Baumuller b maXX BMC-M-SAF-02 User manual

Operating Instructions
Read the Operating Instructions before beginning
Language English
Translation
Document-No. 5.07020.04
Part No. 422418
Status 07.02.2011
b maXX®Systems
b maXX safe PLC
BMC-M-SAF-02
E5.07020.04

©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 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Further applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Warranty conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.10 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.12 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.12.1 Approvals, directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Use of this handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Firefighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.10 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.10.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.12 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.13 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5 Functional Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1 Safety-related parameters for 20 years of operation . . . . . . . . . . . . . . . . . . . . . . . . . . 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 b maXX safe PLC module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.1 Applicable reductions in the functional range of the IEC programming language in the
safety programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2 Configuration of the BMC-M-SAF-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.4 Properties of the standard PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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7.5 Properties of the safety PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.6 Properties of the power supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.7 Properties of the memory card module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.7.1 Data on the memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.8 Danger zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.9 Marking of the control - type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8 Planning of a safety-oriented control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 Installation and wiring plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.3 Determination of the device parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4 Course of the planning phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Preparation for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.4 Installation space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 Assembly instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.6.1 Connection diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.6.2 Requirements for the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.6.3 Safety-related connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.6.4 Requirements on the connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.6.5 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Programming, configuration and parameterization with ProSafety . . . . . . . . . . . . . . . . 57
11 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
11.1 Description of the operation modes, RUN/STOP switch . . . . . . . . . . . . . . . . . . . . . . . 60
11.1.1 Solitary safety PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
11.1.2 Combined operation of the safety PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
11.2 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.3 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.4 Description/inspection of the safety and monitoring equipment. . . . . . . . . . . . . . . . . . 63
11.5 Loading applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.5.1 Downloading projects from the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.6 Setting the station number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.7 Description and inspection of the operation and display elements . . . . . . . . . . . . . . . 64
11.7.1 LEDs for displaying the operation statuses of the BMC-M-SAF-02 (channel 1) . . . . 64
11.7.1.1 Switching on and initialization the BMC-M-SAF-02 . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.7.1.2 Operation of the BMC-M-SAF-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.7.2 Rotary switch S1 of BMC-M-SAF-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.7.3 S2 switch/button for changing operating statuses of the BMC-M-SAF-02. . . . . . . . . 67
11.7.4 Display on channel 2 with the BMC-M-SAF-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.8 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.8.1 Switching on the BMC-M-SAF-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.8.2 Testing the functioning of the BMC-M-SAF-02 (standard PLC). . . . . . . . . . . . . . . . . 70
11.9 Startup and operation options with inserted memory card. . . . . . . . . . . . . . . . . . . . . . 70
11.9.1 Safety-related instructions on the use of memory cards . . . . . . . . . . . . . . . . . . . . . . 70
11.9.2 Starting behavior with inserted memory card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11.9.3 Data transfer from the card to the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.9.4 Data transfer from the control to the card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11.9.5 Description and inspection of the operating and display elements . . . . . . . . . . . . . . 77
11.10 Programming, configuration and parameterization with ProSafety . . . . . . . . . . . . . . . 78

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12 System validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.1 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
14 Troubleshooting and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.3 Error diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.3.1 Detecting internal device errors by using self-tests. . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.3.2 Detecting errors in the periphery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
14.4 Reaction im the event of an error, diagnostic messages. . . . . . . . . . . . . . . . . . . . . . . 86
14.5 Safe status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
14.6 Exchanging devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14.7 Error messages on channel 2 of the BMC-M-SAF-02 . . . . . . . . . . . . . . . . . . . . . . . . . 88
14.7.1 7-segment display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
14.7.2 Error indication of the LEDs on channel 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
15 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
16 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
17 Disassembly, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
17.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
17.2 Requirements on the personnel carrying out the work . . . . . . . . . . . . . . . . . . . . . . . . 94
17.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
17.4 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
17.5 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
18 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
18.1 Safety regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
18.2 Requirements for the personnel carrying out the work . . . . . . . . . . . . . . . . . . . . . . . . 97
18.3 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
18.4 Recycling collection center/offices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Appendix B - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
B.1 List of all accessory items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Appendix C - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C.1 Planning checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
C.2 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
C.3 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
C.4 Modification and retrofitting check list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix D - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
D.1 Connection values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
D.2 Operational conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
D.3 Pin configuration of sub-D socket for RS232 interface. . . . . . . . . . . . . . . . . . . . . . . . 111
D.4 Pin configuration of sub-D socket for RS485 interface. . . . . . . . . . . . . . . . . . . . . . . . 111
D.5 Memory cards for CF cards (BMC-M-CFI-01). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix E - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
E.1 What is an EC directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
E.2 What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
E.3 Definition of the term Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
E.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Operating Instructions b maXX safe PLC BMC-M-SAF-02
Document No.: 5.07020.04 Baumüller Nürnberg GmbH
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Inhaltsverzeichnis
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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Operation Manual b maXX safe PLC BMC-M-SAF-02
Document no.: 5.07020.04
1DOCUMENT HISTORY
Revision
level State Modifications
5.07020.01 18.10.2007 Initial document
5.07020.02 31.03.2009 Revision and CFI module extension
5.07020.03 25.08.2009 Editorially checked contents
5.07020.04 07.02.2011 New declaration of conformity

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Operation Manual b maXX safe PLC BMC-M-SAF-02
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2PREFACE
2.1 Information on the Operation Manual
This Operation Manual provides important information on handling the device. Compli-
ance with all safety instructions operation instructions specified is a prerequisite for work
safety.
Furthermore, it is also necessary to comply with the local accident prevention legislation
and general safety regulations applying to the device’s field of application.
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 to personnel in the immediate vicinity of the device
at all times.

Legend
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2.2
2.2 Legend
Warning notices
Warning notices are indicated by symbols in this Operation Manual. The notices are in-
troduced 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.
Recommenda-
tions
DANGER!
....notifies of an imminent dangerous situation which will lead to death or serious in-
juries if not avoided.
WARNING!
....notifies of a potentially dangerous situation which can lead to death or serious in-
juries if not avoided.
CAUTION!
....notifies of a potentially dangerous situation which can lead to minor or slight inju-
ries if not avoided.
CAUTION!
....notifies of a potentially dangerous situation which can lead to property damage if
not avoided.
NOTICE!
....draws attention to useful tips and recommendations as well as information for effi-
cient and trouble-free operation.

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2.3 Limitation of liability
All statements and instructions in this Operation Manual have been compiled in compli-
ance with the applicable standards and legislation while taking the current level of tech-
nology 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 materials delivered may vary from the explanations and illustrations
described here in cases involving custom designs or the use of additional ordering op-
tions, or as a result of 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, ground-
ing, 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
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 with-
out the written approval of the manufacturer.
CAUTION!
Thefollowingshallapply if thedocument youare readingis designatedas preliminary
information:
This version pertains to preliminary technical information which the user of the de-
scribed devices and functions should receive ahead of time, in order to be able to ad-
just to potential changes and/or functional expansions.
This information is to be considered 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 in-
correct or incomplete version.
Should you detect or suspect content-related and/or serious formal errors in this pre-
liminary information, please contact the contact person assigned to you and inform
us of your findings and comments, so that they can be taken into account and poten-
tially incorporated during the transition from the preliminary information to the final
(reviewed by Baumüller) information. The obligations specified in the following sec-
tion under “Obligations” do not apply to preliminary information.

Further applicable documents
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2.6
2.6 Further applicable documents
Components from other manufacturers are built into the device. Hazard evaluations for
these bought-in parts have been conducted by the applicable manufacturers. The confor-
mity of the designs with the applicable European and national legislation has been de-
clared by the respective component manufacturers.
2.7 Replacement parts
Procure replacement parts from authorized dealers or directly from the manufacturer.
See also ZAppendix B - Accessories– from page 101 onward.
2.8 Disposal
If no return or disposal agreement has been made, dismantled components can be taken
for recycling after proper disassembly.
See also Z18 Disposal– from page 97 onward.
2.9 Warranty conditions
The warranty conditions can be found as a separate document in the sales documenta-
tion.
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
NOTICE!
The content-related statements, texts, diagrams, images and other illustrations are
copyright protected and subject to industrial property rights. Any improper use is lia-
ble to prosecution.
b maXX®is a registered trademark of Baumüller Nürnberg GmbH
Cage Clamp®is a registered trademark of the company WAGO Kontakttechnik
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

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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 contact person responsible can be found at any time via telephone,
fax, E-mail or over the internet.
2.11 Terms used
The terms “PLC” or “safety control” or “BMC-M-SAF-02” are also used for the product
“bmaXX safe PLC.”
The terms “module” or “power supply” are also used in this documentation for the
Baumüller product “power supply for b maXX controller/safe PLC.”
The term “b maXX System” is also used for the product consisting of “power supply for
bmaXX controller/safe PLC,” “b maXX safe PLC” and further system components.
A list of the abbreviations used can be found in ZAppendix A - Abbreviations– from page
99 onward.
2.12 Certification
The programmable safety controller b maXX safe PLC from Baumüller Nürnberg GmbH
has been developed in accordance with the standards specified inZChapter 2.12.1– and
certified by TÜV Rheinland.
Approval no. 968/EZ 358.00/09
Test report: 968/EZ 358.00/09
2.12.1 Approvals, directives and standards
Safety engineering stan-
dards and directives Area of application Approvals
IEC 61508, Parts 1-7 Functional safety of security-
related electric, electronic and
programmable electronic sys-
tems
up to SIL 3
DIN EN ISO 13849-1 Safety-related components of
control units up to performance level E
EN 954-1 Safety-related components of
control units up to category 4

Certification
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2.12
IEC 62061 Appendix E Functional safety of security-
related electric, electronic and
programmable electronic sys-
tems
Fulfilment of increased stability
requirements in accordance with
Appendix E
Additional standards Area of application
EN 61131-2 Generaldevicerequirementsand
tests for control systems
EN 50178 Equipping of high voltage equip-
ment with electronic utilities
Use of ventilation and leakage
paths
EN 60204 Electrical machine equipment

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3USE OF THIS HANDBOOK
This safety handbook contains information on the intended use of the Baumüller b maXX
safe PLC.
Knowledge of regulations and proper technical implementation of the safety instructions
in this handbook by qualified personnel are prerequisites for the safe installation, commis-
sioning and safety during the operation and maintenance of the Baumüller b maXX safe
PLC. Unqualified interventions in the devices, during shutdown or use of the safety func-
tions or failure to comply with the instructions of this handbook can lead to serious per-
sonal injury, property damage or environmental harm, for which Baumüller assumes no
liability.
Baumüller control devices are developed, manufactured and tested in compliance with
the applicable safety standards. They may only be used under the specified environmen-
tal conductions and only in connection with approved external devices.
The Operation Manual contains safety instructions, descriptions of the interfaces and in-
formation 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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Operation Manual b maXX safe PLC BMC-M-SAF-02
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4SAFETY
This section provides an overview of all important safety aspects for the optimum protec-
tion 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 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.

Intended use
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4.3
4.3 Intended use
This device is exclusively designed and constructed for the intended purpose of use de-
scribed here.
The b maXX safe PLC uses for operation an attached power supply (BMC-M-PSB-02).
Furthermore, the safety control can be expanded by the addition of various system com-
ponents.
Your use of the device is considered to be compliant with its intended use if you have read
all instructions and information in this Operation Manual.
WARNING!
Danger due to use other than intended!
Any use of the device different from and/or exceedingbeyondthe scope ofthe intend-
ed use can lead to dangerous situations.
Therefore:
mOnly use the device as intended.
mFollow all specifications of this Operation Manual.
mEnsure that exclusively qualified personnel work on or with this device.
mTake care in project planning to see that the device is always used within its spec-
ifications.
mThe device and/or mounting rail is mounted on a wall which is sufficiently sturdy.
mEnsure that the power supply meets the required specifications.
mOnly operate the device if it is in technically faultless condition.
mOnlyusethe devicein combination withcomponentsapproved by BaumüllerNürn-
berg GmbH.
mOnly operate the device in type two environments. The device has been developed
to meet the requirements of the category C3 according to IEC 61800-3:2005. The
device is not intended to be connected to the public power grid. For operation of
the device in a type one environment of the category C2/C1 (residential, business
and commercial zone without an intermediate transformer directly to the low-volt-
age grid), special measures to reduce emitted interference (grid-bound and radiat-
ed) are to be arranged by a electrical cabinet engineer andmust be demonstrated,
since electromagnetic compatibility disturbances can occur unless additional mea-
sures are taken. It can not be guaranteed that a device described here will achieve
category C2/C1 even with additional measures.

Safety
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4.4 Operator responsibility
The device is implemented in an industrial zone. The operator of the device is thus sub-
ject 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 addi-
tionally 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 op-
eration instructions for the operation of the device.
mThis Operation Manual must be kept in the immediate vicinity of the device and be ac-
cessible 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
All BMC-M-xxx-xx devices must be built into a suitable electrical cabinet in order to com-
ply with the protective categories (IP22) required in EN61800-5-1, Chapter 4.2.3.3.
Protection category
BMC-M-SAF-0x IP 20
DANGER!
Life-threatening danger through electric current!
Immediate life-threatening danger is present if contact with live parts is made.
Therefore:
mOperate the device in an electrical cabinet which provides protection from direct
contact with the devices and meets the requirements of at least EN 61800-5-1,
Chapter 4.2.3.3.

Personnel training
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4.6
4.6 Personnel training
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 conduct-
ed by trained or instructed personnel. These persons must be familiar with the Opera-
tion 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 desig-
nating electrical systems and devices in accordance with the safety engineering stan-
dards.
Qualified personnel is educated ortrained in the maintenance and use of suitable safe-
ty equipment in accordance with the respective local safety engineering standards.
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.