Baumuller BM5-O-SAF-002 User manual

Operation Manual
Read the Operating Instructions before beginning!
Language English
Translation
Document No. 5.11016.03
Part No. 00440935
Date 19.11.2018


BM5-O-SAF-002/3
Safety Module for b maXX 5000

E5.11016.03

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 Safety Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Operator responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Protective category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.6 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.7 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.8 Special dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.9 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.9.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.10 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.11 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.12 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Functional safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Safety-related parameters for an operation of 20 years . . . . . . . . . . . . . . . . . . . . . . . 25
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 Safety Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Compatibility list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3 Safety notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.4 Operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.5 Requirements for the use of rotary encoders for the safety-related monitoring. . . . . . 34
7.5.1 Standstill monitoring of the encoder at the SAF-002/-003 module in the "Software Exten-
sion" version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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7.5.2 Acknowledgment encoder fail status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.6 The Structure of the Safety Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.7 Processing and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.7.1 LEDs for the Display of Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.7.2 Button for verification reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.8 Software Extension SAF-002/-003 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.9 Identification of the Safety Module - Type Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8 Description of the Reset-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Compatibility list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.3 Operating mode of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . 49
8.4 Structure of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5 Identification of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.6 Mode of operation module replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9 Resetting of the safety level by the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.2 Operation of mode of the reset command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10 Safety Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.1 Safety Functions of the Module BM5-O-SAF-002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.2 Safety Functions of the Module BM5-O-SAF-003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.3 Safe Torque Off (STO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.3.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.3.2 Safety notes for the Function STO (Safe Torque Off) . . . . . . . . . . . . . . . . . . . . . . . . 58
10.4 Safe Stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.4.1 Signalize SS1-start to the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.4.2 Error reaction for the safety function „SS1“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.5 Safe Stop 2 (SS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.5.1 Error reaction with function-specific SS1 time for the safety function "SS2" and its follow-
ing function "SOS" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.6 Safe Operating Stop (SOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.6.1 Error reaction with function-specific SS1 time for the safety function "SOS". . . . . . . 66
10.7 Safely Limited Speed (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.7.1 Error reaction with a function-specific SS1 time for the safety function "SLS". . . . . . 69
10.8 Safe Direction (SDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.1 Error reaction with function-specific SS1 time for the safety function "SDI" . . . . . . . 71
10.9 Safe Brake Control (SBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.9.1 Error reaction with a function-specific SS1 time for the safety function "SBC" . . . . . 74
10.10 Safely Limited Position (SLP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10.10.1 Error reaction with function-specific SS1 time for the safety function "SLP" . . . . . . . 77
10.11 Safely Limited Increment (SLI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.11.1 Error reaction with function specific SS1 time for the Safety function "SLI" and the follow-
ing function "SOS" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.11.2 Operating principle of SLI and description of the transition SLI ->STO. . . . . . . . . . . 79
10.12 Safely Limited Acceleration (SLA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.12.1 Error reaction with function-specific SS1 time for the safety function "SLA" . . . . . . . 82
10.13 Safe Speed Monitor (SSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.13.1 Error reaction with function-specific SS1 time for the safety function "SSM". . . . . . . 84
10.14 Safe Cam (SCA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
10.14.1 Error reaction with function-specific SS1 time for the safety function "SCA". . . . . . . 86
10.15 Tolerance for the limit values of the safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . 87

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11 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.1 Connector Assignment Interface X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.1.1 Standard Terminal Configuration BM5-O-SAF-002-000-000 . . . . . . . . . . . . . . . . . . 90
11.1.2 Optional Terminal Configuration BM5-O-SAF-002-001-000 . . . . . . . . . . . . . . . . . . . 91
11.2 Survey of Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.3 External Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
11.3.1 Safe Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.3.2 STO-Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.3.3 Daisy-Chain Cascading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.3.4 Safe Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11.3.5 Cycle Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.4 Power Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
12 Safe Field Bus Communication via FSoE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12.2 FSoE-Master Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.3 Control word "S_ControlWord0": 
Activate and deactivate safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
12.4 Control word "S_ControlWord1": 
Parameter switchover and acknowledge of activated safety function . . . . . . . . . . . . 103
12.5 Status word "S_StatusWord0": 
Display of the selected safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
12.6 Status word "S_StatusWord1": 
Display of activated safety function and of the last active parameter switchover . . . 106
12.7 Status word "S_StatusWord2": 
Reading of digital inputs and outputs for a quicker diagnosis . . . . . . . . . . . . . . . . . . 108
13 Parameterization and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
13.1 Safe Module Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
13.2 Setting of the Safe Module Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
13.3 Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
14 Planning of a safety-oriented control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
14.1 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
14.2 Installation and wiring plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
14.3 Course of the planning phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15 Assembly and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
15.1 General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
15.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 120
15.3 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
15.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
15.4.1 Requirements for the electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
15.4.2 Requirements on the connection cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
16 Commissioning and replacement of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
16.1 General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
16.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 126
16.3 Replacement of the module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17 System validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
17.1 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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18 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
19 Troubleshooting and Error Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
19.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
19.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 137
19.3 Error diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
19.4 Detecting errors in the periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
19.5 Operating states and error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
21 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
21.1 List of all accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
21.1.1 Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
21.1.2 Ferrite ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
22 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
23 Disassembly, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
23.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
23.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 152
23.3 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
23.4 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
23.5 Recommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
24 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
24.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
24.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . 155
24.3 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
24.4 Recycling collection center/offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix B - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
B.1 Planning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
B.2 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
B.3 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
B.4 Modification and retrofitting check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Appendix C - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
C.1 Connection values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
C.2 Technical Data safe inputs, STO-Inputs and Daisy-Chain-Inputs. . . . . . . . . . . . . . . . 163
C.3 Operational conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
C.4 Pin assignment of Safety Module connector X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
C.5 Examples for connecting the Safety Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Appendix D - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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1DOCUMENT HISTORY
Revision
level State Modifications
5.11016.01 25.03.2013 Initial document
5.11016.02 05.10.2015 Chapter C.5: Pin-no. in figures added
Chapter 21: Accessories added
Fig. 17 changed
Chapter 15.4.2 text added
5.11016.03 19.11.2018 Software extension BM5-O-SAF-002-xxx-002-#01-yyy-zzz
Chapter 7.1 text changed (in Abs. 4)
Chapter 7.5 warning notices changed and text added
Chapter 7.5.1 and chapter 7.5.2 new
Chapter 7.7.2 new para. 2
new: Chapter 7.8 software extension SAF-002/3 module
Chapter 7.9 (vorher chapter 7.8) type code extended
Chapter 10.1 and chapter 10.2 para. 2 deleted
Chapter 10.3.1 figure and note new
Chapter 10.4 para. 2 new, figure changed and note new
Chapter 10.4.1 and chapter 10.4.2 new
Chapter 10.5 Abs. 2 new and figure changed
Chapter 10.5.1 new
Chapter 10.6 note 2 new and figure changed
Chapter 10.6.1 new
Chapter.7 figure changed
Chapter 10.7.1 new
Chapter 10.8 figure new
Chapter 10.8.1 new
Chapter 10.9 figure new, 3 notes, text new and figure new
Chapter 10.9.1 new
Chapter 10.10 figure changed, text (para. 5-7) new
Chapter 10.10.1 new
Chapter.11 figure new
Chapter 10.11.1 and chapter 10.11.2 new
Chapter 10.12 figure new
Chapter 10.12.1 new
Chapter 10.13 text changed (in para. 4) and figure new
Chapter 10.13.1 new
Chapter 10.14 figure new
Chapter 10.14.1 new
Chapter 10.15 new
Chapter.11.3 note new continue 

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Chapter.12.3 note under figure new
Chapter 12.6 status word "S_StatusWord1" bits 5-7 new and 2 notes after
table new
Chapter 19.5 operating states added (encoder fail) and text before error list
inserted
Chapter 19.5 error list extended (row „SS1 time general“ and error 31. 77,
78, 109-113) and additional information at error 48 extended (error no. 6,
192-194, 196)
Chapter C.2.5 reaction times extended

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2GENERAL
2.1 Information on the Operation Manual
This operation manual provides important information for the use of the Safety Module.
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 Safety Module'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 Safety Module. The operation manual is a component
of the product and must be kept accessible in the immediate vicinity of the Safety Module
at all times.

Legend
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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.
NOTICE!
....notifies of a potentially dangerous situation which can lead to property damage if
not avoided.
Recommenda-
tions
NOTE!
....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
NOTICE!
Thefollowing shallapply if thedocument youare readingis designatedaspreliminary
information:
This version pertains to preliminary technical information which the user of the
described Safety Modules 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.

Copyright
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2.5
2.5 Copyright
Treat the operation manual as confidential. It is intended exclusively for those working
with the Safety Module. It is not permissible to transfer the operation manual to third
parties without the written approval of the manufacturer.
NOTE!
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 Safety Module. 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 155.

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2
2.9 Warranty and liability
The warranty and liability terms are to be found in a separate document in the sales data.
The operation of the Safety Modules described here in accordance with the specified
methods/procedures/requirements is permissible. Everything else, even the operation of
Safety Modules 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 Safety Modules 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
157 onward.
2.12 Certification
The Safety Module (BM5-O-SAF-002/-003) 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: 01/205/5261.01/18
Test report no.: 968/M 264.06/18, dated 2018-09-07
Notified body: 0035
The declaration of conformity, see Appendix ZAppendix D - Declaration of conformity on
page 175.

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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 unitsup to performance
level e
IEC 62061 Functional safety of safety-related
electric, electronic and
programmable electronic systems
Fulfillment of increased stability
requirements in accordance with
EN 61326-3-1
Additional standards Area of application
IEC 61800-3 Adjustable speed electrical power
drive systems - Part 3: EMC
requirements
IEC 61800-5-1 Adjustable speed electrical power
drive systems - Part 5-1: Safety
requirements - Electrical, thermal
and energy
IEC 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
IEC 60204 Electrical equipment of machines

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3USE OF THIS MANUAL
This safety manual contains information on the intended use of the Baumüller Safety
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 Safety Module. Unqualified interference with the Safety Modules during
shutdown or use of the safety functions or failure to comply with the instructions of this
manual can lead 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 Safety
Modules.
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 at the machine
or installation on site. The observance of this is an important precondition for the safe an
trouble-free operation
4.1 Contents of the operation manual
All persons assigned to work on or with the Safety Module must have read and
understood that operation manual before beginning work with the Safety Module. This
also applies if the person concerned has already worked with such a Safety Module or a
similar Safety Module or has been trained by the manufacturer.
4.2 Alterations and rebuilding of the Safety Module
In order to avoid hazards and ensureoptimum performance, neitheralterations, additions
nor rebuilding work may be conducted on the Safety Module unless explicitly authorized
by the manufacturer.

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4.3
4.3 Intended use
The Safety Module is exclusively designed and constructed for the intended purpose of
use described here.
You are using the Safety Module 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 Safety Module different from and/or exceeding beyond the scope of
the intended use can lead to dangerous situations.
Therefore:
mOnly use the Safety Module as intended.
mOnly use the Safety Module in combination with compatible controllers (see
ZCompatibility list– on page 31).
mFollow all specifications of this operation manual.
mEnsure that exclusively qualified personnel work on or with the Safety Module.
mTake care in project planning to see that the Safety Module is always used within
its specifications.
mEnsure that the power supply meets the required specifications.
mOnly operate the Safety Module if it is in technically faultless condition.
mOnly use the Safety Module with certificated components or in combination with
components approved by Baumüller Nürnberg GmbH.

Safety
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4
4.4 Operator responsibility
The Safety Module is implemented in an industrial zone. The operator of the Safety
Module 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 Safety Module 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 Safety Module in a risk analysis.
The operator must implement these in the form of operation instruction for the total
operation of the machine/application in dependence of the accordant risk assessment.
mThis operation manual must be kept in the immediate vicinity of the Safety Module and
be accessible to persons working on and with the Safety Module at all times.
mThe statements of the operation manual are to be followed completely and absolutely!
mThe Safety Module may only be operated in technically faultless condition and must be
safe for operation.
4.5 Protective category
When installed in the controller, the Safety Module complies with the protective
category IP20.
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

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4.7
commissioning of Baumüller drive systems and commissioning, grounding and
designating electrical systems and Safety Modules 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.
4.7 Personnel protective equipment
Wearing the appropriate personal protective equipment when working is required in order
to minimize hazards to the health.
mAlways wear the respective protective equipment required for the respective task when
working.
mObserve signs on personal safety in the work area!
Protective work clothes
consists of close-fitting workwear of low tear strength, without loose sleeves or
projecting parts. Intended mainly to protect the wearer from moving machine parts.
Do not wear any rings and necklaces.
Protective helmet
for protection from falling and flying parts.
Safety shoes
for protection from heavy falling objects.
Safety gloves
to protect hands from friction, abrasions, puncture, prick wounds or deeper injuries
as well as from contact with hot objects.
To be worn during
special work
Protective glasses
to protect the eyes from flying parts and spraying liquids.