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Pilz PMCprotego S1--2, Operating Manual

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Pilz PMCprotego S1--2 Operating Manual Download Page 6

Introduction

Operating Manual PMCprotego S1­2(­C)
1002528­EN­03

6

CAUTION!

This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.

NOTICE

This describes a situation in which the product or devices could be dam­
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import­
ance.

INFORMATION

This gives advice on applications and provides information on special fea­
tures.

Summary of Contents for PMCprotego S1--2

Page 1: ...PMCprotego S1 2 C Operating Manual 1002528 EN 03 PMCprotego Safe Motion...

Page 2: ...es may be made for internal purposes Suggestions and comments for improving this documentation will be gratefully received Pilz PIT PMI PNOZ Primo PSEN PSS PVIS SafetyBUS p SafetyEYE SafetyNET p the s...

Page 3: ...erview 13 4 2 Inputs and outputs 14 4 2 1 Inputs 15 4 2 2 Outputs 16 4 2 2 1 Single pole outputs 16 4 2 2 2 Dual pole outputs 18 4 2 2 3 Output test 18 4 3 Safety functions 20 4 3 1 Safe Torque Off ST...

Page 4: ...g at a restart 72 7 3 2 Recommissioning after error 73 7 3 2 1 Switching the inputs SS1 Activate or SS1 SIL3 Reset 73 7 3 2 2 Command CLRFAULT 74 7 3 3 Swap safety card 75 7 3 3 1 Download configurati...

Page 5: ...ils of how to set the parameters for the servo amplifier are described in the help for the commissioning software PASmotion All these manuals can be found on the supplied CD ROM Motion Control You wil...

Page 6: ...des information on preventive measures that can be taken NOTICE This describes a situation in which the product or devices could be dam aged and also provides information on preventive measures that c...

Page 7: ...ety card after an error 7 single pole digital inputs which can be assigned the following safety functions in accord ance with EN 61800 5 2 in the safety cards s Configurator Safe Stop 2 SS2 Safe Opera...

Page 8: ...9 10 11 12 13 14 15 16 17 18 19 20 21 22 RUN POWER STO CONFIG X30 X31 8176105 12 100001 1 3 4 5 6 2 1 3 Key 1 Screw for attachment to the servo amplifier 2 LEDs to display operating states 3 Inputs o...

Page 9: ...e safe pulse disabler through deliberate operator action see the section entitled Operation under Testing the safe pulse disabler The following is deemed improper use Any component technical or electr...

Page 10: ...is detected by the safety card as follows Rotary synchronous motors Detected within one mechanical revolution of the motor Linear synchronous motors Detected within the distance travelled in accordanc...

Page 11: ...ery in accordance with the general standards and guidelines for safety technology It is the company s responsibility only to employ personnel who Are familiar with the basic regulations concerning hea...

Page 12: ...onal EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design Part 2 Validation EN 61508 1998 Functional safety of safety related electrical...

Page 13: ...vo amplifier PMCprotego D Safety card PMCprotego S built into the servo amplifier Servo motor synchronous motor with Standard encoder system feedback Brake optional not safety related Safety control s...

Page 14: ...moves the power to the motor if the safe pulse disabler is activated switches the motor to torque free and can also control an internal motor brake The safety control system Activates the safety funct...

Page 15: ...I5 I3 I2 I1 I6 Inputs Outputs Fig Inputs and outputs 4 2 1 Inputs The safety card has safe single pole inputs Inputs with fixed assignment SS1 Activate Safe Stop 1 SS1 SIL3 Reset Additional safe input...

Page 16: ...readiness Outputs with fixed assignment STO Acknowledge 1 Power element switched off Internal error on servo amplifier or safety card Limit values exceeded Activated via SS1 0 Drive in closed loop ope...

Page 17: ...ge Acknowledge 1 Drive is moving within the permitted limit values for speed or position 0 Drive is moving outside the permitted limit values for speed or position or monit oring is not activated SBA...

Page 18: ...e which operates in accordance with the failsafe principle may be connected Supply voltage 24 VDC connection to supply the safety card s digital outputs 4 2 2 3 Output test The outputs are tested regu...

Page 19: ...scan time of the power up test otherwise the load may switch on unintentionally Timing diagram 1 t1 t2 t1 t t2 t1 U 0 1 1 Signal 0 0 Signal t1 Pulse duration on power up test see Technical details t2...

Page 20: ...iconductor outputs 1 Signal Inside the set limit values 0 Signal Outside the set limit values Simultaneous activation of safety functions All safety functions can be active at the same time However sa...

Page 21: ...nd SS1 SIL3 Reset 1 Signal 24 VDC Ready output 1 Signal 24 VDC The safety card is ready for operation STO Acknowledge output 0 Signal To achieve SIL3 or PL e Connect the output STO SIL3 to servo ampli...

Page 22: ...in a controlled manner and removes the power to the motor After a defined period STO delay time or once the motor is at standstill the safety function safe torque off STO removes the power to the mot...

Page 23: ...d while the STO delay time is running the STO delay time has elapsed Input and output assignment Input X30 1 SS1 Activate Outputs X30 5 STO Acknowledge X30 16 Ready Prerequisites for normal operation...

Page 24: ...plifier for controlled braking of the motor The braking ramp must only be configured in the Configurator if monitoring of the brak ing ramp is also activate there Safety Card Servo Amplifier M Input v...

Page 25: ...lay time Tolerance window Braking ramp Limit value Standstill detection SS1 SIL3 Reset 1 0 STO Ready 1 0 t2 Timing diagram STO is started during the STO delay time Braking ramp Tolerance window Brakin...

Page 26: ...rted The braking ramp can be monitored via a maximum position error specified in the Con figurator Braking ramp in normal operation The drive starts with the configured braking ramp when safety functi...

Page 27: ...of the motor The braking ramp is configured in the Configurator Controller activated After the safety function is triggered the control system is sues a command to the servo amplifier for controlled b...

Page 28: ...afety function SS1 SS1 SIL3 Reset Input for SIL 3 and reset SS2 Activate Input for safety function SS2 Ready Output for operating status of safety card and second output for feedback from safety funct...

Page 29: ...t assignment in the Configurator Inputs I0 I6 SOS Activate Outputs O0 O3 SSA Safe Standstill Acknowledge Prerequisites for normal operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready...

Page 30: ...still position is monitored SS1 Activate Input for safety function SS1 SS1 SIL3 Reset Input for SIL 3 and reset SOS Activate Input for safety function SOS Ready Output for operating status of safety c...

Page 31: ...A tolerance range may also be set for the limit values used to monitor the speed This toler ance range modifies the set limit values As a result one off or periodic overshoots that ex ceed the limit...

Page 32: ...nction SLS without tolerance range activated ta Activation of safety function SLS te Once the SLS delay time has elapsed the speed is monitored SS1 Activate Input for safety function SS1 SS1 SIL3 Rese...

Page 33: ...it value ta Activation of safety function SLS te Once the SLS delay time has elapsed the speed is monitored ts Speed v exceeds the limit value and activates the tolerance range tolerance amount tolera...

Page 34: ...the SSR delay time has elapsed the speed is monitored Output SRA Safe Range Acknowledge 1 signal If the limit value is exceeded safety function SS1 is activated A tolerance range may also be set for...

Page 35: ...mum speed SSR SSR SRA Safe Range Acknowledge Fig Safety function SSR without tolerance range activated ta Activation of safety function SSR te Once the SSR delay time has elapsed the speed is monitore...

Page 36: ...alues maximum and minimum speed ta Activation of safety function SSR te Once the SSR delay time has elapsed the speed is monitored ts Speed v exceeds the limit value and activates the tolerance range...

Page 37: ...24 VDC Ready output 1 Signal 24 VDC The safety card is ready for operation STO Acknowledge output 0 Signal Input SDI Pos Activate 1 Signal 24 VDC Input SDI Neg Activate 1 Signal 24 VDC To achieve SIL3...

Page 38: ...Activate Input for safety function SDI negative direction is monitored Ready Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge Output f...

Page 39: ...hen is monitoring of the old direction of rotation deactivated see Case B in the illustra tion and timing diagram NOTICE Please note that the direction of rotation may only ever be monitored in one di...

Page 40: ...the SDI delay time has elapsed the negative direction of rotation is monitored SS1 Activate Input for safety function SS1 SS1 SIL3 Reset Input for SIL 3 and reset SDI Neg Activate Input for safety fu...

Page 41: ...monitored The current position of the motor is recorded and the motor is monitored for compliance with the maximum increment Increment and speed within permitted limits Output SRA Safe Range Acknowled...

Page 42: ...ill s t v t Fig Safety function SLI without automatic activation ta Activation of safety function SLI te Once the SLI delay time has elapsed the increment is monitored SS1 Activate Input for safety fu...

Page 43: ...1 0 SSA Safe Standstill Acknowledge Fig Safety function SLI with automatic activation ta Activation of safety function SLI te Once the SLI delay time has elapsed the increment is monitored SS1 Activat...

Page 44: ...r and external encoder must not overflow during active monitoring of the absolute position Appropriate measures should be used to ensure that the encoder signals are adapted to the mechanical travel I...

Page 45: ...s have a 0 signal INFORMATION When you use the Always monitor position option make sure that the axis can be reset to the permitted range after the limit value is exceeded Timing diagram s t SS1 SIL3...

Page 46: ...with safety function STO This prevents a hazardous movement of the drive axis in a torque free state The safety function SBC can be connected to the servo amplifier s brake signal see INFORMATION belo...

Page 47: ...ion SBC is activated Prerequisites for normal operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready output 1 Signal 24 VDC The safety card is ready for operation STO Acknowledge output...

Page 48: ...dy 1 0 IB t v t SBC SBC 1 0 t1 t2 Fig Safety function SBC t1 Activation of safety function STO and SBC t2 End of safety function SBC SS1 Activate Input for safety function SS1 SS1 SIL3 Reset Input for...

Page 49: ...ke engaged due to DISABLE on the servo amplifier C Brake vented D Brake engaged due to STO on the safety card E Brake engaged due to DISABLE on the servo amplifier Servo amplifier ENABLE ENABLE signal...

Page 50: ...or Inputs I0 I6 SBT Activate Outputs O0 O3 SSA Safe Standstill Acknowledge SBA Safe Brake Acknowledge Prerequisites for normal operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready out...

Page 51: ...time Ventilation Delay time Energisation Monitoring period Fig Safety function SBT t1 Activation of safety function SBT start of SBT delay time t2 Start of brake test brake engages t3 Start of monitor...

Page 52: ...ued The safety card must be reset to resume operation The status of the safety card SS1 activated is transmitted to the servo amplifier As a result the information is available to a higher level contr...

Page 53: ...r applies speed controlled braking with the preset braking ramp until standstill is achieved This status is maintained for as long as safety function SS2 is active If safety function SS2 is deactivate...

Page 54: ...nse and error reaction time takes into account the following processing times Processing time of digital input TIN The time it takes for a 0 or 1 signal in the safety card to be detected once a signal...

Page 55: ...ion control sys tem The control system passes the configuration to the respective safety card Download configuration to safety card Online from configurator to safety card Save configuration to extern...

Page 56: ...for the servo amplifier CAUTION Damage due to electrostatic discharge Electrostatic discharge can damage components Ensure discharge before touching the safety card e g by touching an earthed conduct...

Page 57: ...e servo amplifier When installing please note the guidelines given under Installation in the operating manual for the servo amplifier 1 Remove the film 2 Break the middle link 3 Break the top link and...

Page 58: ...switch off the load Possible remedy Exclude the error by using separate multicore cable for supply voltages Use appropriate wiring to exclude short circuits between the outputs Signal lines must be sh...

Page 59: ...ion 13 I4 Activate safety function 14 I5 Activate safety function 15 I6 Activate safety function 16 Ready Status Safety card ready for op eration and second output for feedback from safety function ST...

Page 60: ...ded shield Strip all the wires and fit end ferrules Use the cable ties to attach the cable to the shielding plate on the side 1 or bottom 2 of the servo amplifier Press the cable s braided shield firm...

Page 61: ...lly Connection 6 5 Digital outputs 6 5 1 Supply voltage The digital outputs need a 24 VDC supply When selecting the power supply please refer to the requirements stated under Tech nical Details The po...

Page 62: ...V Pins 21 and 22 are linked internally Connector pin assignment Supply voltage L3 10 X30 L1 L2 0 V 21 22 24 V PE 24 V XGND Servo Amplifier Max cable length 30 m 24 V connection isolated from external...

Page 63: ...V 16 Ready Status Safety card ready for oper ation and second output for feed back from safety function STO 19 STO SIL3 Second STO shutdown route for SIL 3 21 0 V Supply Supply voltage for digital ou...

Page 64: ...mplifier 6 5 3 Dual pole outputs Connector X30 Pin Designation Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 X30 17 SBC Output Control external brake 18 SBC Output Control exter...

Page 65: ...to do so could result in electric shock The power supplies must comply with EN 60950 1 05 2006 EN 61558 2 6 11 1997 Connector X30 Pin Name Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2...

Page 66: ...inals X30 11 22 across the lines V and 0 V 6 6 2 Incremental encoder with TTL signal If the cable length is 50 m please speak to our Customer Support Connector X31 Pin Name Description 1 5 6 9 1 A Cha...

Page 67: ...pair shielded Shield connection within the housing Connection 6 6 3 Absolute encoder with SSI interface If the cable length is 50 m please speak to our Customer Support Connector X31 Pin Name Descrip...

Page 68: ...PMCprotego S1 2 C 1002528 EN 03 68 Input circuit Incremental encoder 2 7 1 X31 4 Encoder 6 9 CLOCK CLOCK DATA DATA CLOCK CLOCK DATA DATA 0 V Vcc V 0 V X30 0 V V 11 22 Shielded Shield connection within...

Page 69: ...mplifier DANGER Risk of electrocution Never wire the electrical connections on the servo amplifier while voltage is applied Switch off the mains voltages and 24 V supply Make sure that the control cab...

Page 70: ...figured Please note that the inputs SS1 Activate and SS1 SIL3 Reset must always be connected 3 Connect the configuration PC to the servo amplifier or motion control system Connect the PC to the servo...

Page 71: ...successful the servo amplifier s power element is enabled The Ready output has a 1 signal The RUN LED is lit SS1 SIL3 Reset 1 0 1 0 1 0 1 0 1 0 SS1 Activate Ready STO Acknowledge 1 0 LED CONFIG LED R...

Page 72: ...ial commissioning Servo Amplifier 24 V X4 1 BTB RTO X3B 14 15 L1 L2 L3 X0 X8 Safety Card Sx 24 V X30 1 SS1 SIL3 Reset X30 20 Ready X30 16 STO Acknowledge X30 5 SS1 Activate X30 1 Servo Amplifier STO E...

Page 73: ...rror This section describes the recommissioning process after an error has occurred Rectify the error noting The error messages in the error stack The LED display Perform a reset as follows Switch inp...

Page 74: ...isites for using the CLRFAULT command The safety card is in STOP condition The STO LED flashes Both inputs SS1 Activate and SS1 SIL3 Reset have a 1 signal 24 V Alternatively this function can also be...

Page 75: ...number of the new safety card We recommend that you swap the whole unit servo amplifier with safety card Please contact Pilz NOTICE Damage due to electrostatic discharge Electrostatic discharge can da...

Page 76: ...d from an SD card in the servo amp lifier 5 Downloading a configuration via an SD card which is written by the servo ampli fier safety card 2 6 Inserting an SD card from the servo amplifier for safety...

Page 77: ...d insert it into the servo amplifier s SD card read device 3 continue as described under Download configuration from SD card to safety card 2 option 5 Downloading a configuration via an SD card which...

Page 78: ...ng the Configurator During this process the firmware for the servo amplifier is also reloaded Prerequisite The following files must be available on the SD card 3 or 6 default pdis Configuration file f...

Page 79: ...comprises Proper execution of the employed safety functions Inspection of the parameters The result of the check on each safety function must be documented in a test report This test report must be si...

Page 80: ...AFE OPERATION SS1 STO POWER ON Download configuration Safety function deactivated Safety function activated Demand upon Configurator Internal error Error STO Limit values Error SS1 Activate Error Rese...

Page 81: ...esting the safe pulse disabler The safety card meets the requirements of EN IEC 61508 up to SIL 3 and EN ISO 13849 1 up to PL e To achieve category SIL 3 or PL e the operator must ensure that the func...

Page 82: ...edge LED RUN t2 t t1 t1 At least 2 ms time during which SS1 Activate or SS1 SIL3 Reset must have a 0 signal t2 Approx 2 s safety card s run up time SS1 Activate Input for safety function SS1 SS1 SIL3...

Page 83: ...ply voltage is not present Green Supply voltage is present RUN System not ready Green System ready RUN status Green System boots Star tup status CONFIG Normal operation Yellow Downloading the configur...

Page 84: ...s chapter Outputs on the safety card display the state of the safety functions e g STO Acknow ledge Errors and messages are entered in the safety card s error stack The following are displayed in onli...

Page 85: ...he input signal Binary Gray Binary Gray Signal at the data input Differential signal RS 422 Differential signal RS 422 Incremental encoder input 680004 680008 Number of inputs 1 1 Connection type 9 pi...

Page 86: ...cuit proof Yes Yes Times 680004 680008 Response time 4 ms 4 ms Error reaction time 2 ms 2 ms Environmental data 680004 680008 Climatic suitability EN 60068 2 1 EN 60068 2 14 EN 60068 2 2 EN 60068 2 30...

Page 87: ...20 IP20 Mechanical data 680004 680008 Material Front Steel 1 4016 Steel 1 4016 Top Polyester film Polyester film Conductor cross section with screw terminals Rigid single core flexible multi core or m...

Page 88: ...amplifier Number of poles MPOLES Pole pair pitch MPITCH 9 1 1 1 MTTF 10 years Operating mode EN ISO 13849 1 2008 PL EN ISO 13849 1 2008 Category EN 62061 SIL CL EN 62061 PFHD 1 h IEC 61511 SIL IEC 615...

Page 89: ...r all safety functions All the units used within a safety function must be considered when calculating the safety characteristic data 9 1 2 Safe actuator with two encoders Operating mode EN ISO 13849...

Page 90: ...em Sensor Sensor 1 Motor encoder Sensor 2 External encoder Diversity with cross comparison PMCprotego D PMCprotego S1 The safety related characteristic data is valid for all safety functions All the u...

Page 91: ...perating Manual PMCprotego S1 2 C 1002528 EN 03 91 10 Order reference Order reference Product type Features Order no PMCprotego S1 2 Safety Card 680 004 PMCprotego S1 2 C Safety card with coated circu...

Page 92: ...iti ates the STO function if the motor speed drops below a defined limit value or c Initiates the motor delay and then initiates the STO function after an application specific time delay Safe Stop 2 S...

Page 93: ...mo PMCprotego PMCtendo PMD PMI PNOZ Primo PSEN PSS PVIS SafetyBUS p SafetyEYE SafetyNET p the spirit of safety are registered and protected trademarks of Pilz GmbH Co KG in some countries We would poi...

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