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Pilz PMCprotego S1 Operating Manual Download Page 2

This document is a translation of the original document.

All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies 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 spirit of safety

®

 are registered and protected trademarks of

Pilz GmbH & Co. KG in some countries.

SD means Secure Digital.

Preface

Summary of Contents for PMCprotego S1

Page 1: ...Operating Manual No 1001431 EN 06 Safety Card Servo amplifiers Operating Manual PMCprotego S1 Operating Manual PMCprotego S1 PMCprotego S1...

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: ...ability 3 3 3 1 5 Disposal 3 3 3 2 Standards 3 4 Chapter 4 Function Description 4 1 Overview 4 1 4 2 Inputs and outputs 4 3 4 2 1 Inputs 4 3 4 2 2 Outputs 4 3 4 2 2 1 Single pole outputs 4 3 4 2 2 2 D...

Page 4: ...commissioning 7 2 7 3 Recommissioning 7 5 7 3 1 Recommissioning at a restart 7 5 7 3 2 Recommissioning after error 7 6 7 3 2 1 Switching the inputs SS1 Activate or SS1 SIL3 Reset 7 6 7 3 2 2 Command C...

Page 5: ...3 Contents 9 2 1 1 MTTF 10 years 9 3 9 2 1 2 MTTF 57 years 9 3 9 2 2 Safe actuator with two encoders 9 4 Chapter 10 Glossary...

Page 6: ...Contents 4...

Page 7: ...uments from the motion control range The configuration of the expansion card is described in the online help for the Configurator PASconfig SDrive The servo amplifier PMCprotego D is described in the...

Page 8: ...most important fea tures 3 Safety This chapter must be read as it contains important information on safety and intended use 4 Function Description This chapter describes the product s individual funct...

Page 9: ...rns of a hazardous situation that could lead to serious injury and death and indicates preven tive measures that can be taken CAUTION This refers to a hazard that can lead to a less serious or minor i...

Page 10: ...1 3 Definition of symbols 1 Introduction 1 4...

Page 11: ...eed range SSR Safely limited speed SLS Safe direction SDI Funkt_Sicherheitsfunktion_SBT Safe brake test SBT not defined in EN 61800 5 2 Uebersicht_Merkmal_Eing_SIL3_Reset Additional safe input to achi...

Page 12: ...2 1 Unit structure 2 Overview 2 2 LEDs for Supply voltage POWER System status RUN Download of configuration data CONFIG Fault FAULT...

Page 13: ...servo amplifier 2 LEDs to display operating states 3 Inputs outputs and supply voltage 4 Labelling strip with Order number Serial number Number of device version 5 2D code Uebersicht_Front_Legende_Vo...

Page 14: ...2 Overview 2 4...

Page 15: ...r safety functions SS1 or STO have been triggered as a condition of operation or By restarting after safety function SS1 has been triggered by the op erator Sicherheit_Impulssperre_Info Sicherheit_Bes...

Page 16: ...motor encoder sensorless operation is not permitted Work is in progress for use with Asynchronous motors 3 1 2 Permitted motor encoder types Permitted motor encoder types 3 Sicherheit_Bestimm_Motorge...

Page 17: ...read and understood the safety guidelines given in this descrip tion Have a good knowledge of the generic and specialist standards ap plicable to the specific application 3 1 4 Warranty and liability...

Page 18: ...Functional EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design Part 2 Valida tion EN 61508 1998 Functional safety of safety related el...

Page 19: ...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 20: ...al Details under Safety related characteristic data Funkt_Uebersicht_Servoverst The servo amplifier Removes the power to the motor if the safe pulse disabler is activat ed switches the motor to torque...

Page 21: ...after an error Funkt_Eingaenge_Signal Signals at the input 1 0 pulse edge at the input Safety function is activated 0 signal 0 V at the input Safety function is activated 1 signal 24 V at the input Sa...

Page 22: ...no supply voltage or major internal error Funkt_Ausgaenge_Status_SBT_STO_SIL3 SBT Acknowledge 1 Brake test was run within the defined period 0 Brake test must be activated within a selectable time pe...

Page 23: ...outputs 4 Funkt_Ausgaenge_SBC The safety card has a dual pole output to control an external mechanical brake SBC SBC Funkt_Ausgaenge_Signal_zweip Signals at the output 0 signal 0 V at the output SBC S...

Page 24: ...est pulses for outputs that are switched off see technical details Outputs that are switched off are switched on for the duration of the test pulse The load must not switch on because of the test Test...

Page 25: ...4 7 4 2 Inputs and outputs 4 Function Description Characteristic Output capacitance C dependent on load current I 1 2 3 4 5 0 0 2 0 4 0 6 0 8 1 1 2 1 4 1 6 1 8 2 C F I A...

Page 26: ...These inputs operate in accordance with the failsafe principle on switching off The safety control system activates the safety func tions via a 1 0 pulse edge Funkt_Sicherheitsfunktion_Rueck Feedback...

Page 27: ...the safe pulse disa bler on the servo amplifier in order to shut down the power element The safety function Safe Torque Off corresponds to a category 0 stop uncontrolled stop in accordance with EN 60...

Page 28: ...tion STO switched directly due to a 0 signal from SS1 Activate Input for safety function SS1 SS1 SIL3 Reset Input for SIL 3 and reset Ready Output for operating status of the safety card STO Acknowled...

Page 29: ...ampe_Not_Halt E STOP braking ramp The drive starts with the configured braking ramp when there is an internal error limit values are exceeded Sicherheitsfunktion_STO_Ueberwach_Bremsrampe Safety functi...

Page 30: ...heitsfunktion_SS1_SS2_Ausloesung The method by which the servo amplifier receives the command for controlled braking of the motor is defined in the Configurator Drive activated After the safety functi...

Page 31: ...1 Signal Sicherheitsfunktion_haengende_Lasten If any external forces influence the motor axis e g suspended loads additional measures e g a safety holding brake are required in order to eliminate haz...

Page 32: ...SS2 Safe stop 2 SS2 4 Sicherheitsfunktion_SS2_Ueber The safety function Safe Stop 2 SS2 brakes the drive in a controlled manner and monitors it for standstill Features of the safety function The driv...

Page 33: ...specified in the Configurator Safety function SOS is activated when standstill is achieved while the SOS delay time is running the SOS delay time has elapsed Sicherheitsfunktion_Sxx_Voraussetzung_S1 P...

Page 34: ...e configured braking ramp The drive remains in a controlled standstill and is monitored for safe standstill SOS Acknowledge output 1 Signal Sicherheitsfunktion_SS2_S1_Diagramm Drive activated braking...

Page 35: ...SOS Acknowledge Output for feedback from safety function SOS 4 3 4 Safe operating stop SOS Safe operating stop SOS 4 Sicherheitsfunktion_SOS_Ueber The safety function safe operating stop SOS monitors...

Page 36: ...ile the SOS delay time is running the SOS delay time has elapsed Sicherheitsfunktion_Sxx_Voraussetzung_S1 Prerequisites for normal operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready...

Page 37: ...et Input for SIL3 and reset SOS Activate Input for safety function SOS Ready Output for operating status of the safety card STO Acknowledge Output for feedback from safety function STO SOS Acknowledge...

Page 38: ...Sicherheitsfunktion_SLS_Reaktion Reaction SLS delay time starts Once the SLS delay time has elapsed the speed is monitored Output SRA Acknowledge 1 Signal If the limit value is exceeded safety functi...

Page 39: ...ende_SLS ta Activation of safety function SLS te Once the SLS delay time has elapsed the speed is monitored Sicherheitsfunktion_Legende_SLS_S1 SS1 Activate Input for safety function SS1 SS1 SIL3 Reset...

Page 40: ...erheitsfunktion_Legende_ts_t1_t2 ts Speed v exceeds the limit value and activates the tolerance range tolerance amount tolerance time tolerance period t1 Tolerance time t2 Tolerance period Sicherheits...

Page 41: ...SIL3 to servo am plifier terminal X4A 3 Sicherheitsfunktion_SSR_Ausloesung Safety function is activated By a 1 0 pulse edge at the input SSR Activate Sicherheitsfunktion_SSR_Reaktion Reaction SSR dela...

Page 42: ...funktion_SSR_S1_oT_Diagramm Timing diagram without tolerance range activated Fig 4 8 Safety function SSR without tolerance range activated Sicherheitsfunktion_Legende_SSR ta Activation of safety funct...

Page 43: ...egende_SSR_TolBerecih Tolerance amount as of the two limit values maximum and mini mum speed Sicherheitsfunktion_Legende_SSR ta Activation of safety function SSR te Once the SSR delay time has elapsed...

Page 44: ...l operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready output 1 Signal 24 VDC The safety card is ready for op eration STO Acknowledge output 0 Signal Sicherheitsfunktion_SDI_Vorausset...

Page 45: ...dy Output for operating status of the safety card STO Acknowledge Output for feedback from safety function STO SDI Acknowledge Output for feedback from safety function SDI Sicherheitsfunktion_SDI_Umsc...

Page 46: ...the SDI delay time tm is running Only then is monitoring of the old direc tion of rotation deactivated see Case B in the illustration and timing diagram Fig 4 11 Changing the direction of rotation Sic...

Page 47: ...g Activate Input for safety function SDI anti clockwise rota tion is monitored new direction of rotation SDI Pos Activate Input for safety function SDI clockwise rotation is monitored old direction of...

Page 48: ...rpose Sicherheitsfunktion_SBC_Wichtig Sicherheitsfunktion_Sxx_Voraussetzung_S1 Prerequisites for normal operation Input SS1 Activate and SS1 SIL3 Reset 1 Signal 24 VDC Ready output 1 Signal 24 VDC The...

Page 49: ...l output 4 3 9 Safe brake test SBT Safe brake test SBT 4 Sicherheitsfunktion_SBT_Ueber The safety function safe brake test SBT is used to test the external holding brake plus the internal brake motor...

Page 50: ...tween SBC and SBC Sicherheitsfunktion_SBT_Voraussetzung Input SBT Activate 1 Signal 24 VDC Sicherheitsfunktion_Sxx_Voraussetzung_SIL3 To achieve SIL3 or Ple Connect the output STO SIL3 to servo am pli...

Page 51: ...fety function SS1 SS1 SIL3 Reset Input for SIL3 and reset Ready Output for operating status of the safety card SBT Activate Input for safety function SBT SBT Acknowledge Output for feedback from safet...

Page 52: ...4 3 Safety functions 4 Function Description 4 34 SOS Acknowledge Output for feedback from safety function SOS SBC Brake control output...

Page 53: ...lt the information is available to a higher level control system status word The transfer of setpoint values from external servo amplifier interfaces bus system or analogue input is disabled The servo...

Page 54: ...il standstill is achieved This status is maintained for as long as safety function SS2 is active If safety function SS2 is deactivated the status word is updated The servo amplifier automatically swit...

Page 55: ...r 4 Function Description INFORMATION Further information on the command can be found in the servo amplifier s online help on the Motion Control CD file ascii_dd5 protego chm Please also refer to the o...

Page 56: ...time it takes for a 0 or 1 signal in the safety card to be detected once a signal has changed at the input The processing time takes into account the input filter time temperature drift spread of com...

Page 57: ...5 Reaction times 4 Function Description Input T IN Controller T CYCLE Output T OUT PMCprotego Sx PMCprotego Dx Pulse disabler T PULSE Power element t ms 3 4 2 0 Error reaction time 2 ms Response time...

Page 58: ...ive safety card Download configuration to safety card Online from configurator to safety card Save configuration to external SD card Order and serial numbers must be entered in the configuration to en...

Page 59: ...requirements 5 Montage_Allg Please also refer to the operating manual for the servo amplifier CAUTION Damage due to electrostatic discharge Electrostatic discharge can damage components Ensure dis ch...

Page 60: ...5 2 Dimensions 5 Installation 5 2 5 2 Dimensions 5200 Dimensions 5 Montage Fig 5 1 Dimensions stated in mm 103 4 06 87 5 3 45 142 5 59 18 5 0 73...

Page 61: ...n slot 3 of the servo amplifier When in stalling please note the guidelines given under Installation in the op erating manual for the servo amplifier 1 Remove the film 2 Break the middle link 3 Break...

Page 62: ...5 Installation 5 4...

Page 63: ...to switch off the load Possible remedy Exclude the error by using separate multicore ca ble for supply voltages Use appropriate wiring to exclude short circuits between the outputs Signal lines must b...

Page 64: ...0 24 V Supply Supply voltage for digital outputs 24 VDC 11 Encoder Supply Supply voltage for external encoder 12 SSR Activate Activate safety function SSR 13 SDI Neg Activate Activate safety function...

Page 65: ...d to the connector housings The shields for the digital inputs and outputs should be connected to the front of the servo amplifier as shown in the diagram below Verdr_Schirm_Front Remove the outer cab...

Page 66: ...Neg Activate Activate safety function SDI anti clockwise 14 SDI Pos Activate Activate safety function SDI clockwise 15 SBT Activate Activate safety function SBT 20 SS1 SIL3 Reset Input for SIL3 and r...

Page 67: ...ge Failure 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 pin assignment Connector X30 Pin Name Description 10 24 V Suppl...

Page 68: ...s SSR or SLS activated 9 SBT Acknowledge Status Brake test 10 24 V Supply Supply voltage for digital outputs 24 V 16 Ready Status Safety card ready for operation 19 STO SIL3 Second shutdown route 21 0...

Page 69: ...Verdr_DO_Belegung_SBC Verdr_DO_Anschluss_SBC Connection Output circuit Digital output 24 VDC Referenced to earth 0V Supply INFORMATION If the STO SIL3 output is not used 24 VDC must be applied to the...

Page 70: ...tego D 48 D 72 X4 Pin 3 Connection External mechanical brake Digital output Shielded cable Max cable length 30 m Brake s supply voltage 24 VDC tolerance 0 15 Please note the following Link X30 Pin 21...

Page 71: ...05 2006 EN 61558 2 6 11 1997 Connector pin assignment Connector X30 Pin Name Description 11 Encoder Supply Supply voltage for external encoder 22 0 V Encoder Supply Supply voltage for external encode...

Page 72: ...ent Connector X31 Pin Name Description 1 A Channel A 2 B Channel B 3 Z Reference pulse Z 4 V Supply voltage 5 n c 6 A Channel A inverted 7 B Channel B inverted 8 Z Reference pulse Z inverted 9 0 V Sup...

Page 73: ...afety card please read the safety guide lines in the Commissioning chapter in the instructions for the servo amplifier Verdr_nie_unter_Spg_2 Inbetrieb_Start_Warnung_Pilz DANGER Risk of electrocution N...

Page 74: ...tor The servo amplifier is ready for commissioning see operating manual for the servo amplifier 2 Wire up the safety card Connect the 24 VDC supply voltage to X30 10 to X30 21 Wire up the inputs and o...

Page 75: ...erface To perform the download you will need to enter the safety cards order and serial numbers for identification purposes On multi axis systems the safety cards can be selected individually for the...

Page 76: ...aded RUN LED System is ready RUN System is ready for operation CONFIG Downloading the configuration data STARTUP System starts up with the downloaded configuration The inputs and outputs on the safety...

Page 77: ...plifier and safety card at a restart The safety card has already been configured see Initial commissioning Inbetrieb_Neustart_S1 Servo Amplifier 24 V X4 1 BTB RTO X3B 14 15 L1 L2 L3 X0 X8 Safety Card...

Page 78: ...ess STO Acknowledge Status STO activated t3 Safety card s run up time 7 3 2 Recommissioning after error Recommissioning after error 7 Inbetrieb_Wiederinbetrieb_nach_Fehler This section describes the r...

Page 79: ...tart_CLRFAULT_S1 The safety card can be reset using the CLRFAULT command via the serial interface or fieldbus interface on the servo amplifier Prerequisites for using the CLRFAULT command The safety c...

Page 80: ...y card following a defect for example you will need to download the configuration data to the safety card again You can download the configuration data to the safety card as follows From the Configura...

Page 81: ...configuration from the Configurator directly to safety card 1 Downloading a configuration via an SD card which is written by the PC Inserting an SD card into the read device of the servo amplifier for...

Page 82: ...Remove the SD card from the external SD card read device and in sert it into the servo amplifier s SD card read device continue as described under Download configuration from SD card to safe ty card 2...

Page 83: ...d or default pdis Configuration file for the safety card default bin or default s19 Firmware for the servo amplifier default par Parameter file for the servo amplifier INFORMATION Further information...

Page 84: ...to 100 stops at 100 and then counts from 100 to 0 The servo amplifier is restarted The parameter file default par is loaded The safety card is restarted The CONFIG LED flashes 7 Wait until dis drive i...

Page 85: ...port must be signed Regular checks Check the safety functions at regular intervals The aim of these regular checks is to uncover any changes to the plant machine safety functions and ambient condition...

Page 86: ...7 Commissioning 7 14...

Page 87: ...are Commissioning is complete The safety card contains the configuration data The safety functions have been tested The RUN LED is lit During operation Any pulse edge change at the safety card s safe...

Page 88: ...the CONFIG operating state STO is active NORMAL OPERATION No safety function activated Transition to state of STO Internal error Transition to SAFE OPERATION A safety function is activated SAFE OPERAT...

Page 89: ...function SS1 Transition to STO After activation of SS1 drive is brought to a stand still with a defined braking ramp STO There is no power to the motor after execution of safety function STO Transiti...

Page 90: ...st the safe pulse disabler proceed as follows Betrieb_Neustart_S1 1 Switch input SS1 Activate or SS1 SIL3 Reset to 0 V The safety card performs the safety function SS1 Safe Stop 1 and switches to a ST...

Page 91: ...ing states Legend LED Meaning Name Colour Status POWER Supply voltage is not present Green Supply voltage is present RUN System not ready Green System read RUN status Green System boots Startup sta tu...

Page 92: ...this chapter Outputs on the safety card display the state of the safety functions e g STO Acknowledge Errors and messages are entered in the safety card s error stack The following are displayed in o...

Page 93: ...0 50 A Monitoring threshold of semiconductor output 7 0 V Permitted current range 0 50 A Residual current at 0 signal 0 02 mA Max duration of on time during self test 200 s Max duration of off time d...

Page 94: ...aximum threshold frequency 0 5 MHz Environmental data Climatic suitability EN 60068 2 14 EN 60068 2 1 EN 60068 2 2 EN 60068 2 30 EN 60068 2 78 Ambient temperature in accordance withDIN EN 60721 3 3 0...

Page 95: ...tego S The safety related characteristic data is valid for all safety functions Si_Kennzahlen_Erl uterung_1 All the units used within a safety function must be considered when cal culating the safety...

Page 96: ...ctuator with two encoders 9 SI_Kennzahlen_protego S_zwei_Geber SI_Kennzahlen_protego S1_zwei_Geber The safety analysis of the plant or machine may necessitate a second encoder external encoder Example...

Page 97: ...tic data is valid for all safety functions Si_Kennzahlen_Erl uterung_1 All the units used within a safety function must be considered when cal culating the safety characteristic data Subsystem Safe ac...

Page 98: ...9 Technical Details 9 6...

Page 99: ...function in accordance with EN 61800 5 2 monitors the stop posi tion that has been reached and keeps this position within a defined range SOS is the abbreviation for safe operating stop SS1 Safe stop...

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