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HB-37500-810-11-16F-EN SCU Installation Manual - Master and Slaves - SARC

Page 10 of 303

Status: 09.06.2022

Man

1.2.

Table of illustrations

Fig. 1: rating plated SCU-2-EC/NM ............................................................................ 28

Fig. 2:Network EtherCAT ......................................................................................... 32

Fig. 3:example FSoE Netzwerk FSoE ......................................................................... 33

Fig. 4: strucutre of SCU-2-EC/NM ............................................................................ 35

Fig 5: structure of SCU-1-EC ................................................................................... 35

Fig. 6: structure of SDU-11-PXV ............................................................................... 36

Fig. 7: structure of SDU-22A .................................................................................... 37

Fig. 8: structure SIO-2 ............................................................................................ 38

Fig. 9: structure of SSB-6-x* ................................................................................... 39

Fig. 10: mounting of the top-hat rail ......................................................................... 47

Fig. 11: 2-channel architecture ................................................................................. 83

Fig. 12: total architecture ........................................................................................ 83

Fig. 13: Digital sensor 2-channel parallel ................................................................... 85

Fig. 14: Digital sensor 2-channel serial ...................................................................... 85

Fig. 15: digital sensor one-channel ........................................................................... 86

Fig. 16: Single-Channel sensor, without cross-shorting test ......................................... 92

Fig. 17: Single-channel sensor with cross-shorting test ............................................... 92

Fig. 18: dual-channel sensor homogenous without cycling, with positive disconnection .... 94

Fig. 19: dual-channel input element heterogeneous, without cycling ............................. 94

Fig. 20 dual-channel sensor homogenous with clock .................................................... 96

Fig. 21: dual-channel sensor system with separate signal processing ............................ 99

Fig. 22: Sensor system with single-/dual-channel partial system .................................. 99

Fig. 23 Course of fault in V-detection ....................................................................... 105

Fig. 24: Single-channel switching P-output................................................................ 120

Fig. 25: Single-channel switching relay output. .......................................................... 120

Fig. 26: Single-channel relay output with testing ....................................................... 121

Fig 27: Single-channel switching outout QX00_PP with dual-channel external circuit
and monitoring at output 13 as group feedback ......................................................... 122

Fig. 28: Single-channel switching output QX00_PP with dual-channel external circuit as
combination of electro-mechanical element and hydraulic/pneumatic valve and
monitoring at two inputs ......................................................................................... 123

Fig. 29: Two-channel switching relay output with external monitoring

–

group feedback . 124

Fig. 30: Dual-channel output with relay output and semi-conductor output

–

external

control circuit with monitoring ................................................................................. 125

Fig. 31: Dual-channel output with relay output

–

external control circuit in PL e ............ 126

Fig. 32: Dual-channel output with semi-conductor output and external control
circuit in PL e ........................................................................................................ 126

Fig. 33 wiring of a notification output ....................................................................... 127

Fig. 34: Two-channel output with single-channel wiring without testing ........................ 129

Fig. 35: Two-channel output with single-channel wiring with testing............................. 130

Fig. 36: two-channel output in connection with a device with examined disconnection .... 131

Fig. 37: two-channel output in connection with two-channel cut-off circuit with testing .. 131

Fig. 38: Redundant two-channel outputs in the same group in connection with
two-channel cut-off circuit ...................................................................................... 132

Fig. 39: Redundant two-channel outputs in different groups in connection with
two-channel switching-off circuit .............................................................................. 133

Fig. 40: Timing of Reset ......................................................................................... 139

Fig. 41: Reset function 1 ........................................................................................ 140

Fig. 42: Reset function 2 ........................................................................................ 140

Fig. 43: Reset function 3 ........................................................................................ 141

Fig. 44: starting TwinCAT ....................................................................................... 151

Fig. 45: TwinCAT

–

Geräte einfügen [TwinCAT - insert devices] ................................... 151

Fig. 46: TwinCAT - Master einfügen [TwinCAT

–

insert Master] .................................... 152

Fig..47: TwinCAT

–

SCU einfügen [TwinCAT - insert SCU] ........................................... 152

Fig .48: TwinCAT

–

IO devices ................................................................................. 153

Fig. 49: TwinCAT

–

IO devices ................................................................................. 154

Summary of Contents for SCU Series

Page 1: ...tion Manual English SCU Series FSoE Master and Slaves Read and observe installation manual before initial commissioning initial startup integration of the module Observe safety instructions Keep for future use ...

Page 2: ... is complete Obtain this document only through the original publisher Subject to technical changes The content of this documentation has been compiled with the utmost carefulness and corresponds to our current state of information Nevertheless we point out that the technical update of this documentation cannot always be carried out simultaneously with the technical evolution of our products Inform...

Page 3: ...i Information HB 37500 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 3 of 303 Status 09 06 2022 Man ...

Page 4: ...lied documents 15 2 8 Symbols and signal words 16 2 8 1 Safety information 16 3 Safety 17 3 1 General safety information 17 3 2 Target group 18 3 3 Terms 20 3 4 Relevant standards and directives 21 3 5 Intended use 22 3 6 Storage and transport 23 3 7 Placement 24 3 8 Electrical connection 25 3 9 Behaviour in case of emergencies 26 3 10 Safe status 26 3 11 Scope of delivery SCU 27 3 12 Labelling ra...

Page 5: ... 42 6 1 SCU Master 42 6 1 1 SCU 0 EC x 42 6 1 2 SCU 1 EC x 42 6 1 3 SCU 2 EC x 42 6 2 SCU Slaves 42 6 2 1 SDU 11 42 6 2 2 SDU 11 NM 42 6 2 3 SDU 11 PXV 42 6 2 4 SDU 12 42 6 2 5 SDU 21 43 6 2 6 SDU 21A 43 6 2 7 SDU 22 43 6 2 8 SDU 22A 43 6 2 9 SIO 1 43 6 2 10 SIO 2 43 6 2 11 SSB x x x 43 6 3 Additional information 44 6 3 1 Cable lengths 44 6 3 2 Derating outputs 44 7 Connection and installation 45 ...

Page 6: ... 2x 65 7 9 3 8 Connection of HTL proximity switch SDU12 SDU22x 65 7 9 3 8 1 HTL encoder with A A or B B signal 65 7 9 3 8 2 HTL encoder with A or B signal 66 7 10 Configuration of measuring distances 67 7 10 1 Genreal description of encoder configuration 67 8 Sensor type diagnoses 68 8 1 Absolute encoder 68 8 2 Incremental encoder 70 8 3 SinusCosinus encoder Standard mode 70 8 4 SinusCosinus encod...

Page 7: ... 3 1 Exemplary connection of analog sensors 111 10 2 3 1 1 Voltage and current sensor 111 10 2 3 1 2 Voltage sensor with test pulse 112 10 2 3 1 3 Current sensor with test pulse 112 10 3 Safety related characteristic data and wiring of the outputs 113 10 3 1 Charakteristic of output elements 113 10 3 2 Diagnoses in the cut off circuit 115 10 3 2 1 Diagnostic functions 115 10 3 2 2 Overview DC with...

Page 8: ...witch on sequence 137 11 2 Reset behaviour 138 11 2 1 Types of Reset and triggering events 138 11 2 2 Timing of Reset 139 11 2 3 Reset functions 140 11 3 LED displays 142 11 4 Parametrization 143 11 5 Regular function test 143 11 6 Validation 143 11 6 1 Process 144 11 6 2 Configuration report 145 11 6 2 1 Structure of the configuration report 145 11 6 2 2 Creating a configuration report 145 11 6 2...

Page 9: ...ent 171 18 3 6 Consideration of systematic failures 172 18 3 7 Fault exclusions 173 18 3 8 Hardware design and software design 174 18 3 8 1 Testing of the hardware design 174 18 3 8 2 Analysis of the circuit diagram 174 18 3 8 3 Iterative test of the achieved safety level 175 18 3 8 4 Verification of the software and parameters 175 18 3 8 5 Validation of the functional scheme against the Instructi...

Page 10: ...rcuit and monitoring at output 13 as group feedback 122 Fig 28 Single channel switching output QX00_PP with dual channel external circuit as combination of electro mechanical element and hydraulic pneumatic valve and monitoring at two inputs 123 Fig 29 Two channel switching relay output with external monitoring group feedback 124 Fig 30 Dual channel output with relay output and semi conductor outp...

Page 11: ...on 157 Fig 55 TwinCAT time parameters 158 Fig 56 TwinCAT RUN 158 Fig 57 TwinCAT EoE settings 159 Fig 58 TwinCAT IP ports 159 Fig 59 TwinCAT pinging of the Slaves 160 Fig 60 TwinCAT SafePLC2 160 Fig 61 risk analysis 161 Fig 62 risk graph according to EN 13849 1 162 Fig 63 technical documents according to the Machine Directive 164 Fig 64 V model 165 Fig 65 safety requirements 169 Fig 66 decision pat...

Page 12: ...3 List of tables Table 1 reaction time 77 Table 2 calculation of response time without Overspeed 82 Table 3 calculation of response time with Overspeed 82 Table 4 7 segment display 138 Table 5 types of Reset 139 Table 6 Reset functions 140 Table 7 LED displays 142 Table 8 Phases of the V model 166 Table 9 Abbreviations 177 ...

Page 13: ...s as well as on their operation and service The programming and parameterization of the devices are described in the programming manual Their exact knowledge and understanding is a mandatory prerequisite for installation or modification of the device function or device parameters The documentation is intended for all persons involved in integration and installation planning and who perform assembl...

Page 14: ...ance of this documentation and the documentation on the connected devices from BBH Products GmbH is a basic prerequisite for safe operation and for achieving the specified product properties and performance characteristics BBH Products GmbH assumes no liability for personal injury property damage or financial loss resulting from non observance of the documentation Liability for material defects is...

Page 15: ...SCU Error list SDU devices HB 37500 813 03 xxF EN error list SCU SDU modules Validation report validation according to SafePLC print Print of programming software Inspection report TÜV inspection report for type release of the assemblies SCU etc Inspeciton report SCU series Manufacturer documentation of the components integrated via the bus and of the directly integrated components External Docume...

Page 16: ...n that can cause death or severe injury if it is not avoided CAUTION Draws your attention to a dangerous situation that can cause minor to moderate injury if it is not avoided Material damage ATTENTION Draws your attention to possible malfunctions and material damage No damage NOTICE Draws your attention to useful hints and tips that can facilitate handling and operation SAFETY NOTE Draws your att...

Page 17: ...a risk of serious personal injury or property damage Further information can be found in the documentation DANGER Working on the wiring or on the electric system can cause electric shock Electric shock can cause death or severe injuries due to electric current Therefore work on the electric system may only be carried out by qualified persons in according to TRBS 1203 For qualified persons knowledg...

Page 18: ...tion for electrical electronic systems in combination with special knowledge of the laws regulations standards and guidelines for the protection of persons and property when dealing with machines and plants All installation commissioning troubleshooting and maintenance work must be carried out by a qualified electrician IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and IEC 60664 or DIN VDE 0110 and ...

Page 19: ...ining guidelines Knowledge of Safety regulations wiring guidelines circuit diagrams professional making of electrical connections Commissioning engineer Basic technical education university of applied sciences engineering education or corresponding professional experience knowledge of safety regulations the operation of the machine or system basic functions of the application system analysis and t...

Page 20: ...andards The term Safe function for applications up to PL e or SIL 3 indicates functions in line with the above standards with appropriate integrity reliability The term non safe refers to functions and data interfaces that do not or not completely fulfill the requirements according to the aforementioned standards The system software SafePLC2 serves for programming and configuration of the SCU asse...

Page 21: ... von Maschinen Teil 32 Anforderungen für Hebezeuge DIN EN 61800 5 2 2014 06 Elektrische Leistungsantriebssysteme mit einstellbarer Drehzahl Teil 5 2 Anforderungen an die Sicherheit Funktionale Sicherheit DIN EN 574 2008 12 Sicherheit von Maschinen Zweihandschaltungen Funktionelle Aspekte Gestaltungsleitsätze DIN EN 55011 2014 11 Industrielle wissenschaftliche und medizinische Geräte Funkstörungen ...

Page 22: ...with recommended or approved third party devices The SCU series has been developed manufactured tested and documented in compliance with the relevant directives and standards Therefore if the described instructions and safety related notes are observed the product does not normally present any hazards with regard to damage to property or to the health of persons The SCU assemblies are safety relat...

Page 23: ...in the loss of any type of warranty claim and of any type of damage claims The technical data and the information on connection conditions can be found on the rating plate and in this documentation and must be observed 3 6 Storage and transport The assemblies are stored and dispateched in protected boxes The boxes protect the assemblies against falling and impact The information concerning transpo...

Page 24: ...ircumstances WARNING Intended use The following areas of application are expressly excluded for the control module Use in areas subject to explosion or fire hazards Use in mining Use outdoors Use in damp rooms or rooms with splash water hazard use in environments with highly polluted air use in environments with harmful oils acids gases vapors dusts radiation etc the use in non stationary applicat...

Page 25: ...on The applicable national accident prevention regulations e g BGV A3 must be observed when working on live equipment The electrical installation must be carried out in accordance with the relevant regulations e g cable cross sections fuses protective conductor connection Further instructions are contained in the documentation Instructions for EMC compliant installation such as shielding grounding...

Page 26: ... be de energized because short circuits or incorrect tensions can cause failures in the block DANGER Working on the wiring or on the electric system can cause electric shock Electric shock can cause death or severe injuries due to electric current Therefore work on the electric system may only be carried out by persons who are qualified persons according to TRBS 1203 3 10 Safe status The safe stat...

Page 27: ...he output connectors and the power supply connectors The assemblies are enclosed in the product informaton of the SCU series Among others the product information includes the link to download the complete documentatkion INFORMATION The documentation installation manual programming manual are free available via online download INFORMATION Programming software dongle Hard Lock programming cable etc ...

Page 28: ...f the assembly and contains the following information Type Type designation Product No Product number Serial No Serial number HW Release Hardware Release marking SW Release Software Release marking NORM Safety category Power Properties of the voltage supply Input Properties of the inputs Output Properties of the outputs Date Manufacture date week number year Fig 1 rating plated SCU 2 EC NM ...

Page 29: ...1 Type Type designation 2 CE Mark of conformity 3 Date Manufacture date week number year 4 HW Release Hardware Version 5 FW Release Firmware Version 6 Product No Product number decimal with barcode 7 Serial No Serial number decimal 8 Power Properties of power supply 9 INPUT Properties of the inputs 10 OUTPUT Properties of the outputs 11 Pin assignment 1 2 3 4 5 6 7 8 9 1 0 1 1 6 7 3 4 5 1 2 11 10 ...

Page 30: ...r summarizes the FSoE data received by the Slaves and transfers them tot he SCU FSoE Master In the opposite data direction the EtherCAT Master receives the overall data framework of the FSoE data containers from the SCU and distributes the FSoE data containers to the different Slaves The S variants of the assemblies are identical to the standard devices NOTICE The EtherCAT Master transfers the FSo...

Page 31: ...RC are transferred together as one package via the non safe EtherCAT network Due to the additional calculation effort the transfer of data package and CRC takes place every 1ms 4 1 2 2 EtherCAT network The EtherCAT network consists of one Master and of a determined number of Slaves Data transfer takes place via Ethernet connections between the EtherCAT Master and every participant As a rule these ...

Page 32: ...ices are fixed by the individual participant description file ESI file 4 1 2 4 FSoE and EtherCAT The Ethernet frame of the EtherCAT network can contain safe data as well as non safe data The safe data are called FSoE data and are assigned to the protocol stack of the FSoE Master and the FSoE Slave FSoE data are transferred cyclically Thus they are contained in the PDO of the respective participant...

Page 33: ... FSoE SIO Safe IO Slave assembly by BBH to import IOs SDU Safe Drive Unit Slave assembly by BBH to import one axle SSB Safe Sensor Box Slave assembly by BBH to import 6 axles Generally also assemblies by other manufacturers can be integrated if they offer an FSoE communication SCU S N N Fig 3 example FSoE Netzwerk FSoE EtherCAT Master In Out In Out Slave In Out Slave In Out Slave In Out Slave FSoE...

Page 34: ...d they can be transferred and used in a safe way This can be necessary to optimize response times 4 2 Operation and service The SCU assembly is designed for to be used in a protected environment switch cabinet cf Technical specifications of the SCU series Before mounting the assembly and before removing the assembly or before separating signal lines the assembly must be de energized To de energize...

Page 35: ...CAT cable IN 9 7 segement display system status 10 Connection socket EtherCAT cable OUT 11 Connection socket Service interface 12 LED display status outputs 13 LED display status inputs 14 LED display status outputs 15 LED display status inputs 16 LED display EtherCAT connection 17 Connection terminal outputs 18 Connection terminal inputs 19 Connection terminal outputs 20 Connection terminal input...

Page 36: ...ltage supply sensor 5 Connection terminal inputs 6 STATUS LED display system status 7 LED display status inputs clock outputs 8 LED display status inputs 9 Memory card slot 10 Reset button for displaying the CRC 11 7 segement display system status 12 STATUS LED display fieldbus interface 13 Service interface connection socket 14 Connection socket fieldbus 15 Connection Encoder interface 16 LED dis...

Page 37: ...0 Memory card slot 11 Reset button for displaying CRC 12 7 segment display system status 13 4 encoder interface connections 14 Connection socket fieldbus 15 LED display status fieldbus interface 16 Connection socket service interface 17 LED display status outputs 18 LED display status outputs 19 LED display status inputs 20 LED display status inputs 21 Connection socket fieldbus 22 Connection term...

Page 38: ...inputs 10 Reset button for displaying CRC 11 7 segment display system status 12 Connection socket EtherCAT cable IN 13 Connection socket EtherCAT cable OUT 14 Connection socket service interface 15 LED display status outputs 16 LED display status outputs 17 LED display status IOs 18 LED display status EtherCAT connection 19 LED display status inputs 20 LED display status inputs 21 Connection termi...

Page 39: ...ATUS LED display system status 3 7 segment display system status 4 LED dispay status EtherCAT connection 5 Connection socket EtherCAT cable IN 6 Connection socket EtherCAT cable OUT 7 Connection socket outputs optional 8 Connection socket voltage supply inputs optional available in EnDat 2 2 and Hyperface DSL with or without I O s SinCos in preparation Fig 9 structure of SSB 6 x 1 6 2 3 4 8 7 5 1 ...

Page 40: ...erface Serial Synchronous Interface SSI SSI with variable data length of 12 28 Bit Data format Binary Graycode Physical Layer RS 422 compatible SSI Master operation Taktrate 150 kHz SSI Listener operation Slave mode Clock rate ENC 1 1 ENC 2 1 ENC 1 2 ENC 2 2 250 kHz 350 kHz Min clock pause time 150 µsec Max clock pause time 1 msec Type of connection D SUB 9pole Resolver Measuring signal Sin Cos tr...

Page 41: ...ty sensor Signal level 24V 0V Max counting pulse frequency switching logic debounced 10 kHz Pulse width 50 µsec Type of connection X23 Plug in terminals with spring or screw connection Proxi extended monitoring Signal level 24V 0V Max counting pulse frequency switching logic debounced 4 kHz Physical Layer PUSH PULL Measuring signal A B Track with 90 degree phase difference Type of connection X23 P...

Page 42: ... 1 2 SCU 1 EC x Specification sheet General technical data Dimensions SCU 1 EC SCU 1 EC NM 6 1 3 SCU 2 EC x Specification sheet General technical data Dimensions SCU 2 EC SCU 2 EC NM 6 2 SCU Slaves 6 2 1 SDU 11 Specification sheet General technical data Dimensions 6 2 2 SDU 11 NM Specification sheet General technical specifications Dimensions 6 2 3 SDU 11 PXV Specification sheet General technical ...

Page 43: ...pecification sheet General technical specifications Dimensions 6 2 7 SDU 22 Specification sheet General technical specifications Dimensions 6 2 8 SDU 22A Specification sheet General technical specifications Dimensions 6 2 9 SIO 1 Specification sheet General technical specifications Dimensions 6 2 10 SIO 2 Specification sheet General technical specifications Dimensions 6 2 11 SSB x x x Specificatio...

Page 44: ...wires engine brakes etc How to be laid outside the switch cabinet o Electric wires separated by separators in metal cable ducts o Cable arrangement in metallic tube o Cable arrangement separated from power wires with a distance of 10cm rectangular intersections 6 3 2 Derating outputs Maximum current load based on temperature This derating should be considered for all 2A outputs IO Board and REL Bo...

Page 45: ...tic compatibility EMC The SCU is intended for use in the drive environment and meets the EMC requirements mentioned above It is also assumed that the electromagnetic compatibility of the overall system is ensured by application of appropriate measures SAFETY NOTE Electric power supply lines of the SCU and discontinuous action lines of the power converter must be isolated from each other Signal lin...

Page 46: ...n guidelines of the converter manufacturer must be observed All contactors in the environment of the power converter must be equipped with appropriate suppressor circuits Suitable measures must be taken to protect against overvoltages Symbols used according to UL 61010 1 Symbol 14 The temperature at the connection terminals can exceed 60 C Suitable cable types must be used above this temperature ...

Page 47: ...ed in switch cabinets that at leas meet the requirements of protection category IP54 The assemblies must be mounted vertically on a top hat rail NOTICE Air circulation The vent slots must be kept sufficiently clear to warrant air circulation within the assembly 7 2 1 Mounting The SCUs are mounted on C standard rails by means of a snap on latch The SCUs are inserted into the rail diagonally from ab...

Page 48: ...me a PELV due to the design of both the assembly and the connections Protective low voltage circuits must always be installed in a way that they are safely insulated from power circuits with dangerous voltage If power supply units are used it must be guaranteed that in case of failures the maximum voltage is 60 V The real behaviour of the power supply unit used must be inquired at the manufacturer...

Page 49: ...ion Manual Master and Slaves SARC Page 49 of 303 Status 09 06 2022 7 4 Terminal schemes 7 4 1 SCU Master SCU 0 EC x SCU 1 EC x SCU 2 EC x 7 4 2 SCU Slaves SDU 11 SDU 11 NM SDU 11 PXV SDU 12 SDU 21 SDU 21A SDU 22 SDU 22A SIO 1 SIO 2 SSB 6 EnDAT x SSB 6 DSL x SSB 6 A x ...

Page 50: ...omply with local regulations The external voltage resistance of the SCU module is DC 32 V protected by suppressor diodes at the input SAFETY NOTICE The SCU module must be individually protected by a 3 15A min 30 VDC back up fuse which must be placed near by the terminals of the modules Recommended fuse type 3 15A circuit breaker Class B or safety fuse inert Note Reliable galvanic isolation from th...

Page 51: ...2 I03 I04 UE1 UE1 QY00 QY01 I10 I11 I12 I05 I06 I07 I08 CPU ENC I09 1 1 X15 X16 4 4 1 1 X26 4 4 X25 ENC 2 1 NC NC NC NC UE2 UE2 NC NC NC NC NC NC NC NC NC ENC NC 1 1 X19 X20 4 4 1 1 X30 4 4 X29 ENC 2 2 NC NC NC NC UE4 UE4 UR4 NC H2B H3B NC H1A H2A H3A NC EXT ENC H1B 1 1 X17 X18 4 4 1 1 X28 4 4 X27 ENC 1 2 NC NC NC NC UE3 UE3 UR3 NC H2B H3B NC H1A H2A H3A NC EXT ENC H1B NC NC NC NC NC NC NC NC NC N...

Page 52: ... 3 only SDU 22 The SDU module supports encoder voltages of 5 V 8 V 10 V 12 V 20 V and 24 V that are monitored internally according to the selected configuration in SafePLC2 If an encoder system is not supplied via the SDU module it must be ensured that the GND of the encoder is connected to the GND of the SDU module If the GND of the encoder is only at pin 2 of the D sub connector the terminal UE ...

Page 53: ...0 V DC 29 5 V DC 7 6 2 Resolver 1 SDU X15 1 2 L _ENC1 2 L _ENC1 2 X17 3 2 1 X15 1 2 L _ENC1 2 L _ENC1 2 X19 3 2 2 ENC 1 2 L _ENC2 L _ENC2 3 7 1 ENC 2 2 L _ENC2 L _ENC2 3 7 2 Referenz Signal generierung Referenz Signal generierung 1 only SDU 12 and SDU 22 2 only SDU 22 When using resolvers in Master Mode an additional 24V DC power supply is required for generating the reference signal NOTICE Make s...

Page 54: ...k outputs T1 and T2 available The clock outputs are switching type 24 VDC outputs The clock outputs are solely intended for monitoring external switching elements and cannot be used for any other function within the application This monitoring can only be used in conjunction with the safe digital inputs Not with the safe digital I Os that may be present The switching frequency is 125 Hz for each o...

Page 55: ...cle T1 Input is assigned to the cycle T2 Input assigned to continous voltage DC 24 V 7 8 Connection of analog inputs With the executions with analog processing max 2 analog signals to be processed safely The analog inputs can be connected as follows NOTICE The modules can optionally be equipped with voltage and or current inputs SAFETY NOTE The GND connection AIN must be connected to the GND of th...

Page 56: ...dule remains unoccupied If an external sensor voltage supply is not recirculated through the encoder plug any failure of this supply must be included in the fault examination of the overall system This in particular requires evidence that this fault is detected or can be excluded when the specified operating voltage of the overall system is fallen short of exceeded EMC measures such as shielding e...

Page 57: ...oltage e g converter Lines twisted in pairs for signal transmission acc to RS485 standard must be used for data and clock signals or track A and track B The wire cross section must in each individual case be chosen in compliance with the current consumption of the encoder and the cable length required for the installation The following applies when using absolute encoders In Slave mode the clock s...

Page 58: ...x the connection is inverse to the presented and to ENC 1 1 ENC 2 1 with application of an incremental counting system With encoders not connected inversely to ENC 1 2 ENC 2 2 the direction of rotation is thus indicated inversely The indicated direction of rotation can be corrected in the software see programming manual SCU Direction up down SSI Absolut ENC1 2 ENC2 2 SSI Absolut ENC1 1 ENC2 1 SIN ...

Page 59: ...coder as master Sub D Stecker 9 polig SMX Absolut Encoder Master Betrieb n c n c CLK DATA DATA n c CLK Versorgungspannung Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Ground With this type of the connection the clock pulses of the module SDU run to the absolute encoder and the data from the encoder to the SDU S D U Sub D plug 9 pin SDU absolute encoder Master mode Supply voltage GND of th...

Page 60: ...ut Encoder Slave Betrieb n c Ground n c CLK DATA DATA n c CLK Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 externes Abtastsystem Versorgungsspannung With this type of connection both clock signals and data are read in In this example the module does not supply the encoder with voltage GND of the supply voltage 24 V DC Sub D plug 9 pin SDU Absolute encoder Slave mode External sensing syste...

Page 61: ...22 7 9 3 3 Connecting an incremental encoder with TTL Signal level Sub D Stecker 9 polig SMX Inkremental Encoder n c Ground n c B A A n c B Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Versorgungsspannung Pins 1 3 and 7 stay open and are reserved for later expansions Sub D plug 9 pin SDU Supply voltage Incremental encoder ...

Page 62: ...of a SIN COS encoder Sub D Stecker 9 polig SMX SIN COS Geber n c Ground n c COS SIN SIN n c COS Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Versorgungsspannung Pins 1 3 and 7 stay open and are reserved for later expansions GND der Versorgungsspannung 24 V DC Sub D plug 9 pin SDU SIN COS encoder Spply voltage GND of the supply voltage 24 V DC ...

Page 63: ...er Betrieb Reference Out COS SIN SIN COS Monitor Reference Voltage Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Reference Out Reference In Reference In With this type of connection the clock signals are submitted from the SDU module to the absolute encoder and the data from the encoder to the SDU GND of the supply voltage 24 V DC GND of the supply voltage 24 V DC Sub D plug 9 pin SDU Reso...

Page 64: ...rs as slave Sub D Stecker 9 polig SMX Resolver Slave Betrieb externes Abtastsystem nc COS SIN SIN COS Monitor Reference Voltage Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Monitor Reference Voltage GND Reference In Reference In GND Ref Ref COS COS SIN SIN GND of the supply voltage 24 V DC Sub D plug 9 pin SDU Resolver Slave mode Exxternal sensing system ...

Page 65: ...L encoders please bear in mind that the tracks A and B or A and B must be combined accordingly 7 9 3 8 Connection of HTL proximity switch SDU12 SDU22x The connection is made via plug connectors X27 and X28 or X29 and X30 7 9 3 8 1 HTL encoder with A A or B B signal Klemmleiste X27 1 X29 2 Inkremental Encoder A A 1 2 Versorgungsspannung 3 Ground B B Klemmleiste X28 1 X30 2 1 2 3 Klemmleiste X17 1 X...

Page 66: ... encoder with A or B signal Klemmleiste X27 1 X29 2 Inkremental Encoder A 1 2 Versorgungsspannung 3 Ground B Klemmleiste X28 1 X30 2 1 2 3 Klemmleiste X17 1 X19 2 1 2 Spannungsversorgung Geber 1 SDU 12 Encoder 3 2 SDU 22 Encoder 4 Terminal strip X27 1 X29 2 Terminal strip X28 1 X30 2 Terminal strip X17 1 X19 2 Supply voltage Power supply Encoder ...

Page 67: ...ual channel recording with high degree of diagnostic coverage is required for Pl e acc to EN ISO 13849 1 For possible single channel components e g mechanical connection of the sensors encoders with only one shaft fastening fault exclusions acc to EN ISO 13849 2 may be used if this should be necessary For Pl d acc to EN ISO 13849 1 one may work with a reduced degree or diagnostic coverage Simple d...

Page 68: ...t Binary or Gray code Physical Layer RS 422 compatible SSI Master operation Clock rate 150kHz SSI Listener operation Slave mode Max external clock rate 250 KHz 1 or 350 kHz 2 Min clock pause time 150 µsec Max clock pause time 1 msec Diagnoses Diagnosis Parameters Fault threshold Supply voltage monitoring Fixed values 5 V 8 V 10 V 12 V 20 V 24 V 20 2 measuring tolerance Monitoring of differential l...

Page 69: ...ample SSI Frame Length 28 cycles Data Length 22 bit Status 5 bit 3 bit Fault 2 bit Warning ready for operation K Daten O Status Status information Error Maske 0 dont t care 1 aktiv Ergebnis Maske für Error False Auswertung aktiv Temperatur 1 Error Intezität 1 Error HW 1 Error Warnung Verschmutzung 1 Error Betriebsart 1 OK 1 1 0 0 1 0 0 0 0 Start Clk 0 Clk ClkN 6 Clk 1Clk Anzahl Clk Framelength 0 0...

Page 70: ...rential level on input Fixed value RS 485 level 20 2 measuring tolerance Monitoring of the counting signal separated for each track A B Fixed value DP 4 Increments 8 3 SinusCosinus encoder Standard mode Physical Layer 0 5 Vss without voltage offset Measuring signal A B Track with 90 degree phase difference Maximum frequency of input clock pulses 200 KHz 1 or 500 kHz 2 Diagnoses Diagnosis Parameter...

Page 71: ...nosis Parameters Fault threshold Supply voltage monitoring Fixed values 5 V 8V 10V 12V 20V 24V 20 2 measuring tolerance Monitoring of amplitude SIN COS Fixed value 1VSS 65 of 1 VSS 2 5 measuring tolerance Monitoring of phases A B Fixed value 90 30 5 measuring tolerance Monitoring of counting signal signal phase quadrant Fixed value 45 8 5 Proxi Switch Signal Level 24V 0V Max counting frequency 10k...

Page 72: ...cessive switching distance of proximity switch For diagnostic purposes both status conditions of the counting signal are additionally recorded synchronously and compared logically A damping of at least one of the two signals must be guaranteed for each shifting gate The logic will evaluate this instruction The diagnose must be designed for at least the following limiting values Max counting freque...

Page 73: ...ditions must be exchanged crosswise through the SPI Logic processing The following evaluation must be made in both channels Signal A Signal B Result Low Low False High Low True Low High True High High True 8 7 HTL Sensor Signal level 24V 0V Physical Layer Push Pull Measuring signal A B track with 90 phase difference Max counting clock frequency 200 kHz at X27 28 or X29 30 only SDU12 SDU 22 Diagnos...

Page 74: ...ers Fault threshold Monitoring of ratio 2 1 3 2 4 1 parameterizable 20 2 measuring tolerance Monitoring of signal amplitude Depending on the ratio Min 3 8 Vss 5 measuring tolerance Max 8 Vss 5 measuring tolerance Monitoring of phases A B Fixed value 90 7 2 measuring tolerance Monitoring of reference frequency 4 kHz to 16 kHz parameterizable 20 5 measuring tolerance Form of reference signal Sinusoi...

Page 75: ...given below must be used Particular care must be taken when using filter function Depending on filter length filter time the reaction period can be considerably longer This prolongation of the reaction time must be considered during the safety relevated design In case of particularly critical problem formulations the temporal behaviour must be validated by means of measurements During start up of ...

Page 76: ...ne input at one FSoE Slave Logic processing and switching of the local output at SCU Activation of output relay via digital input at FSoE Slave 391 571 Activation of one input and switching of the output Deactivation of digital output via digital input at FSoE Slave 291 461 Deactivation of one input and thus deactivation of the output Deactivation of relay output via digital input at FSoE Slave 47...

Page 77: ...on of an already activated monitoring function including PLC edit in case of postion processing and speed processing via digital output 392 622 If the monitoring function that has already been activated by ENABLE the block needs one cycle to calculate the current speed value In the next cycle after the monitoring function has been calculated the information is processed and edited via the PLC That...

Page 78: ... FSoESlave Ttyp 1 5 TZyklus x TECAT 1 5 TSlave Reading in of digital input of FSoESlave on digital output of FSoESlave Ttyp 1 5 TSlaveSDI x TECAT TZyklus 1 5 TSlaveSDO TSlave processing period Slave TECAT processing period EtherCAT X 1 synchronous to DC FSoE Master X 2 asynchronous to FSoE Master TWD FSoE 16 ms xxx ms TZyklus 16 ms In the worst case scenario the watchdog time of the FSoE connectio...

Page 79: ...response time on the side of the SCU is 2 T_FCcycle T_transmission To this the Response time of the Slave block is added Response timemax 2 response timeSlave 2 TFCcycle Ttransmission Fort he worst case treatment the Watchdog time of the FSoE connection must be included Response timeWorstCase 2 TWatchdog response timeOutput Response timeOutput response time of the output at the corresponding Slave...

Page 80: ...r Threshold value tthreshold value for monitoring SLS or SCA VS constant for all t Parameterized filter value XF constant for all t Maximum possible acceleration of the application aF constant for all t Delay after shutdown aV constant for all t Scanning time for occurrence of a WorstCase event Terror Response time of the SCU system treact Response time of the SCU system tfilter For WorstCase cons...

Page 81: ...9 Reaction time HB 37500 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 81 of 303 Status 09 06 2022 Diagramm 1 Drive response with without overspeed distance ...

Page 82: ...rer etc aF aV not specified Estimation from application Va2 aF treact VS 2 2 aF XF 1 2 Table 3 calculation of response time with Overspeed NOTE The effect of the filter is that the set speed threshold Va is pushed upward by a value delta_v_filter ΔVFilter For the application the new values for the response time Treact Tscu Tfilter as well as the speed resulting thereof must be considered when swit...

Page 83: ... im im PES Aktuator SA SB Fig 11 2 channel architecture Thus the total architecture shows the following structure Eingang Sensor PES Ausgang Aktuator Eingang Sensor input sensor PES PES Ausgang Aktuator output actuator Fig 12 total architecture Double import of every input and diagnostics by cross comparison The specific safety related characteristics must be taken from the technical characteristi...

Page 84: ...al characteristic data in chapter 6 When using several sensors with different functions e g position indicator access door speed detection for a safety function e g safe reduced speed when access door is open these must be assumed as being connected in series for the safety related assessment of the overall system See also exemplary calculation in appendix The safety regulations and EMC directives...

Page 85: ...he electro magnetic input terminal The following list contains details for classification the DC and the achievable PI or SIL 10 2 1 1 Charakteristics of sensors input elements IA OA LA IB OB LB m m i i c im im Sensor PES Actuator SA SB Fig 13 Digital sensor 2 channel parallel Two channel input element in parallel connection cat 4 fault tolerance 1 with high DC due to signal processing in two chan...

Page 86: ...tial input systems the input is considered a High input should the signal level deviate between both channels the input is set to Low state Dynamic test of the partial input system switching thresholds The switching thresholds for the detecting the High level are tested cyclically with a high cycle rate Falling below the defined threshold value a module triggers a module alarm Dynamic test of the ...

Page 87: ...he input signals for compliance with the defined level connections within a time window of 0 5 seconds Defining the levels over a time period of 0 5 seconds triggers a module alarm Start up test Each time the safety module SCU module is switched on the input element must be tested in direction of the Low signal status defined Safe State e g by actuating the Emergency Stop button or a door lock aft...

Page 88: ...Cyclic test pulse by dynamic change of input signals Only effective if pulse assignment is active X O O 90 99 Cyclic test pulse by dynamic change of input signals DC depending on frequency of start cyclic test DC 90 test only in 4 week intervals DC 99 test at least 1 x day or 100 time request rate Dual channel 90 Cross comparison of input signals with dynamic test if short circuits cannot be detec...

Page 89: ...ated time out function for input element SAFETY NOTE The manufacturer s data MTTFD FIT numbers etc must be used for a safety related assessment of the partial system Sensors The DC values listed in the table must be used conservatively and compliance with the boundary conditions see table under Remarks must be ensured According to the applicable standards fault exclusions are permitted The boundar...

Page 90: ...t as well as fault exclusions in the external wiring SDU x I00 I03 I08 I13 PL e Suitable for any kind of input elements with without pulse achievable PL depending on the MTTFd of the input element as well as fault exclusions in the external wiring I04 I07 PL e Single channel with pulse Mainly High level required THigh 100 TLow At least one request day required by application Fault detection upon r...

Page 91: ...elated analysis Digital inputs Achievable performance level Comment IQIx Without pulse single channel static signal auxiliary input PL e Without pulse dual channel static signal At least one request day required by application Fault detection only upon request PL d Without pulse dual channel static signal Less than one request day required by application PL e Single channel with pulse Mainly High ...

Page 92: ...3 I04 I13 I14 T1 T2 L L X14 X12 Fig 16 Single Channel sensor without cross shorting test The single channel sensor is connected to the SCU module without clocking or without cross shorting test This design is not recommended for safety applications PL b acc to EN ISO 13849 1 can maximally be reached 10 2 1 4 2 Single channel sensor with cross shorting test Fig 17 Single channel sensor with cross s...

Page 93: ... channel switch off PL d acc to EN ISO 13849 1 can be achieved by using a suitable switching element and with cautious wiring of the sensor In special cases i e in connection with suitable switching elements and permissible fault exclusions one may also achieve PL e as per EN ISO 13849 1 SAFETY NOTE PL e or higher acc to EN ISO 13849 1 is achieved if the short circuit between input and associated ...

Page 94: ... sensors switching elements with fault exclusion for not opening the switch contacts This is permissible when using positively disconnecting switches with correct constrained actuation The use of sensors with self monitoring output contacts is also permitted PL e in accordance with EN ISO 13849 1 can be achieved when using sensors input elements with sufficiently high MTTFd in connection with temp...

Page 95: ...N ISO 13849 1 is achieved by using switching elements sensors with positively opening contacts or positive actuation acc to EN 60947 5 1 Using devices for which the fault exclusion double fault for the intended safety level can be specified for the switching elements is permitted We would like to draw your attention to the applicable regulations in the EC machine directive 2006 42 EC ...

Page 96: ...witching elements with independent manipulation dto However with actuation via a common actuation device in connection with an error exclusion for this device Fig 20 dual channel sensor homogenous with clock I00 I01 I02 I03 I12 I13 T1 T2 X14 L L T2 T1 X12 SAFETY NOTE PL d or higher in accordance with EN ISO 13849 1 is achieved by using switching elements sensors with positively actuation When usin...

Page 97: ... MTTFD high Connection in control cabinet or protected routing e I00 I03 I08 I13 e All faults at the input element Short circuit at input signal line Input element does not comply with min PL r Connection in control cabinet or protected routing all X d Getting caught Short circuit at input signal line Mainly High level required THigh 100 TLow Positively disconnecting MTTFD high Connection in contr...

Page 98: ...ed routing MTTFD high Dual channel serial I01 I04 I09 I14 d Short circuit at input signal line Getting caught positively disconnecting Connection in control cabinet or protected routing MTTFD medium O O e Short circuit at input signal line Connection in control cabinet or protected routing MTTFD high all O O d Short circuit at input signal line Connection in control cabinet or protected routing MT...

Page 99: ...results for the corresponding partial system IA OA LA IB OB LB m m i i c im im Sensor PES Actuator SensorA SensorB Fig 21 dual channel sensor system with separate signal processing Dual sensor system with separate signal processing in two channels diagnose by cross comparison in the PES IA OA LA IB OB LB m m i i c im im Sensor PES Actuator Single channel partial system Mech Sendeopt Track A Track ...

Page 100: ...ate sensors the dual channel partial system of single channel sensors incremental encoder Diagnose for the single and dual channel partial system of especially suitable sensor systems SIN COS encoder resolver Dynamic operation no standstill monitoring Monitoring of 2 channel sensor systems or the corresponding partial system of sensors for dynamic operation Not to be used for standstill monitoring...

Page 101: ... x Proxi 1 x Proxi X Operating Actuator n a 99 80 90 Incremental NC X Mech Encoder connection Code disk mounting 60 99 80 90 Incremental Incremental X X n a 99 95 Incremental 1 x Proxi X n a 99 90 95 Incremental 2 x counter Proxi 90 X X n a 99 90 95 Incremental SIN COS X X n a 99 99 Incremental HTL X X n a 99 90 95 Incremental Resolver X X n a 99 99 Incremental SSI X X X n a 99 90 95 SIN COS NC X ...

Page 102: ...sk mounting 60 90 99 90 95 NC Resolver X X Mech Encoder connection Code disk mounting 60 90 99 90 95 NC HTL X Mech Encoder connection Code disk mounting 60 99 80 90 2 x counter Proxi 90 SSI X X X n a 99 90 95 SSI Fieldbus ECAT etc X X X n a 99 90 95 For the mechanical connection a fault exclusion can be made with the note only positive connections are permissible for the shaft hub connection of th...

Page 103: ... be analyzed in detail For a possible fault exclusion the relevant notes in the standard EN IEC 61800 5 2 Annex D 3 16 Table D 8 must be observed For speed measurement by means of Proxi the actuator and the mounting of the Proxi shall be analyzed with regard to their reliability For a possible fault exclusion the relevant notes in the standard EN IEC 61800 5 2 Annex D 3 16 Table D 8 shall be appli...

Page 104: ...nitoring of the reference signal Form factor analysis of the measured signal Plausibility test position signal versus speed Monitoring of Clk frequency Encoder interface specific diagnoses Interface X 31 32 X23 Incremental X X X SIN COS X X SSI X X Proxi 2 x counting input X Proxi 1 x counting input X Interface X 33 34 Incremental X X X X HTL X X Resolver X X X X X X SIN COS X X X1 SSI X X X X Int...

Page 105: ...threshold describes the tolerable deviation in speed between both sensing channels A and B Diagnostic functions for the determination of optimal parameter values for the applications are available within the SCOPE dialog of the parameterization tool NOTE Speed and acceleration are detected values with a minimal digital resolution This fact limits the smallest possible detection of speed or acceler...

Page 106: ... acceleration resolution is limited by a maximum peak time of 256 ms and the encoder resolution The garphs below show the lowest measurable acceleration in dependence on the resolution in revolutions min mm s and m s Graph acceleration rotary Values in rev min s Graph acceleration linear values in mm s and m s Resolution Value Wer t Acceleration rev min s Acceleration mm s and m s ...

Page 107: ...hecked with respect to the specific encoder as specified in the table Specific diagnostic measures for position and speed sensors If in doubt the matter must be clarified by the manufacturer The DC values listed in the table must be used conservatively and compliance with the boundary conditions see table under Remarks must be ensured In order to determine the DC value for safety functions with st...

Page 108: ...ration of the specifically required fault exclusions and their permissibility Normally one should use encoders with proven safety related characteristics the safety level of which meets the demanded level SAFETY NOTE They use of standard encoders or a combination of standard encoders is permitted A safety related evaluation is strictly required for the overall arrangement consisting of encoders se...

Page 109: ...all arrangement Encoders with proven safety related characteristics should preferably be used The SCU module generally detects the following faults in the external encoder system Short circuits between safety relevant signal lines Interruptions in safety relevant signal lines Stuck at 0 or 1 on one or all safety relevant signal lines Each encoder type has further specific diagnoses for fault detec...

Page 110: ...n of input signals with dynamic test if short circuits cannot be detected for multiple inputs outputs 90 Comparison of the analog input values with identical characteristics for both channels Monitoring of dual channel systems with identical characteristic of the input signals Cross comparison of input signals with immediate and intermediate results in the logic L and temporal as well as logic pro...

Page 111: ...e chosen method This applies also for a combination of digital and analog sensors e g safely reduced speed with open safety door door contact encoder for speed detection 10 2 3 1 Exemplary connection of analog sensors By using suitable sensors and careful wiring of the sensor PL e acc to EN ISO 13849 1 can be achieved The analog current inputs are all equipped with the fixed loading resistor of 50...

Page 112: ...00 X13 L L Spannungssensor mit Testeingang für Signalhub 10 2 3 1 3 Current sensor with test pulse 1 AIN 1 2 AIN 1 4 AIN 2 3 AIN 2 X25 26 1 UE1 2 UE1 4 QY01 3 QY00 X13 L L Stromsensor mit Testeingang für Prüfimpuls SAFETY NOTE PL e acc to EN ISO 134849 1 is achieved when using two non reactive sensors for which Common Cause faults can be ruled out Voltage sensor with test input for signal stroke C...

Page 113: ...c as specified in the following description must be accounted for 10 3 1 Charakteristic of output elements IA OA LA IB OB LB m m i i c im im PES Aktuator K1 Single channel output and single channel actuator without diagnostics IA OA LA IB OB LB m m i i c im im PES Aktuator K1 Single channel output and single channel actuator with diagnostic IA OA LA IB OB LB m m i i c im im PES Aktuator K1 K2 Sing...

Page 114: ...tuator with at least single channel diagnostic IA OA LA IB OB LB m m i i c im im PES Aktuator K1 K2 Single channel output with internal dual channel processing IQx and dual channel actuator with dual channel diagnostic IA OA LA IB OB LB m m i i c im im PES Aktuator K1 K2 Dual channel output and dual channel actuator with single channel diagnostic IA OA LA IB OB LB m m i i c im im PES Aktuator K1 K...

Page 115: ...e SCU SDU module are thus detected with DC High Test of cutout ability for QX03 and QR0 only control of relay QX00 QX01 QX02 QX03 The cutout ability of these outputs is cyclically tested Failure of the cutout possibility is clearly detected Parametrizable diagnostics functions Readback of the actuator status via auxiliary contacts position indicators etc The current status of the actuator is detec...

Page 116: ...y circuit or monitoring of safety circuits with elements for switching amplification of pneumatic hydraulic control valves in connection with readback functions from their switching status Cross comparison of input signals with immediate and intermediate results in the logic L and temporal as well as logic program sequence monitoring and detection of static failures and short circuits for multiple...

Page 117: ...ccessful the output is activated again without further delay If the permissible voltage level is still not reached after 400 µs an alarm is triggered and all safe outputs second channel with safe outputs are deactivated The following representation shows the ideal green curve and typical red curve For the determination of the maximally permissible capacity or inductance the time constant of the re...

Page 118: ...ional QX02_PP und QX03_PN 4 Complete tripping channel in compliance with architecture category 4 acc to EN ISO 13849 1 QX02_PP Non safe Only functional QX03_PN Non safe Only functional QX00 QX03 4 Complete tripping channel in compliance with architecture category 4 acc to EN ISO 13849 1 T1 Non safe Auxiliary output T2 Non safe Auxiliary output The QXx_PP QXx_PN and QX00 QX03 outputs are subjected ...

Page 119: ...uties Any use for safety duties is only permitted for High Side Low Side combination Note not relevant from FW release 05 00 00 01 A mixed operation with the relay contacts is not permitted Mixed operation A dangerous contact voltage potential may not be mixed with a protective low voltage Example FALSE 230 V AC 120 VAC cULus are switched over QR0L QR0 and 24 V DC are switchable over QR1L QR1 TRUE...

Page 120: ...dule will not recognize bonding of one or several external contacts The following circuit example is only limited suitable for safety applications PL b acc to EN ISO 13849 1 can maximally be achieved Q1_PP X21 X14 Q2_PN Q3_PP Q4_PN I01 I02 I03 I04 L L Fig 24 Single channel switching P output Q5 1 Q5 2 Q6 1 Q6 2 L L X22 Fig 25 Single channel switching relay output SAFETY NOTE Not recommended for sa...

Page 121: ...s the dangerous situation immediately The achievable PL is mainly depending on the test rate PL d acc to nach EN ISO 13849 1 can maximally be achieved Q1_PP X21 X12 Q2_PN Q3_PP Q4_PN NC NC Y1 Y2 X13 I13 I14 T1 T2 L L Fig 26 Single channel relay output with testing SAFETY NOTE Only conditionally recommended for safety applications In this context see also the notes in EN ISO 13849 1 concerning the ...

Page 122: ... testing the complete chain and a notification warning device is further required when an error is recognized see notes under 10 3 4 2 2 Q1_PP X21 X12 Q2_PN Q3_PP Q4_PN NC NC Y1 Y2 X13 I13 I14 T1 T2 L L Fig 27 Single channel switching outout QX00_PP with dual channel external circuit and monitoring at output 13 as group feedback The two external monitoring contacts are switched in series supplied ...

Page 123: ...ts SAFETY NOTE Only conditionally recommended for safety applications In this context see also the notes in EN ISO 13849 1 concerning the application and the required fault exclusions For PL c and higher a message warning feature is required which informs the operator immediately about a dangerous situation For higher requirements you must make sure that at least 1 switching operation must take pl...

Page 124: ...ing group feedback The two external monitoring contacts are switched in series supplied by the clock signal T1 and read in from I00 configured as EMU input In case of higher demands one must consider that at least 1 switching process must take place every 24 hours SAFETY NOTE For achieving PL e acc to EN ISO 13849 1 a sufficiently high testing rate is required For applications with frequent safety...

Page 125: ...t is controlled in dual channel mode via a relay and a semi conductor output Each of the two external cutout paths is monitored For PL e acc to EN ISO 13849 1 a sufficiently high testing rate and MTTFD high is demanded for the external circuit Fig 30 Dual channel output with relay output and semi conductor output external control circuit with monitoring Q1_PP X21 X12 Q2_PN Q3_PP Q4_PN Q5 1 Q5 2 Q6...

Page 126: ...for the external circuit Fig 31 Dual channel output with relay output external control circuit in PL e L L Q5 1 X22 Q5 2 Q6 1 Q6 2 STO Pl e 10 3 4 2 7 Dual channel output with semi conductor output and external control circuit in PL e For safety applications from PL d and higher acc to EN ISO 13849 1 The external circuit is controlled in dual channel mode via the semi conductor outputs For PL e ac...

Page 127: ...303 Status 09 06 2022 10 3 4 2 8 Wiring of a auxiliary output Both semi conductor outputs implemented on the SDU module can be wired for functional applications These outputs are not pulse commutated Fig 33 wiring of a notification output Applications with notification outputs are not accepted L L Y1 Y2 X13 QY00 QY01 ...

Page 128: ...Os IQx when used as output Classification Achievable Pl acc to EN ISO 13849 1 Comment Static single channel 2 PL c Fault detection or fault reaction acc to cat 2 Static two channel 2 PL d Same group 1 Time shifted triggering on PLC level Fault approach short circuit on both outputs Different group 1 Nom further requirements necessary PL e Different group1 required Dynamically single channel 2 PL e...

Page 129: ...st be taken into account that and adherence of one or several external contacts of the SCU 2 EC x or SIO 2 module ist not recognized The following circuitry example is only suitable in a restrictive manner maximally PL b according to EN ISO 13849 1 can be reached IQ00 X46 X47 IQ01 NC NC L L IQ02 IQ03 IQ04 IQ05 IQ06 IQ07 IQ08 IQ09 X48 Fig 34 Two channel output with single channel wiring without tes...

Page 130: ...ly The achievable PI is mainly depending on the test rate PI d acc to EN ISO 13849 1 can maximally be achieved IQ02 X47 X42 IQ03 IQ04 IQ05 IQ00 IQ01 NC NC X46 I12 I13 T1 T2 L L Fig 35 Two channel output with single channel wiring with testing SAFETY NOTE Only conditionally recommended for safety applications In this context see also the notes in EN ISO 13849 1 concerning the application and the re...

Page 131: ...nnection with a device with examined disconnection 10 3 5 2 4 Wiring in connection with two channel switching cut off Suitable for PL d and higher acc to EN ISO 13849 1 Use of one output IQx in conjunction with two channel external wiring with test Positively guided auxiliary contacts are especially needed for electro mechanical devices and message contacts for the valve position are required for ...

Page 132: ... channel output Suitable for PL d and higher acc to EN ISO 13849 1 Use of two outputs IQx in connection with a dual channel external wiring 10 3 5 2 5 1 Wiring dual channel in the same group IQ00 X46 X47 IQ01 NC NC L L IQ02 IQ03 IQ04 IQ05 IQ06 IQ07 IQ08 IQ09 X48 Fig 38 Redundant two channel outputs in the same group in connection with two channel cut off circuit ...

Page 133: ...ly and compliance with the boundary conditions see table under Remarks must be ensured According to the applicable standards fault exclusions are permitted The boundary conditions mentioned in this context must permanently be met When using elements for switching amplification in safety circuits their function must be monitored by means of suitable readback contacts etc see circuitry examples Suit...

Page 134: ...d and positively guided auxiliary contact Cat 2 60 90 Depend ing on switchi ng frequen cy Medium B Auxiliary output required for warning in case of detected malfunction Contactor and downstream actuators appropriately designed for safety application Hoch C As before D As before DC 90 due to a sufficiently high test rate with reference to the application Single channel without dynamic output test Q...

Page 135: ...uator with safety function cat 4 e g STO Cat 4 99 Monitor ing in both externa l shut down circuits High e Contactor and downstream actuators appropriately designed for safety application Monitoring of electro mechanical components by means of positively guided switches position monitoring of control valves etc Dual channel without dynamic output test QR0 and QR1 2 x IQ00 IQ09 Zweikanalig Schütz Ve...

Page 136: ...e channel or actuator with safety function cat 4 e g STO Cat 4 99 Monito ring in both extern al shut down circuits High e Contactor and downstream actuators appropriately designed for safety application Monitoring of electro mechanical components by means of positively guided switches position monitoring of control valves etc For applications with frequent safety shut down requests these tests sho...

Page 137: ...egment display Mode Description 1 STARTUP Synchronization between the two processor systems and check of the configuration data check of the firmware data 2 SENDCONFIG Distribution of the configuration data Configuration of the firmware data and second check of these data Afterwards range check of the configuration data 3 STARTUP BUS If available initializing of a bus system 4 RUN Standard operati...

Page 138: ... start up function after voltage recovery General Reset and a status reset alarm reset Internal Reset The latter is triggered via the button at the front side or via an appropriately configured input Reset element with enabled Alarm reset function The following table offers a survey of the Reset functions and of the effects of the Reset functions 11 2 1 Types of Reset and triggering events Reset t...

Page 139: ...input for internal Reset is monitored with respect to time Under the condition T 3 sec between the rising edge the falling edge an Internal Reset is triggered with the falling edge of the Reset input Reset_In Reset_Status Max 3 sec Max 3 sec Max 3 sec Fig 40 Timing of Reset NOTICE For time based functions the condition T 3sec is only possible by using a block reset see SCU Programming Manual chapt...

Page 140: ...formed When exceeding the parametrized limits process values do not change the initial status of the monitoring function Time based function timers provoke a reset of the initial status of the monitoring functions A response only takes place if the parametrized limit values are once more exceeded Pos_Ist Reset_In SOS_Result SOS_Pos_Max SOS_Pos_Min Max 3 sec Max 3 sec Pos_Ist SOS_Pos_Max Fig 41 Res...

Page 141: ...e based function reset of output status if limit is exceeded again NOTICE In case of time based functions e g time monitoring of complementary input signals the input status is reset In this case a status defined as faulty is detected only if the time limit value is exceeded again As protective measures against unintended use e g repeated triggering of the Reset function to bypass an alarm status ...

Page 142: ...artup phase or STOP or firmware update is carried out Orange Permant light Assembly in local mode without network connection Green Blinking Control function correct applicatoin runs but has not yet been validated Green Permanent light Control function correct application runs and is validated Red Blinking Alarm application error the assembly is in safe operating state Error status can be reset Red...

Page 143: ... to grant its correct functioning and its reliability Validation of safety functions takes place on different levels Validation is explained in a more detailed way in the standard EN 13849 2 Validation of the safety function in the programming tool Additional validation of the safety function on the finished machine Carrying out of function tests with respect to the diagnostics measures and with r...

Page 144: ... the software SafePLC2 in the form of a configuration report The concept of the SCU x EC assumes the following basic conditions Parameter data and PLC data that are deposited in the flash of the SCU x EC cannot change on their own This is ensured by online tests and the corresponding signatures in the course of basic measures Nevertheless the configuration in itself cannot be rated by the SCU x EC...

Page 145: ... be filled in directly in the PDF documents Validation can also be carried out by means of a print of the configuration report 11 6 2 3 Filling in the configuration report The configuration report is filled in the following way Enter the plant specific data in the Header section The plant specifica data are informative but their content and their volume should both be coordinated with the acceptan...

Page 146: ...safety controller b When using diagnostic functions e g pulse assignment a check should be carried out e g by short circuiting him pulses etc c If safety functions are used which are based on speed and or position data the correct recording of the speed or position must first be checked The check is possible e g by the diagnostic function for speed and position which can be selected in the SafePLC...

Page 147: ...ng manual SCU On the first two pages of the validation reports general details concerning the plant can be entered On the following pages of the validation report all functions used are printed with their parameters as itemization of the safety inspection After the configuration data and the program data have been transmitted to the SCU assembly the status LED blinks yellow This indicates that the...

Page 148: ...se electric shock Electric shock can cause death Thus only persons qualified according to TRBS 1203 may carry out work on the wiring or work on the electrical system Repair Assemblies must always be replaced completely Repairs can and may only be carried out in the factory Warranty Warranty expires if the assembly is unduly opened NOTICE If the assembly is modified the safety authorisation expires...

Page 149: ...sembled The plant and their components e g the joining module contain valuable raw materials Thus the plant and its components must be recycled separately by an appropriately specialised company Disassembly Is carried out analogous to chapter 15 Replacing an assembly Disposal NOTICE Please observe tne national regulations concerning the disposal of electrical devices The symbol of the crossed out ...

Page 150: ...First the program must be installed completely For program installation Beckhoff provides the following installation program TC31 Full Setup 3 1 4020 0 exe By calling up the program the program is installed automatically Please follow the instructions and complete the installation 17 2 Creating a new project Creating a new EtherCAT network First the program TwinCAT3 must be started The program Twi...

Page 151: ...aster and Slaves SARC Page 151 of 303 Status 09 06 2022 The following window appears Fig 44 starting TwinCAT Please insert the real time capable devices and check the insertion via the menu TWINCAT Show Realtime Ethernet Compatible Devices Fig 45 TwinCAT Geräte einfügen TwinCAT insert devices ...

Page 152: ... insert new I O devices via the following menu I O Devices click right mouse button Add new items There please select the Master assembly Then the following window appears Fig 46 TwinCAT Master einfügen TwinCAT insert Master To insert EtherCAT Slaves e g the assemblies manufactured by BBH please use the menu I O Devices Device1 EtherCAT click right mouse button klicken Add new items BBH Products G...

Page 153: ...vices1 EtherCAT click right mouse button Add new items LTi DRIVES GmbH ServoOneCM 3 Axis module The selected module is parametrized by inserting Slots in the SCU assembly To insert Slots in the SCU assembly please double click on the SCU assembly Select the Slot table and afterwards 10 Bytes In 10 Bytes Out in Slot 1 Slot 2 and Slot 3 Fig 48 TwinCAT IO devices The respective Slots are parametrized...

Page 154: ...T Slave with TwinCAT3 HB 37500 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 154 of 303 Status 09 06 2022 Fig 49 TwinCAT IO devices There the following settings must be made Fig 50 TwinCAT setting Slaves ...

Page 155: ... 155 of 303 Status 09 06 2022 The linking of the inputs and the of the outputs of the two devices must be set as follows Inputs from Box 1 SCU Outputs from Drive 2 Drive Outputs from Box 1 SCU Inputs from Drive 2 Drive Fig 51 TwinCAT linking The SCU assembly is inserted via the menu SDC SCU SYSTEM Tasks Add New Items ...

Page 156: ...F EN SCU Installation Manual Master and Slaves SARC Page 156 of 303 Status 09 06 2022 Fig 52 TwinCAT insert SDC SDC SCU SYSTEM Tasks Task 4 Inputs Add New Items Fig 53 TwinCAT Task The parameters are set via SDC SCU SYSTEM Tasks Task 4 Inputs Var 961 Change Link ...

Page 157: ...0 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 157 of 303 Status 09 06 2022 Fig 54 TwinCAT connection Setting the time parameters I O Devices Device 1 EtherCAT In the adapter table the value for the Freerun Cyle must be set to 1ms ...

Page 158: ...lation Manual Master and Slaves SARC Page 158 of 303 Status 09 06 2022 Fig 55 TwinCAT time parameters Finally please reload the device and activate Free run aktivieren wenn nun Danach läuft das FSoE Netzwerk RUN und die Geräte müssen in den Status OP wechseln Fig 56 TwinCAT RUN ...

Page 159: ...out the EoE settings the virtual Ethernet Switch must be enabled Enable Virtual Ethernet Switch I O Devices Device1 EtherCAT Open the EtherCAT tab Advanced Settings EoE Supprt Fig 57 TwinCAT EoE settings Then set the IP ports I O Devices Device1 EtherCAT Drive 2 Drive and Open the EtherCAT tab Advanced Settings Mailbox EoE Fig 58 TwinCAT IP ports IP address Slave TCP IP setting of the Ethernet net...

Page 160: ...aster and Slaves SARC Page 160 of 303 Status 09 06 2022 Afterwards the pinging testing of the Slave carried out with FSoE being enabled RUN cmd ping 192 168 39 5 Fig 59 TwinCAT pinging of the Slaves Finally SafePLC2 can be connected with the program if FSoE is enabled Fig 60 TwinCAT SafePLC2 ...

Page 161: ...or delivered For safety evaluation the respective valid relevant directives and standards must be consulted The objective of the safetyreview and of the measures resulting thereof must be to reduce danger to persons to an acceptable level Fig 61 risk analysis The risk analysis must consider all operating conditions of the machine e g operation setting up and maintenance or installing and decommiss...

Page 162: ...hkeit des unerwünschten Ereignisses Risk evaluation according to EN ISO 13849 1 Fig 62 risk graph according to EN 13849 1 S Serve physical injury S1 minor reversible injury S2 severe irreversible injury F Frequency and or duration of Exposure to danger F1 rarely not cyclic F2 frequently up to permanent and or long duration cyclic operation P Possibility of risk prevention P1 possible slow movement...

Page 163: ...ery put into circulation within the EU the minimum risks to be considered are specified in the EU Machine Directive 2006 42 EG or rather In the lastest version of this directive Further information concerning risk evaluation and the safe design of machinery is contained in the standards ISO TR 14121 2 Safety of machinery Risk assessment EN 12100 Safety of machinery basic concepts Measures applied ...

Page 164: ...cuments must be supplied by the manufacturer Their minimum scope is also included in the relevant directives and standards For example according to the EU Machinery Directive the following documents must be supplied at a minimum Fig 63 technical documents according to the Machine Directive Source BGIA Report 2 2008 The documents must be easy to understand and they must be written in the respective...

Page 165: ...standards Subsequently the method in case of applications with assemblies of the SCU series is exemplified Spezifikation der Sicherheitsmaßnahmen Spezifikation des funktionalen Sicherheitssystems Spezifikation der Hardware für das funktionale Sicherheitssystem Spezifikation der Software Sicherheitsfunktionen für das funktionale Sicherheitssystem Hard und Softwaredesign Prüfung der Umsetzung Hardwa...

Page 166: ...tion of the software specification of the safety functions Specification of the functionality of the particular safety functions and definition of the de energizing circuit etc Definition of the parameters for the particular safety functions such as e g max speed stop ramps and stop categories etc Prüfung der korrekten Umsetzung der Funktionsvorgaben durch Analyse FUP Programmierung Validation of ...

Page 167: ...7500 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 167 of 303 Status 09 06 2022 18 3 1 Specification of the safety requirements On the basis of the standards to be observed e g product standars the safety requirements must be analyzed in detail ...

Page 168: ...18 Information for design programming validation and test HB 37500 810 11 16F EN SCU Installation Manual Master and Slaves SARC Page 168 of 303 Status 09 06 2022 ...

Page 169: ...d Active protective functions are for example safely reduced speed in certain system states monitored stop and standstill functions area monitoring processing of monitoring devices such as light grids switching mats etc The safety functions must be differentiated in each case and the specific requirements defined in terms of function and safety level Definition of the safety functions The definiti...

Page 170: ...s max system speed in setup mode etc must be determined for each of the safety functions defined in this way Examples of safety functions SF1 STO Safe Turn Off to protect the plant from a safe start SF2 safe speeds SF3 safe positions SF4 Required Performance Level PL r additional emergency stop Now the required Perfolrmance Level PL r must be determined from the safety functions SF1 that have been...

Page 171: ...lant structure together with their specific identification data The hardware specification serves as basis for the determination of the achieved safety level The achieved safety level is determined on the basis of the architecture and of the identification data of all devices that participate in a safety function Furthermore in the hardware specification also the constructive protective measures a...

Page 172: ...orrect selection incorrect dimensioning faulty software Fault in integration incorrect selection faulty wiring after commissioning e g Power failure fluctuations environmental influences Wear overloading Faulty maintenance Measures for the avoidance of failures Black Box test Automatic testing Redundant hardware hardware diversity Desmodromic operation mode Contacts with positive guidance with for...

Page 173: ...usions should be substantiated e g by references to the legitimate fault exclusions according to relevant standards e g EN ISO 13849 1 If particular measures are necessary for these fault exclusions the necessary measures must be indicated Examples of fault excludions and assigned measures Positive locking connection in case of mechanical shaft connections Dimensioning on the basis of sufficient t...

Page 174: ...signment of the functions to the safety functions Understandable presentation of the functions by o Unique designations o Understandable comments o Use of tested functions or tested function block to the greatest possible extent Defensive programming 18 3 8 1 Testing of the hardware design After planning is completed it must be checked if the hardware design complies with the stipulations indicate...

Page 175: ...ion report or rather verification of the given parameters against the parameters listed in the validation report Verification of the functional scheme For verification the actually programmed function chart must be compared to the stipulations of the specifications The clearer programming has been structured with respect to the safety functions the more efficient is the comparison 18 3 8 5 Validat...

Page 176: ...Unit Safety function ELC Emergency Limit Control Safety function EMC Electromagnetic compatibility EN European Norm EtherCAT EtherCAT name Data protocol FSoE Fail Safe over EtherCAT Safe data transfer via EtherCAT protocol FUP Function plan GND Ground Ground potential 0 VDC H HISIDE High Side Positive switching output 24 VDC HW Hardware I Input IL Instruction List List of the commands within the a...

Page 177: ... Device to Device Communication SDU Safe Drive Unit FSoE assembly to record encoder values SDP Safe Drive Profile Data profile for safe encoder data SELV Safe Extra Low Voltage Safe fused low voltage SIO Safe IO FSoE Slave assembly to record digital inputs digital outputs SMMC Safe Master to Master Communication SSB Safe Sensor Box FSoE Slave assembly to record encoder data from 6 encoders SSI Syn...

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