GND_DIG1_IN_1 GND_DIG3_IN_2 GND_DIG3_IN_1 GND_DIG2_IN_1 DIG1_IN_A DIG1_IN_A DIG3_IN_A DIG3_IN_A CLK_OUT_A CLK_OUT_A DIG_OUT_A DIG_OUT_A 24V 24V DIG_OUT_B DIG_OUT_B STO_IN_A STO_IN_A DIG2_IN_A DIG2_IN_A GND_STO GND_STO GND_DIG2 GND_DIG2 GND24V GND24V DIG1_IN_B DIG1_IN_B DIG3_IN_B DIG3_IN_B CLK_OUT_B CLK_OUT_B STO_IN_B STO_IN_B DIG2_IN_B DIG2_I...

Page 174: ...IG1_IN_xA DIG3_IN_xA CLK_OUT_xA DIG_OUT_xA 24Vx GND24Vx DIG1_IN_xB DIG3_IN_xB CLK_OUT_xB DIG_OUT_xB x 1 2 STO_IN_xA DIG2_IN_xA STO_IN_xB DIG2_IN_xB GND_STO_IN_x GND_DIG2_IN_x GND_DIG1_IN_x GND_DIG3_IN_x pink green brown white red gray purple blue yellow black yellow brown white green red blue gray pink gray brown white yellow white gray brown green Figure 63 Pin assignment adapter for safety I O t...

Page 175: ...175 of 180 Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 APPENDIX D DECLARATION OF CONFORMITY ...

Page 176: ...t put into operation until the machinery into with it is incorporated has been declared to be in conformity with the Machinery Directive 2006 42 EC Nuremberg 09 13 2018 Location Date Subject to change of this declaration of EC conformity without notice Actual valid edition on request Standard Title IEC 62061 2015 Corr 1 2015 Safety of machinery Functional safety of safety related electrical electr...

Page 177: ...igned and manufactured in accordance with the EMC Directive 2014 30 EU Applied harmonised standards Attention should be paid to the safety instructions in the manual Nuremberg 09 13 2018 Location Date Subject to change of this declaration of EC conformity without notice Actual valid edition on request Standard Title IEC 61800 3 2017 Adjustable speed electrical power drive systems Part 3 EMC requir...

Page 178: ...Operation Manual Safety Module for b maXX 5000 BM5 O SAF 002 3 Document no 5 11016 03 Baumüller Nürnberg GmbH 178 of 180 ...

Page 179: ...TFd 27 Mechanical properties 166 O Operating personnel 19 Outputs Cycle Outputs 97 Power Outputs 98 P Pin assignment X1 167 Planning phase 117 Power Outputs 98 Probability of dangerous Failure on Demand PFD 26 Probability of dangerous Failure per Hour PFH 26 Protective category 19 Protective equipment 20 Q Qualified personnel 19 R Risk assessment 115 S Safe Cam SCA 85 Safe Direction SD 70 Safe Dir...

Page 180: ...zeichnis Safely Limited Position SLP 75 Safely Limited Speed SLS 68 Safety instructions 17 SafetyModule SAF 002 003 Exchange 127 Safety related parameters 25 Standards 14 STO inputs 94 Storage 152 T Technical data 163 Terms Definition 13 Type Key 46 Type plate 46 W Warning notices general 10 Warranty and liability 13 Wiring plan 117 ...

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Page 182: ...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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