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schmersal PSC1-C-10 Series, Installation Manual

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schmersal PSC1-C-10 Series Installation Manual Download Page 149

Installation manual  

 

 

PSC1-C-10 Installation manual V2.6 

 

Page 149 of 173 

Version: 57E 

12.3

 

Steps required for designing, realisation and testing 

The realisation of parts of systems with a safety-related function requires particular care during 
planning, realisation and testing. Guidelines on these issues are also given in the applicable standards 
(cf. EN ISO 13849-2 or EN ISO 61508). The effort here depends on the complexity of the task for parts 
of the system with a safety-related function.  
For the realisation of such functions with the aid of safety-related control and monitoring functions, 
the PSC1 series offers efficient support in the form of the system architecture (architecture cat. 4 
according to EN ISO 13849-1) and above all also the programming language and tested safety 
functions. Programming is in the form of FUP (function plan-orientated programming) as 
recommended in the safety standards. It also corresponds to the requirements on a limited variability 
programming language (LVL) for which significant simplifications in the documentation and test scope 
apply. 
In any case the individual steps require careful planning and analysis of the methods and systems used. 
The individual steps are also to be documented so they are clearly traceable. 

V model (simplified): 

The implementation of safety-related functions requires a structured procedure as is shown, for 
example, in the V model recommended in applicable standards. In the following as an example the 
procedure for applications with modules from the PSC1 series is shown. 
 

     

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 

Hardware durch Analyse 

Anlagenaufbau / 

Komponenten /Schaltung

Prüfung der Umsetzung 
Software durch Analyse 

FUP

Prüfung der korrekten 

Programmierung und 

Parametrierung durch 

Analyse Validierungsreport

Prüfung des funktionalen 

Sicherheitssystems durch 

FIT (Fault Injection Test) 

Gesamtvalidierung der 

Sicherheitsmaßnahmen

Funktionales Sicherheitssystem

Spezifikation und Prüfung 

Funktionales Sicherheitssystem

Spezifikation und Prüfung 

der Software

Spezifikation und Prüfung 

der Hardware incl. Nachweis Pl

Realisierung

Spezifikation und Validierung 

aller Sicherheitsmaßnahmen

 

 

 

Summary of Contents for PSC1-C-10 Series

Page 1: ...Installation manual for PSC1 modules Series PSC1 C 10 PSC1 C 10 SDMx PSC1 E 3x...

Page 2: ...iversal communication interface 3 in preparation Note The German version is the original version of the installation instructions As of 05 2021 Valid from firmware release 5 0 0 1 Subject to technical...

Page 3: ...dded Reference to protective circuit for contactors etc Additional reference to derating in Chap 4 3 4 Note on the use of the read back contacts on the PSC1 E 1 33 module V 2 2 May 2020 Programming ex...

Page 4: ...ety related characteristic data and circuitry for sensors connected 38 4 2 1 Digital sensors 38 4 2 1 1 Characteristics of the sensors input elements 38 4 2 1 2 DC digital sensors inputs 39 4 2 1 3 Cl...

Page 5: ...onnection of the external encoder supply 105 5 8 1 Incremental SIN COS SSI 105 5 9 Connection of the digital inputs 106 5 10 Connection of position and speed sensors 107 5 10 1 General instructions 10...

Page 6: ...ts breakdown 151 12 3 3 Specification of the functional safety system 154 12 3 3 1 Definition of the safety functions 154 12 3 3 2 Performance Level required PLr additional emergency stop 154 12 3 3 3...

Page 7: ...Make sure that those responsible for planning and integration system and operation as well as persons who work independently with the modules have read and understood the documentation completely The...

Page 8: ...achinery directive 2006 42 EC for product modules PSC1 C 10 PSC1 C 10 MC 1 PSC1 C 10 FBx 2 PSC1 C 10 SDM1 PSC1 C 10 SDM1 MC 1 PSC1 C 10 SDM1 FBx 2 PSC1 C 10 SDM2 PSC1 C 10 SDM2 MC 1 PSC1 C 10 SDM2 FBx...

Page 9: ...rm Encoder Position measuring system position angle Encoder interfaces Electrical connection feature for an individual encoder rotary encoder or proximity switch FW Firmware software embedded in elect...

Page 10: ...us connector backplane bus PELV Protective Extra Low Voltage PLC Programmable Logic Controller SD bus Serial diagnostic bus for electronic Schmersal safety switches SDDC in preparation Safe Device Dev...

Page 11: ...for providing safety functions according to EN 61800 5 2 As a logic unit for signal conversion and signal processing in a two hand circuit according to EN ISO 13851 The devices in series PSC1 C 10 and...

Page 12: ...ng i e commencing operated as intended is only allowed on compliance with the EMC directive The EMC test standards EN55011 2007 A2 2007 and EN 61000 6 2 2005 are used as the basis For storage and tran...

Page 13: ...there is no electrical power present on the wires During the installation and removal of the module appropriate measures are to be taken to prevent electrostatic discharges on the external terminals a...

Page 14: ...functions For the safety related signal processing pre configured blocks are available for a large number of input devices The same applies for safety functions for drive monitoring You will find det...

Page 15: ...pn switching pp switching 2 4 2 4 2 4 2 4 Safe analogue inputs Relay outputs 1 channel 2 2 2 4 2 Signal outputs 2 2 2 2 2 2 Pulse outputs 2 2 2 2 2 2 Integrated communication interface FB1 EtherNet I...

Page 16: ...safe digital outputs o Max 20 safe digital I O o Max 5 safe relay outputs 2 channel o Max 6 signal outputs Logic processing up to PL e according to EN ISO 13849 1 or SIL 3 according to EN 61508 Freel...

Page 17: ...ntroller o Safe cross communication for the exchange of data between several basic devices o Safe remote IO communication for the exchange of data with distributed IO systems 3 o Serial diagnostic bus...

Page 18: ...is monitoring Encoder interfaces D Sub screw terminal Encoder technology See table Encoder specifications Electrical data Supply voltage tolerance 24 VDC 2A 15 20 Fuse A1 1 min 30 VDC max 3 15A A1 2 m...

Page 19: ...equipment 2000m Overvoltage category III Level of contamination 2 Mechanical data Size HxDxW mm PSC1 C 10 100x115x45 PSC1 C 10 FBx 1 MC 100x115x67 5 Weight PSC1 C 10 300 g PSC1 C 10 FBx 1 MC 400 g Att...

Page 20: ...2 safe digital outputs o Max 20 safe digital I O o Max 5 safe relay outputs 2 channel o Max 6 signal outputs o Max 1 safe axis Logic processing up to PL e EN ISO 13849 1 or SIL 3 as per EN 61508 Movem...

Page 21: ...ed status indication via 7 segment display and status LEDs on front Multi function button Quit Start Reset can be operated from the front Optional Universal communication interface o Standard and safe...

Page 22: ...logic PSC1 C 10 SDM1 3 1W PSC1 C 10 SDM1 FBx 1 6 5W Rated data digital inputs 24 VDC 20 mA type 1 according to EN61131 2 Rated data digital outputs pn switching 24 VDC 2A pp switching 24 VDC 2A Signal...

Page 23: ...ncluded in the items supplied PSC1 C 10 SDM1 2 PSC1 C 10 SDM1 FBx 1 MC 3 Min connection cross section AWG 0 2 mm 24 Max connection cross section AWG 2 5 mm 12 Options Maximum 2 encoders axis pn pp can...

Page 24: ...fe digital outputs o Max 20 safe digital I O o Max 5 safe relay outputs 2 channel o Max 6 signal outputs o Max 2 safe axes Logic processing up to PL e EN ISO 13849 1 or SIL 3 as per EN 61508 Movement...

Page 25: ...onal Universal communication interface o Standard and safe fieldbus protocols for communication with a higher level controller o Safe cross communication SMMC for the exchange of data between several...

Page 26: ...10A Max power consumption logic PSC1 C 10 SDM2 3 1W PSC1 C 10 SDM2 FBx 1 6 7W Rated data digital inputs 24 VDC 20 mA type 1 according to EN61131 2 Rated data digital outputs pn switching 24 VDC 2A pp...

Page 27: ...l Number of T bus connector Included in the items supplied PSC1 C 10 SDM2 3 PSC1 C 10 SDM2 FBx 1 MC 4 Min connection cross section AWG 0 2 mm 24 Max connection cross section AWG 2 5 mm 12 Options Maxi...

Page 28: ...for relay outputs 10 6 status LEDs for I O Properties of the module 12 safe inputs OSSD support 10 safe I O can be configured as input or output o PSC1 E 33 with a total of 4 relay outputs 1 channel a...

Page 29: ...al data Supply voltage tolerance 24 VDC 2A 15 20 Fuse A1 1 30 VDC 10 A Max power consumption logic 7 1 W Rated data digital inputs 24 VDC 20 mA type 1 according to EN61131 2 Rated data digital outputs...

Page 30: ...Number of T bus connector Included in the items supplied PSC1 E 31 2 PSC1 E 33 3 Min connection cross section AWG 0 2 mm 24 Max connection cross section AWG 2 5 mm 12 Options Derating see section Der...

Page 31: ...related user program FB2 Decentral SDDC 1 and SMMC interface 2x RJ 45 Communication interface for decentral slave and master modules Fieldbus interface Sub D Standard and secure fieldbus Memory Card...

Page 32: ...0 50 C operating temp 25C 70C storage transport Degree of protection IP 20 Climatic class 3k3 according to DIN 60721 3 EMC Corresponding to EN 55011 and EN 61000 6 2 Mechanical data Size HxDxW mm 100...

Page 33: ...length 12 28 Bit Data format binary Gray code Physical Layer RS 422 compatible SSI Master Frequency 150 kHz SSI Listener Slave Frequency X1 X2 X3 X4 250 kHz 350 kHz Min pause time 150 s Max pause time...

Page 34: ...the following information 3 4 1 Type plate Type designation Part number item number Serial number Hardware release identifier Software release identifier Safety category Properties of the power suppl...

Page 35: ...signal terminals not including encoder connection Not included in the items supplied Programming adapter order designation PSC1 A 90 PROG CABLE SafePLC2 software package order designation PSC1 A 91 SA...

Page 36: ...on of the layout corresponds to category 4 in EN ISO 13849 1 IA OA LA IB OB LB m m i i c im im PES Aktuator SA SB The overall architecture therefore has the following layout Sensor PES Aktuator Double...

Page 37: ...r a safety function e g safely limited speed with access door open these are to be considered as connected in series for the safety related assessment of the overall system On this topic see example c...

Page 38: ...LB m m i i c im im Sensor PES Aktuator SA SB Dual channel input element in parallel circuit cat 4 fault tolerance 1 with high DC due to signal processing in two channels and diagnostics using cross co...

Page 39: ...efined threshold is dropped below a module alarm is triggered Diagnostic functions that can be activated by configuring parameters Cross circuit test The PSC1 modules have pulse signal outputs on whic...

Page 40: ...g actuation of the emergency stop button or a door lock after system start Operative organisational tests Beyond the diagnostic measures on the PSC1 modules stated above cyclic testing can be underta...

Page 41: ...90 test only at intervals 4 weeks DC 99 test at least 1 x day or 100 times demand rate Dual channel 90 Cross monitoring of input signals with dynamic test if short circuits are not detectable for mult...

Page 42: ...ues stated in the table are to be used conservatively and compliance with the boundary conditions see Comments in table ensured Fault exclusions are allowed according to the applicable standards The b...

Page 43: ...h without pulses achievable PL dependent on MTTFd of the input element as well as fault exclusions in the external cabling I04 I07 PL e Single channel with pulses Predominantly high level required THi...

Page 44: ...PL Digital inputs Achievable Performance Level Remark IQIx Without pulse single channel static signal Signal input PL e Without pulse dual channel static signal At least one demand day due to applica...

Page 45: ...re quickly e g I00 4 2 1 4 1 Single channel sensor without cross circuit testing I00 I01 I02 I03 T0 T1 L L X14 X12 Single channel sensor without cross circuit testing The single channel sensor is conn...

Page 46: ...l dual channel shutdown On the usage of a suitable switching element and careful wiring of the sensor PL d according to EN ISO 13849 1 can be achieved In special cases i e in conjunction with suitable...

Page 47: ...nsors switching elements with fault exclusion for the failure of the switching contacts to open This exclusion is allowed on the usage of positively opening switches with correct positive actuation It...

Page 48: ...opening contacts or positive actuation according to EN 60947 5 1 When using sensors with no positive break contacts the Universal Input Module macro group must be used in SafePLC2 The usage of devices...

Page 49: ...to However with actuation via a common actuating device in conjunction with a fault exclusion for this device I00 I01 I02 I03 T0 T1 X14 L L T1 T0 X12 Homogeneous dual channel sensor with test pulses S...

Page 50: ...t signal wire Input element corresponds at least to Plr Connection in the switch cabinet or protected laying All X d Stuck Short circuit on the input signal wire Predominantly high level required THig...

Page 51: ...t Cyclic test in operation Dual channel serial I00 I04 I08 I13 d Short circuit on the input signal wire Stuck positive opening Connection in the switch cabinet or protected laying MTTFd medium O O e S...

Page 52: ...der combination The safety assessment for the related sub system is as follows IA OA LA IB OB LB m m i i c im im Sensor PES Aktuator SensorA SensorB Dual channel sensor system with separate signal pro...

Page 53: ...e dual channel sub system for single channel sensors incremental encoders Diagnostics for the single and dual channel sub system comprising specially suited sensor systems SIN COS encoders Dynamic ope...

Page 54: ...C X Mech Encoder mounting Code disc mounting 60 99 80 90 Incremental Incremental X X n a 99 95 Incremental 1 x Proxy X n a 99 90 95 Incremental 2 x Counter Proxy 90 X X n a 99 90 95 Incremental SIN CO...

Page 55: ...ion to the desired level of safety comprehensible evidence must be provided in any case e g oversizing with a form fitting shaft hub connection The corresponding information on fault exclusion in the...

Page 56: ...ring Monitoring of the permissible quadrants Monitoring of the count signal separately for track A B Monitoring of the reference signal measured signal transmission ratio Reference signal frequency mo...

Page 57: ...B Diagnostic functions are available in the SCOPE dialogue box in the parameter configuration tool to determine the optimal parameter values for the application Note Speed and acceleration are acquire...

Page 58: ...anual V2 6 Page 58 of 173 Version 57E Graph of acceleration resolution rotary values in rev min s Graph of acceleration resolution linear values in mm s and m s Resolution Resolution Value Value Accel...

Page 59: ...fic diagnostic measures for position and speed sensors in relation to the specific encoders If in doubt clarification by the manufacturer is required The DC values stated in the table are to be used c...

Page 60: ...nimum to the level required Safety instructions The usage of standard encoders or a combination of standard encoders is permissible A safety related assessment is required for the overall arrangement...

Page 61: ...Short circuits between the safety related signal wires Open circuit in the safety related signal wires Stuck at 0 or 1 on one or all safety related signal wires Further specific diagnostics for the d...

Page 62: ...m im PES Aktuator K1 Single channel output PSC1 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 PSC1 and single channel actuator...

Page 63: ...SC1 with internal dual channel processing IQQx and dual channel actuator with dual channel diagnostics IA OA LA IB OB LB m m i i c im im PES Aktuator K1 K2 Dual channel output PSC1 and dual channel ac...

Page 64: ...th DC high Testing the shutdown capability for Q4 and Q5 only operation of the relay Q0 Q1 Q2 Q3 The shutdown capability of these outputs is tested cyclically The failure of the ability to shut down i...

Page 65: ...of safety circuits with elements for increasing the switching rating or pneumatic hydraulic control valves in conjunction with readback function for their switching status Cross comparison of output s...

Page 66: ...elay If the permissible voltage has still not been reached after 400 s an alarm is triggered and all safe outputs second channel for safe outputs are deactivated The illustration shows below the ideal...

Page 67: ...orresponding to architecture category 4 according to EN ISO 13849 1 Q2_P Not safe Only functional Q3_N Not safe Only functional Q0 Q3 4 Complete shutdown channel corresponding to architecture category...

Page 68: ...le INCORRECT 230 V AC 120 VAC cULus are switched via Q4 1 Q4 2 and 24 V DC are switched via Q5 1 Q5 2 CORRECT 230 V AC 120 VAC cULus are switched via Q4 1 Q4 2 and Q5 1 Q5 2 or 24 V DC are switched vi...

Page 69: ...ired external contactors can be used With single channel connection without external testing it is to be noted that sticking of one or more external contacts will not be detected by the PSC1 C 10 x mo...

Page 70: ...device must immediately make clear the hazardous situation to the operator The achievable PL is heavily dependent on the test rate a maximum of PL d according to EN ISO 13849 1 can be achieved Q0_P X2...

Page 71: ...ce for testing the complete chain and a signaling warning device on the detection of a fault are required to achieve PL c or higher see comments in 4 3 4 2 2 Q0_P X21 X12 Q1_N Q2_P Q3_N NC NC Y0 Y1 X1...

Page 72: ...ring on two inputs Safety instructions Only recommended to a limited extent for safety applications On this topic see also the information in EN ISO 13849 1 on usage and the fault exclusions necessary...

Page 73: ...with external monitoring collective feedback The two external monitoring contacts are connected in series supplied with pulse signal T0 and read by I00 configured as EMU input With increased requireme...

Page 74: ...circuit are required for PL e according to EN ISO 13849 1 Q0_P X21 X12 Q1_N Q2_P Q3_N Q4 1 Q4 2 Q5 1 Q5 2 X22 I12 I13 T0 T1 P N L L Dual channel output with relay output and semiconductor output exter...

Page 75: ...semiconductor outputs PL e is required for the external circuit for PL e according to EN ISO 13849 1 STO Pl e Q0_P X21 Q1_N Q2_P Q3_N Dual channel output with semiconductor output and external control...

Page 76: ...as an output Classification Achievable PL according to EN ISO 13849 1 Remark Static single channel 2 PL c Fault detection and fault reaction as per sec 2 Static dual channel 2 PL d Same group1 Operati...

Page 77: ...with an external single channel circuit without external testing it is to be noted that sticking of one or more external contacts will not be detected by the PSC1 C 10 x module The example circuit in...

Page 78: ...X13 IQI00 IQQ01 T0 T1 L L Dual channel output with single channel circuit with testing Safety instructions Only recommended to a limited extent for safety applications On this topic see also the infor...

Page 79: ...d shutdown 4 3 5 2 4 Circuit in conjunction with dual channel shutdown circuit Suitable for PL d or higher according to EN ISO 13849 1 Usage of one output IQQx in conjunction with a dual channel exter...

Page 80: ...or higher according to EN ISO 13849 1 Usage of two outputs IQQx in conjunction with a dual channel external circuit 4 3 5 2 5 1 Dual channel circuit in same group IQQ00 X12 X21 IQQ01 T0 T1 L L IQQ02 I...

Page 81: ...dary conditions see Comments in table ensured Fault exclusions are allowed according to the applicable standards The boundary conditions listed are to be ensured over the long term On the usage of ele...

Page 82: ...alve brake etc with direct feedback for diagnostics in at least one channel or Actuator operated with single channel with safety function cat 3 e g STO Cat 2 90 Monitorin g only in one external shutdo...

Page 83: ...erent groups groups of 6 4 contiguous IQQ ports e g IQQ0 5 IQQ6 9 or Operation delayed at PLC level Short circuit on external operation Dual channel Q0 Q1 Q2 Q3 or Dual channel with dynamic output tes...

Page 84: ...ength of the cables for the digital inputs and outputs should in general not exceed 30 m If the cable length exceeds a value of 30 m suitable measures are to be taken to exclude inadmissible overvolta...

Page 85: ...d The screen at the sensor end must be laid according to customary methods Attention is to be paid to the correct installation in relation to EMC of the power converter technology in the area of the P...

Page 86: ...ion modules is permitted A free space of 20 mm must be maintained to adjacent devices that can generate waste heat 5 3 Mounting backplane bus The backplane bus comprises a 5 pin connector with spring...

Page 87: ...C1 C 10 Installation manual V2 6 Page 87 of 173 Version 57E 5 3 1 Arrangement examples 5 3 1 1 PSC1 C 10 SDM1 PSC1 E 31 PSC1 E 33 5 3 1 2 PSC1 C 10 SDM2 PSC1 E 33 PSC1 E 33 PSC1 E 31 PSC1 C 10 SDM1 PS...

Page 88: ...modules are mounted on standard C rails using a snap action catch 5 4 1 Mounting on C rail The devices are fitted to the rail from above at an angle and snapped downward They are removed using a screw...

Page 89: ...this purpose the module is fitted to the connector at an angle from above and snapped to the C rail Fit module at an angle from above and snap down onto the C rail The backplane connection can later b...

Page 90: ...evice 5 4 3 1 Physical address configuration for the slave modules The bus address must be set on the PSC1 E 3x modules by means of the address switch The address is set on the rear panel depending on...

Page 91: ...his principle of operation an incomplete or disconnected network can operate in sections without changing the configuration To be able to co ordinate several masters with different cycle times a SMMC...

Page 92: ...ules must be directly connected to the associated master If switches are used they should be used solely for the SDDC or SMMC signals Due to the short cycle time of the SMMC SDDC communication it is a...

Page 93: ...unication of a PSC1 C 10 with Central expansion modules via SDDC backplane bus SMMC Ethernet 2 Communication of a PSC1 C 100 with Central expansion modules via SDDC backplane bus SMMC Ethernet 3 Commu...

Page 94: ...6 Terminal assignment Attention Identifiers for Xxy terminal blocks e g X11 are not printed on the terminal blocks They are used in this Section to find the individual terminals more quickly e g A1 1...

Page 95: ...upply 0 VDC 4 A2 2 X12 1 I 12 Safe digital inputs 2 I 13 3 Y0 Signal outputs 4 Y1 X21 1 Q0 Output pn switching Q0_PP pp switching Q0 optionally can be configured in the parameters via SafePLC2 2 Q1 Ou...

Page 96: ...REL X11 1 A1 1 Device power supply 24 VDC 2 A1 2 Device power supply 24 VDC outputs 3 A2 1 Device power supply 0 VDC 4 A2 2 X12 1 I 12 Safe digital inputs 2 I 13 3 Y0 Signal outputs 4 Y1 X21 1 Q0 Out...

Page 97: ...X24 4 4 I12 I13 Y0 Y1 Q4 1 Q4 2 Q5 1 Q5 2 Q0 Q1 Q2 Q3 REL A1 1 A1 2 A2 1 A2 2 Option FB1 FB2 X99 Terminal assignment Unit Terminal Pin Description Note REL X11 1 A1 1 Device power supply 24 VDC 2 A1 2...

Page 98: ...Installation manual PSC1 C 10 Installation manual V2 6 Page 98 of 173 Version 57E 2 I 09 3 I 10 4 I 11...

Page 99: ...ction X25 1 NC No function 2 NC No function 3 NC No function 4 NC No function X26 1 NC No function 2 NC No function 3 NC No function 4 NC No function Option FB1 FB 2 X99 1 A1 3 Power supply SD Bus 24...

Page 100: ...inal Pin Description Note IO X11 1 A1 1 Device power supply 24 V DC Attention see External 24 VDC power supply 2 A1 2 Device power supply 24 V DC 3 A2 1 Device power supply 0V DC 4 A2 2 X12 1 IQ 00 Sa...

Page 101: ...T0 T1 I09 I10 I11 I04 I05 I06 I07 CPU I08 1 1 X23 X24 4 4 Note If the relays are used for safety tasks the readback signals must be monitored because the module does not recognize a sticking of the i...

Page 102: ...1 Safe relay output 3 1 channel 2 Q2 2 3 Q3 1 Safe relay output 4 1 channel 4 Q3 2 IO X11 1 A1 1 Device power supply 24 V DC Attention see External 24 VDC power supply 2 A1 2 Device power supply 24 V...

Page 103: ...nically regulated unit is recommended The power supply unit must satisfy the requirements according to EN 61000 4 11 voltage drop The connection cable must be designed according to the local regulatio...

Page 104: ...C connection is not connected internally to GND 1 1 4 4 1 1 4 4 A1 1 UE1 UE1 NC NC I09 I10 I11 I08 X1 1 1 4 4 I00 I01 I02 I03 I04 I05 I06 I07 1 1 4 4 UE2 UE2 NC NC H2B H3B NC H1B X2 1 1 4 4 NC NC NC N...

Page 105: ...der is connected to the GND of the PSC1 If the GND of the encoder is only at pin 2 of the D sub connector the terminal UE must also be connected to GND see also chapter 5 7 Above that the supply volta...

Page 106: ...e pulse outputs are only intended to be used for monitoring the digital inputs I0 I13 and cannot be used for any other functions in the application o The switching frequency is 125 Hz for each pulse o...

Page 107: ...voltage is not fed back via the encoder connector the failure of this supply is to be included in the fault analysis for the overall system In particular it is therefore necessary to demonstrate that...

Page 108: ...al transmission for the data and clock signals or track A and track B On the selection of the cross section of the wire the current consumption of the encoder and the cable length in the installation...

Page 109: ...PSC1 C 10 Installation manual V2 6 Page 109 of 173 Version 57E 5 10 2 Encoder interface assignment X1 X21 Options 1 only PSC1 C 10 SDM2 Note Pins marked as n c are reserved for later expansion and mus...

Page 110: ...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 connection the clock signals pass from th...

Page 111: ...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 the clock signals and the data are re...

Page 112: ...0 3 3 Connection of an incremental encoder with TTL signal level Pins 1 3 and 7 are reserved for later expansion and must remain open Sub D Stecker 9 polig SMX Inkremental Encoder n c Ground n c B A A...

Page 113: ...Connection 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 are...

Page 114: ...only Connection is via the connector X23 to the digital inputs I04 I07 The exact pin assignment is dependent on which encoder type is used and is given in the connection diagram in the programming sof...

Page 115: ...EN ISO 13849 2 in some circumstances sensor systems with a simple layout only speed monitoring may be adequate On this topic see APPENDIX 1 Note Further configuration is described in the programming m...

Page 116: ...4 N 3 N 2 N 1 N 0 Clk ClkN Status 2 Status 0 Status 3 Result 2 Result 3 Result 0 Result 1 Example SSI Frame length 28 pulses Data length 22 bits Status 5 bits 3 bits error 2 bits warning ready for ope...

Page 117: ...4 increments 5 12 3 SinCos encoder standard mode Physical layer 0 5 Vpp without voltage offset Measured signal A B Track with 90 degree phase difference Maximum input pulse frequency 200 kHz Diagnosti...

Page 118: ...ition the following parameters must be met Max blanking 0 signal 50 Min overlap 10 The easiest way to achieve this is to use a 2 1 division This also simplifies the correct assembly of the associated...

Page 119: ...imes are to be defined for each safety function in the required behaviour and compared against the actual value with the aid of the following information Particular care is required on the usage of fi...

Page 120: ...ic implemented this results e g in the switching of an output Response of an already activated monitoring function including PLC processing for position and speed processing via safety relay 39 If a m...

Page 121: ...response times can be stated 4 ms worst case condition Safety instructions On the usage of the FAST_CHANNEL it is to be noted that a shutdown in the time stated above for a specified speed threshold...

Page 122: ...ant for all t Filter value configured XF constant for all t Maximum possible acceleration for the application aF constant for all t Delay after shutdown aV constant for all t Sampling point for occurr...

Page 123: ...1 VS aF tResp For the V and s curves with overspeed distance the following applies Parameter Acceleration method Remark tResp Value from PSC1 response time data delay in external shutdown chain Delay...

Page 124: ...lanation Worst case delay input in the basic module to the PAE TIN_BASE 10 E g activation of a monitoring function by an input signal in the basic module Worst case delay input PSC1 E 31 to the PAE in...

Page 125: ...and processing in PLC output on basic module TTOTAL TIN_31 TPLC TOUT_Base 18 ms 8 ms 0 ms 26 ms Example 2 Input on basic module activation of SLS and processing in PLC output on expansion module TTOT...

Page 126: ...istribution of the configuration firmware data and further checking of these data Subsequent range calculation for the configuration data 3 STARTUP BUS If present initialisation of a bus system 4 RUN...

Page 127: ...n or an input configured accordingly start reset element with activated alarm reset or logic reset function The following table provides an overview on the reset functions and their effect 7 3 1 Reset...

Page 128: ...As the start reset element is configured here as a logic reset and connected as an element to a flip flop element the flip flop is reset at high signal The status of the monitoring functions is forme...

Page 129: ...3 sec Q I1 AND I2 Time based function reset the output status triggering if limit exceeded again Safety instructions For time based functions e g monitoring of the timing of complementary input signa...

Page 130: ...is realised by a Safety door function 2 channel with time monitoring and an Enable function The Safety door logic signal is generated using input pre processing with complementary inputs and time moni...

Page 131: ...n the PLC program the activation of the outputs while bypassing the alarm state for this time is prevented Example 1 The enable function for the outputs AND function is also linked to a reset timer Th...

Page 132: ...E Example 2 The enable function for the outputs AND function is also linked to FF This operator prevents the activation of the outputs after a reset if there is a fault present in the input circuit Th...

Page 133: ...validated Red Flashing Alarm Red Continuous Fatal error Yellow red Flashing System OK configuration not validated SMMC configured but device Green red Flashing System OK configuration validated SMMC...

Page 134: ...rst be created in the root directory on the memory card and the files then stored here In addition the files must be renamed according to the following table Project Configuration Sampleproject cfg2 c...

Page 135: ...er of a configuration must then be carried out via a direct connection with the SafePLC2 programming software 7 6 Function test To ensure the safety of the module a functional test of the safety funct...

Page 136: ...General information on the installation can be provided on the first two pages On the pages of the validation report that follow all functions used and their parameters are printed out as itemised ev...

Page 137: ...of a module On the replacement of a module the following should be noted Disconnect power converter from the main supply Switch off power supply for the device and disconnect Disconnect encoder connec...

Page 138: ...000m 10 2 Safety related characteristic data Max achievable safety class SIL 3 as per EN61508 Category 4 as per EN945 1 Performance Level e as per EN ISO 13849 1 System structure 2 channel with diagno...

Page 139: ...ontact ffner Ausgang 2 sSwitch_1s S A 0 0 1 1 Normally open contact like type 1 Schlie er Ausgang 3 eSwitch_2o NC1 NC2 A 0 0 0 1 0 0 0 1 0 1 1 1 AND operation both inputs ffner 2 Ausgang ffner 1 4 t e...

Page 140: ...Installation manual PSC1 C 10 Installation manual V2 6 Page 140 of 173 Version 57E...

Page 141: ...t eSwitch_1s1oT S NC A 0 0 0 1 0 0 0 1 1 1 1 0 Time monitoring Like 5 however with time monitoring of state changes On signal change on one of the NC complementary signal must follow within time t 3...

Page 142: ...1 0 0 1 0 Time monitoring Like 7 however with time monitoring of state changes On signal change on NO attention common wire or NC complementary signal must follow within time t 3 s If not change to fa...

Page 143: ...h_3oT NC1 NC2 NC 3 A 0 0 0 0 1 0 0 0 0 1 0 0 1 1 0 0 1 1 1 1 Time monitoring Like 8 however with time monitoring of state changes On signal change on one of the NC inputs the other inputs must follow...

Page 144: ...signals i e further NO 0 or NC 1 must follow within 0 5 s If not the output remains 0 No malfunction evaluation No time monitoring on change to inactive state ffner 2 Ausgang ffner 1 max 0 5 s 12 eTw...

Page 145: ...ector switch Unambiguous operator for the permissible switch positions Schlie er Ausgang ffner 14 eMode_3switch NO 1 N O2 S3 O 1 O 2 O 3 1 0 0 1 0 0 0 1 0 0 1 0 0 0 1 0 0 1 1 1 0 0 0 0 1 0 1 0 0 0 0 1...

Page 146: ...iple the manufacturer of a machine must ensure the machine designed and supplied is safe The related applicable directives and standards are to be used for the assessment The goal of the safety assess...

Page 147: ...rcely possible high acceleration in event of a fault Risk assessment according to EN ISO 61508 a 1 2 3 4 b W3 a 1 2 3 4 W2 a 1 2 3 W1 keine Sicherheitsanforderung a Keine speziellen Sicherheitsanforde...

Page 148: ...ndards EN 14121 Safety of machinery Risk assessment EN 12100 Safety of machinery General principles for design Measures that are applied to reduce the hazards identified must correspond as a minimum t...

Page 149: ...ual steps require careful planning and analysis of the methods and systems used The individual steps are also to be documented so they are clearly traceable V model simplified The implementation of sa...

Page 150: ...ical tests Specification of the software safety functions Specification of the functionality of individual safety functions incl definition of the shutdown circuit etc Definition of the parameters for...

Page 151: ...of 173 Version 57E 12 3 2 Specification of the safety requirements breakdown The safety requirements are to be analysed in detail based on the standards to be applied e g product standards Source Gene...

Page 152: ...ameters e g brakes Monitoring mechanisms must be provided for such cases Application boundaries the automatic system automatically collects new cabs and moves them through a processing area In the pro...

Page 153: ...Installation manual PSC1 C 10 Installation manual V2 6 Page 153 of 173 Version 57E Example for a hazard analysis...

Page 154: ...ions The definition of the safety function must State the risk to be covered Describe the exact function List all sensors controls involved Identify all controllers Identify the related shutdown circu...

Page 155: ...Monitoring of the maximum speed for 0 07 m s 3 1 d 1 x WCS absolute encoder 1 x incremental encoder on motor drive wheel Monitoring using tested safety function SLS for fixed limits 70mm s Overspeed d...

Page 156: ...ed specification of the safety functions if this contains all specifications see example in 12 3 3 3 However it is recommended to prepare an extracted list This list should contain the following infor...

Page 157: ...ee below Continuous Reset Reset button Operating stop SF 1 3 1 1 6 Backstop Monitoring for return d Mechanical limit switch 22S2 Digital incremental encoder Monitoring using tested function direction...

Page 158: ...12 3 5 1 Selection of SRP CS and equipment The SRP CS safety related parts of control system are to be selected appropriately for achieving the safety level required for each safety function The comp...

Page 159: ...A 3 1 4 10000 0 Data sheet 99 Inst Handb PSC1 Sensor 2 1 Incremental encoder motor feedback SIN COS G 1 1 4 30 Gen specificatio ns 99 Inst Handb PSC1 Cat 4 in conjunction with eval PSC1 PES Safety PLC...

Page 160: ...s these are to be stated and specified in detail Fault exclusions can be e g mech shaft fracture sticking switching contacts short circuits in cables and wires etc The admissibility of the fault exclu...

Page 161: ...sible depiction of the functions by means of Unambiguous identifiers Comprehensible comments Wide ranging usage of tested functions function blocks Defensive programming 12 3 7 Check on the hardware d...

Page 162: ...urces and the diagnostic coverage information from manufacturer of PES or general sources The appropriate methods are to be found in the underlying safety standard As an example a calculation accordin...

Page 163: ...DCPES 99 Mains contactor B10d 20 106 NOP 20 working days 3990 year 309 working days year MTTFd B10d 0 1 Nop 32362 Jahre DCPES 60 MTTFd_A 1 1 MTTFd_T rz 1 MTTFd_SinCos 1 MTTFd_PES 1 MTTFd_Netzsch 23 y...

Page 164: ...for the PL If a higher safety level is to be achieved a correspondingly higher quality switch is to be used Note It is also possible to determine the PL using the tool Sistema from the BGIA among oth...

Page 165: ...mum speed for 1 1 VMax Monitoring FW Max Speed is continuously activated and triggers if a speed of 550 rpm is exceeded Safety function Limitation of the max travel speed of the running gear FW in the...

Page 166: ...in the validation report Validation report PLC program Index Command Operand Validated 1 NO1 SLI_EN 1 2 NO1 SLI_EN 2 3 NO1 SLI_EN 3 4 NO1 SCA_EN 1 5 NO1 SCA_EN 2 6 NO1 SCA_EN 3 7 NO1 SLS_EN 2 8 NO1 S...

Page 167: ...parameters in the specifications by comparing Example SLS Validation report Safely Limited Speed SLS Index Parameter Value Validated SLS 1 Selected axis 1 Speed threshold 200 0 SLS 2 Selected axis 1 S...

Page 168: ...ent length 500 0 Type Rotary Position processing Active Maximum speed 2000 0 Switch off position 10 0 Shutdown speed 100 0 Sensors 1 2 Type SSI standard SSI standard Format Binary Binary Count directi...

Page 169: ...iagnostics on the actual speed versus SLS limit Tamper with the setting up speed so it is above permitted limited speed 2 Test SSX for stop category 2 Movement with max speed Actuate EMERGENCY STOP Di...

Page 170: ...rk Category categorisation SIL categorisation 1 normally closed contact EMERGENCY STOP simple PL d1 SIL 2 2 normally closed contact EMERGENCY STOP for increased requirement PL e SIL 3 2 normally close...

Page 171: ...ment that the user cannot change Light curtain Switch type Remark Category categorisation SIL categorisation 2 normally closed contact Light curtain for increased requirement PL e SIL 3 2 normally clo...

Page 172: ...Monitored sensor input PL e SIL 3 1 normally open contact 1 normally closed contact Sensor input for increased requirement PL e SIL 3 1 normally open contact 1 normally closed contact time monitored M...

Page 173: ...ation manual PSC1 C 10 Installation manual V2 6 Page 173 of 173 Version 57E 13 2 CE declaration of conformity EC Declaration of Conformity for Safety Components in the context of the EC Directive 2006...

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