Baumuller BM5-O-SAF-000 User manual

Operation Manual
Read the Operating Instructions before beginning!
Language English
Translation
Document No. 5.09013.07
Part No. 432449
Date Nov. 19, 2018


BM5-O-SAF-000/-001
Safety Module for b maXX 5000

E5.09013.07

Baumüller Nürnberg GmbH
Ostendstr. 80 - 90
90482 Nürnberg
Germany
Tel. [phone] - 0 
Fax: [phone] - 1 30
E-Mail: [email protected]
Internet: www.baumueller.de

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Table of Contents
1 Document history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Information on the Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Preliminary information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Further applicable documents from other manufacturers . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.12 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.12.1 Approvals, directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Use of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Contents of the operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Alterations and rebuilding of the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Operator responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.7 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.8 Special dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.10.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.12 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.13 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Functional safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Safety-related parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1 SAF-001-000-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.2 SAF-001-001-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Packaging and shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Disposing of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.4 To be observed when shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Description of the Default and Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Compatibility list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3 Working principle parameter module (BM5-O-SAF-000-000-000). . . . . . . . . . . . . . . . 32
7.4 Setting of the switch-on behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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7.5 Structure of the SAF-000 Default- and Parameter module . . . . . . . . . . . . . . . . . . . . . 35
7.6 Identification of the SAF-000 Default- and Parameter module. . . . . . . . . . . . . . . . . . . 35
8 Description of the Safety Module (SAF-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1.1 Safety Module SAF-001-000-xxx and SAF-001-001-000 with safety function STO . 37
8.1.2 Safety Module SAF-001-001-001 with safety function SS1 (time controlled) . . . . . . 37
8.2 Compatibility list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2.1 Compatibility list SAF-001-000-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2.2 Compatibility list SAF-001-001-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2.3 Compatibility list SAF-001-000-002 with automatic restart . . . . . . . . . . . . . . . . . . . . 39
8.3 Safety notes on the STO (Safe Torque Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.4 Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.4.1 SAF-001-000-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.4.2 SAF-001-001-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.5 Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.5.1 SAF-001-000-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.5.2 SAF-001-001-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.6 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.6.1 Structure of the Safety Module (SAF-001-000-xxx). . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.6.2 Structure of the Safety Module (SAF-001-001-000) . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.6.3 Structure of the Safety Module (SAF-001-001-001) . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.7 Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.7.1 Pin assignment of connector X1 (SAF-001-000-xxx). . . . . . . . . . . . . . . . . . . . . . . . . 50
8.7.2 Pin assignment of connector X1 (SAF-001-001-xxx). . . . . . . . . . . . . . . . . . . . . . . . . 51
8.7.3 Pin assignment of connector X1 (SAF-001-000-002 with automatic restart). . . . . . . 51
8.8 Switching thresholds for voltage and current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.9 Maximum response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.10 Properties of the parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.11 Operation and display elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.11.1 LEDs for indicating the operation statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.11.2 Button for verification purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.12 Restart inhibit (SAF-001-000-xxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.13 Automatic restart (SAF-001-000-002 and SAF-001-001-xxx) . . . . . . . . . . . . . . . . . . . 58
8.14 Marking of the Safety Module (SAF-001) - type code . . . . . . . . . . . . . . . . . . . . . . . . . 59
9 Description of the Reset-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2 Compatibility list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3 Operating mode of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . 61
9.4 Structure of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.5 Identification of the Reset-Module (SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.6 Mode of operation module replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 Resetting of the safety level by the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2 Operation mode of the reset command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11 Planning of a safety-oriented control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.1 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.2 Installation and wiring plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.3 Course of the planning phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
12.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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12.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 72
12.3 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
12.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.4.1 Requirements for the electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.4.2 Requirements on the connection cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13 Commissioning and exchange of the module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
13.1 General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
13.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 78
13.3 Exchanging the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
14 System validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.1 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
16 Troubleshooting and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
16.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
16.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 87
16.3 Error diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
16.4 Detecting errors in the periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
16.5 Safe status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
19 Disassembly, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
19.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
19.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 94
19.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
19.4 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
19.5 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
20 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
20.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 95
20.3 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
20.4 Recycling collection center/offices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Appendix B - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
B.1 Planning checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
B.2 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B.3 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
B.4 Modification and retrofitting checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Appendix C - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C.1 Connection values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C.2 Operational conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C.3 Pin assignment of Safety Module (SAF-001-000-xxx) connector X1 . . . . . . . . . . . . . 104
C.4 Pin assignment of Safety Module (SAF-001-001-xxx and SAF-001-000-002) connector X1
105
Appendix D - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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1DOCUMENT HISTORY
Revision
level State Modifications
01 16.11.2010 Initial document
02 17.05.2011 SAF-000 Default- and Parameter module added
03 07.08.2012 Push button combination for push button S1 added;
Chap. 8.12 times added
Mode of operation SAF-000 and SAF-001 changed
Type code SAF-000 and SAF-001 changed
Chap. 8.11.1 LED display corrected
Chap. 9 SAF-100 Reset module added
Chap. 10 Resetting by the controller added
Chap. 13.3 Exchanging the module changed
04 27.05.2014 SAF-001-000-002 (automatic restart) added
Chap. 8.3 Compatibility list SAF-001-000-002 new
Chap. 8.9 Pin assignment SAF-001-000-002 new
Chap. 8.15 Automatic restart SAF-001-000-002 new
Chap. 8.16 Type code SAF-001-000-002 added
Chap.8: SAF-001-000-001 removed
05 08.11.2016 New declaration of conformity
06 20.09.2017 Safety Module SAF-001-001-xxx added
Chap. 8.3 Compatibility list SAF-001-001-xxx new
Chap. 8.6.2 Working principle SAF-001-001-xxx new
Chap. 8.7.2 Input circuitry SAF-001-001-xxx new
Chap. 8.8.2 Structure Safety Module (SAF-001-001-xxx) added
Chap. 8.9.2 Pin assignment of connector X1 (SAF-001-001-xxx) added
Chap. 8.10 Switching thresholds SAF-001-001-xxx added
Chap. 8.16 Type code SAF-001-001-xxx added
Declaration of conformity SAF-001-001-xxx added
07 19.11.2018 Safety Module SAF-001-001-001 (Safe Stop 1) added
Chap. 8.1.2 SAF-001-001-001 added
Chap. 8.2.2 Compatibility list SAF-001-001-001 added
Chap. 8.4.2 Working principle SAF-001-001-001 added
Chap. 8.14 Type code SAF-001-001-001 added

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2GENERAL
2.1 Information on the Operation Manual
This operation manual provides important information for the use of the device. Respect
of the safety guidelines and instructions in this operation manual are prerequisites for the
safe work.
Furthermore, the local accident prevention legislation and general safety regulations
applying to the device's field of application must also complied with.
Read the operation manual completely, in particular the chapter on safety instructions,
before beginning any work on the device. The operation manual is a component of the
product and must be kept accessible in the immediate vicinity of the device at all times.

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2.2
2.2 Legend
Warning notices
Warning notices are marked by symbols in this operation manual. The notices are
introduced by signal words which express the extent of the hazard.
Comply with the notices under all circumstances and act with caution in order to avoid
accidents, personal injury and property damage.
DANGER!
....notifies of an imminent dangerous situation which will lead to death or serious
injuries if not avoided.
WARNING!
....notifies of a potentially dangerous situation which can lead to death or serious
injuries if not avoided.
CAUTION!
....notifies of a potentially dangerous situation which can lead to minor or slight
injuries if not avoided.
CAUTION!
....notifies of a potentially dangerous situation which can lead to property damage if
not avoided.
Recommenda-
tions
NOTICE!
....draws attention to useful tips and recommendations as well as information for
efficient and trouble-free operation.

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2
2.3 Limitation of liability
All statements and instructions in this operation manual have been compiled in
compliance with the applicable standards and legislation while taking the current level of
technology and our long-term experience and findings into account.
The manufacturer assumes no liability for damages resulting from:
mfailure to observe the operation manual
mapplication for purposes other than those intended
muse by untrained personnel
The actual scope of materialsdelivered can vary from the explanations and illustrations
described here in the event of custom designs, the use of additional ordering options or
due to the most recent changes in technology.
The user assumes the responsibility of conducting maintenance and commissioning in
accordance with the safety regulations of the applicable standards and all other relevant
national or regional legislation relating to conductor dimensioning and protection,
grounding, circuit breakers, overvoltage protection, etc.
The person who conducted the assembly or installation shall be accountable for damages
occurring during assembly or connection.
2.4 Preliminary information
CAUTION!
Thefollowing shallapply if thedocument youare readingis designatedaspreliminary
information:
This version pertains to preliminary technical information which the user of the
described devices and functions should receive ahead of time, in order to be able to
adjust to potential changes and/or functional expansions. 
This information is to be seen as preliminary, since it has not yet been subjected to
the Baumüller internal review process. In particular, this information is still subject to
changes, meaning that this preliminary information cannot be construed as legally
binding. Baumüller assumes no liability for damages resulting from this potentially
incorrect or incomplete version. 
Should you detect or suspect content-related and/or serious formal errors in this
preliminary information, please contact the contact person at Baumüller assigned to
you and inform us of your findings and comments, so that they can be taken into
account and potentially incorporated during the transition from the preliminary
information to the final (reviewed by Baumüller) information.

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2.5
2.5 Copyright
Treat the operation manual as confidential. It is intended exclusively for those working
with the device. It is not permissible to transfer the operation manual to third parties
without the written approval of the manufacturer.
NOTICE!
The content-related statements, texts, diagrams, images and other illustrations are
copyright protected and subject to industrial property rights. Any improper use is
liable to prosecution.
2.6 Further applicable documents from other manufacturers
Components from other manufacturers are built into the device. Hazard evaluations for
these bought-in parts have been conducted by the applicable manufacturers. The
conformity of the designs with the applicable European and national legislation has been
declared by the respective component manufacturers.
2.7 Replacement parts
WARNING!
Improper or defective replacement parts can lead to damage, malfunctions or total
failure as well as jeopardize safety.
Therefore:
mOnly use original replacement parts from the manufacturer
Procure replacement parts from authorized dealers or directly at the manufacturer.
2.8 Disposal
If no return or disposal agreement has been made, dismantled components can be taken
for recycling after proper disassembly.
See also ZDisposal– on page 95.

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2.9 Warranty and liability
All the information in this operation manual is non-binding customer information; it is
subject to ongoing further development and is updated on a continuous basis by the
permanent change management system of Baumüller Nürnberg GmbH.
Claims of warranty or liability towards Baumüller Nürnberg GmbH are rejected, in
particular if one or more of the reasons listed in chapter ZIntended use– on page 18 has/
have been the cause of the damage/s.
The operation of the devices described here in accordance with the specified methods/
procedures/requirements is permissible. Everything else, even the operation of devices
in installation positions not depicted here, for instance, is not permissible and must be
clarified with the factor on a case-by-case basis. The warranty will be rendered null and
void if the devices are operated differently than described here.
2.10 Customer service
Our customer service is available for technical support.
Information on the competent contact person can be found at any time via telephone, fax,
E-mail or over the Internet.
2.11 Terms used
A list of the abbreviations used can be found in ZAppendix A - Abbreviations– from page
97 onward.
2.12 Certification
The Safety Module (BM5-O-SAF-001-000) from Baumüller Nürnberg GmbH has been
developed in accordance with the standards specified in ZChapter 2.12.1– and certified
by TÜV Rheinland.
EC Type Examination Certificate Number: 01/205/5031.01/16
Test report no.: 968/M 264.05/16
Notified Body: 0035
The Safety Module (BM5-O-SAF-001-001) from Baumüller Nürnberg GmbH has been
developed in accordance with the standards specified in ZChapter 2.12.1– and certified
by TÜV Rheinland.
EC Type Examination Certificate Number: 01/205/5563.03/18
Test report no.: 968/FSP 1400.03/18
Notified Body: 0035

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2.12
2.12.1 Approvals, directives and standards
Safety engineering
standards and directives Area of application Approvals
IEC 61508, Parts 1-7 Functional safety of safety-related
electric, electronic and programmable
electronic systems
up to SIL 3
DIN EN ISO 13849-1 Safety-related components of control
units upto performance level e
up to category 4
IEC 62061 Functional safety of safety-related
electric, electronic and programmable
electronic systems
Fulfillment of increased stability
requirements in accordance with
reference to EN 61326-3-1
Additional standards Area of application
DIN EN 61800-3 Adjustable speed electrical power
drive systems - Part 3: EMC
requirements
DIN EN 61800-5-1 Adjustable speed electrical power
drive systems - Part 5-1: Safety
requirements - Electrical, thermal and
energy
DIN EN 61800-5-2 Adjustable speed electrical power
drive systems - Part 5-2: Safety
requirements - Functional
EN 61131-2 Programmable controllers - Part 2:
Equipment requirements and tests
EN 60204-1 Electrical equipment of machines

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3USE OF THIS MANUAL
This safety manual contains information on the intended use of the Baumüller plug-in
module.
Knowledge of the regulations and proper technical implementation of the safety
instructions in this manual by qualified personnel are prerequisites for the safe
installation, commissioning and safety during the operation and maintenance of the
Baumüller plug-in module. Unqualified interference with the devices during shutdown or
useof the safetyfunctionsorfailuretocomplywith the instructions of this manual canlead
to serious personal injury, property damage or environmental harm, for which Baumüller
assumes no liability.
Baumüller safety components and systems are developed, manufactured and tested in
compliance with the applicable safety standards. They may only be used under the
specified environmental conditions and only in connection with approved external
devices.
The operation manual contains safety instructions, descriptions of the interfaces and
information on the phases of the product's life cycle:
nPlanning
nInstallation/Assembly
nCommissioning
nValidation
nOperation
nModification/Retrofitting
nTroubleshooting
nMaintenance/Repair
nDisassembly

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4SAFETY
This chapter provides an overview of all important safety aspects for the optimum
protection of the personnel as well as for safe and trouble-free operation.
4.1 Contents of the operation manual
All persons assigned to work on or with the device must have read and understood that
operation manual before beginning work with the device. This also applies if the person
concerned has already worked with such a device or a similar device or has been trained
by the manufacturer.
4.2 Alterations and rebuilding of the device
In order to avoid hazards and ensureoptimum performance, neitheralterations, additions
nor rebuilding work may be conducted on the device unless explicitly authorized by the
manufacturer.

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4.3
4.3 Intended use
The plug-in module is exclusively designed and constructed for the intended purpose of
use described here.
You are using the device according to the terms, as soon as you regard all notes and
information in this operation manual.
WARNING!
Danger due to use other than intended!
Any use of the device different from and/or exceeding beyond the scope of the
intended use can lead to dangerous situations.
Therefore:
mOnly use the plug-in module as intended.
mOnly use the plug-in module in combination with compatible converters (see
ZCompatibility list SAF-001-000-xxx– on page 38, ZCompatibility list SAF-001-
001-xxx– on page 38 and ZCompatibility list SAF-001-000-002 with automatic
restart– on page 39).
mFollow all specifications of this operation manual.
mEnsure that exclusively qualified personnel work on or with the plug-in module.
mTake care in project planning to see that the plug-in module is always used within
its specifications.
mEnsure that the power supply meets the required specifications.
mOnly operate the plug-in module if it is in technically faultless condition.
mOnly use the plug-in module in combination with components approved by
Baumüller Nürnberg GmbH.

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4
4.4 Operator responsibility
The plug-in module is implemented in an industrial zone. The operator of the device is
thus subject to the legal work safety obligations.
In addition to the work safety instructions in this operation manual, the safety, accident
prevention and environmental protection regulations applicable to the area of application
of this device must also be complied with. In doing so, the following applies in particular:
mThe operator must inform himself of the applicable work safety regulations and
additionally ascertain hazards arise through the special work conditions at the place of
use of the device in a risk assessment. The operator must implement this in the form
of operation instructions for the operation of the device.
mThis operation manual must be kept in the immediate vicinity of the device and be
accessible to persons working on and with the device at all times.
mThe statements of the operation manual are to be followed completely and absolutely!
mThe device may only be operated in technically faultless condition and must be safe for
operation.
4.5 Protective equipment
When installed in the converter, the plug-in module complies with the protective
category IP20.

Personnel training
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4.6
4.6 Personnel training
WARNING!
Risk of injury if operated by insufficiently qualified persons!
Improper handling can lead to severe personal injury and property damage.
Therefore:
mOnly allow certain activities to be conducted by persons specified in the respective
chapters of this operation manual.
The following qualifications for various areas of operation are specified in the operation
manual:
mOperating personnel
The drive system may only be operated by persons who have been trained, instructed
and authorized to do so.
Troubleshooting, repairs, cleaning, maintenance and exchange may only be
conducted by trained or instructed personnel. These persons must be familiar with the
operation manual and act according to it.
Commissioning and instruction may only be conducted by qualified personnel.
mQualified personnel
Electrical engineers and specialist electricians of the customer or a third party who are
authorized by Baumüller Nürnberg GmbH, trained and certified in the installation and
commissioning of Baumüller drive systems and commissioning, grounding and
designating electrical systems and devices in accordance with the safety engineering
standards.
Qualified personnel is educated or trained in the maintenance and use of suitable
safety equipment in accordance with the respectivelocal safetyengineeringstandards.