BBH SCU Series User manual

Installation Manual
English
SCU Series
FSoE Master and Slaves
Read and observe installation manual before initial
commissioning/initial startup/ integration of the module!
Observe safety instructions!
Keep for future use!

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HB-37500-810-11-16F-EN SCU Installation Manual - Master and Slaves - SARC Page 2 of 303
Status: 29.04.2022
Installation manual for SCU series devices
Status: 06/2022
INFORMATION
The German version is the original Version of the installation manual.
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Contact the manufacturer immediately if the instructions are missing!
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Always keep the manual at hand!
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Make sure that the manual is complete!
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Obtain this document only through the original publisher!
Subject to technical changes!
The content of this documentation has been compiled with the utmost
carefulness, and corresponds to our current state of information.
Nevertheless, we point out that the technical update of this
documentation cannot always be carried out simultaneously with the
technical evolution of our products.
Information and specifications can always be changed. For the current
version, please refer to www.bbh-products.de.
Manufaturer BBH Products
BBH Products GmbH
Böttgerstraße 40
92637 Weiden
GERMANY

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1. Inventories
1.1. Table of contents
1. Inventories .................................................................................................4
1.1. Table of contents 4
1.2. Table of illustrations 10
1.3. List of tables 12
2. Basic information ......................................................................................13
2.1. Identification 13
2.2. Important information for use 13
2.3. Warranty claims 14
2.4. Liability exclusion 14
2.5. Copyright 14
2.6. Brands 14
2.7. Supplied documents 15
2.8. Symbols and signal words 16
2.8.1. Safety information 16
3. Safety .......................................................................................................17
3.1. General safety information 17
3.2. Target group 18
3.3. Terms 20
3.4. Relevant standards and directives 21
3.5. Intended use 22
3.6. Storage and transport 23
3.7. Placement 24
3.8. Electrical connection 25
3.9. Behaviour in case of emergencies 26
3.10. Safe status 26
3.11. Scope of delivery SCU 27
3.12. Labelling / rating plate SCU 28
3.12.1. Rating plate SSB-x-x-x 29
4. Use............................................................................................................30
4.1. Device description 30
4.1.1. Function 30
4.1.2. Embedding into the EtherCAT network and into FSoE 31
4.1.2.1. FSoE data transfer 31
4.1.2.2. EtherCAT network 31

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4.1.2.3. EtherCAT data transfer 32
4.1.2.4. FSoE and EtherCAT 32
4.1.3. The principle of safe monitoring with SCU 34
4.2. Operation and service 34
5. General structure of the SCU assemblies ..................................................35
5.1. FSoE Master (SCU) 35
5.2. FSoE-Slaves (SDU, SIO, SSB) 36
5.2.1. SDU-x 36
5.2.2. SIO-x 38
5.2.3. SSB-x-x-x 39
5.3. Encoder specifications 40
6. Technical specifications of the SCU series.................................................42
6.1. SCU Master 42
6.1.1. SCU-0-EC/x 42
6.1.2. SCU-1-EC/x 42
6.1.3. SCU-2-EC/x 42
6.2. SCU Slaves 42
6.2.1. SDU-11 42
6.2.2. SDU-11/NM 42
6.2.3. SDU-11-PXV 42
6.2.4. SDU-12 42
6.2.5. SDU-21 43
6.2.6. SDU-21A 43
6.2.7. SDU-22 43
6.2.8. SDU-22A 43
6.2.9. SIO-1 43
6.2.10. SIO-2 43
6.2.11. SSB-x-x-x 43
6.3. Additional information 44
6.3.1. Cable lengths 44
6.3.2. Derating outputs 44
7. Connection and installation.......................................................................45
7.1. General notes on installation 45
7.2. Installation / mounting 47
7.2.1. Mounting 47
7.3. Wiring 48
7.4. Terminal schemes 49
7.4.1. SCU Master 49
7.4.2. SCU Slaves 49
7.5. External DC 24 V –voltage supply 50
7.6. Connection of the external encoder supply 52
7.6.1. Incremental, HTL, SIN/COS, SSI 52

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7.6.2. Resolver 53
7.7. Connection of digital inputs 54
7.8. Connection of analog inputs 55
7.9. Connection of position and speed sensors 56
7.9.1. General information 56
7.9.2. Assignment of encoder interface 58
7.9.2.1. ENC 1.1 / ENC 2.11) 58
7.9.2.2. ENC 1.2 / ENC 2.22) 58
7.9.3. Connection varaints 59
7.9.3.1. Connection of an absolute encoder as master 59
7.9.3.2. Connection of an absolute encoder as slave 60
7.9.3.3. Connecting an incremental encoder with TTL-Signal level 61
7.9.3.4. Connection of a SIN/COS encoder 62
7.9.3.5. Connection of a resolver as master 63
7.9.3.6. Connection of a resolvers as slave 64
7.9.3.7. Connection of proximity switch SDU-1x/-2x 65
7.9.3.8. Connection of HTL/proximity switch SDU12/SDU22x 65
7.9.3.8.1. HTL-encoder with A+/A- or B+/B- signal 65
7.9.3.8.2. HTL-encoder with A+ or B+- signal 66
7.10. Configuration of measuring distances 67
7.10.1. Genreal description of encoder configuration 67
8. Sensor type diagnoses ..............................................................................68
8.1. Absolute encoder: 68
8.2. Incremental encoder: 70
8.3. SinusCosinus encoder –Standard mode 70
8.4. SinusCosinus encoder –High resolution mode: 71
8.5. Proxi –Switch 71
8.6. Extended monitoring Proximity switch / proximity switch 72
8.7. HTL –Sensor 73
8.8. Resolver 74
9. Reaction time............................................................................................75
9.1. Response time at standstill: 75
9.2. Response time of FSoE in Fastchannel operation: 79
9.3. Response times for error distance monitoring 80
10. Safety-related characteristics ................................................................83
10.1. Internal architecture 83
10.2. Safety related characteristic data and wiring for the connected
sensors 85
10.2.1. Digital sensors 85
10.2.1.1. Charakteristics of sensors / input elements 85
10.2.1.2. DC of digital sensors / inputs 86

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10.2.1.3. Classification of digital inputs 90
10.2.1.3.1.Digital inputs I00 … I13 90
10.2.1.3.2.Digital inputs I/Os (IQIx) 91
10.2.1.4. Exemplary connections of digital sensors 92
10.2.1.4.1.Single-channel sensor, without cross-shorting test 92
10.2.1.4.2.Single-channel sensor with cross-shorting test 92
10.2.1.4.3.Dual-channel sensor without time-out and without cross-shorting 94
10.2.1.4.4.Dual-channel sensor with time-out and cross-shorting test 96
10.2.1.5. Overview of achievable PL for digital safety inputs 97
10.2.2. Sensors for speed and/or position detection 99
10.2.2.1. General safety related structure of sensor interface for position
and/or speed 99
10.2.2.2. General diagnostic measures for encoder interface 100
10.2.2.3. Encodertypen und deren Kombination, Diagnosekenndaten 101
10.2.2.4. Specific diagnostic measures with regard to the encoder type used 104
10.2.2.5. Safety-related switch-off threshold encoder systems for position
and speed detection 105
10.2.2.6. Safety-related evaluation of encoder systems, resolvers or their
combination 108
10.2.3. Analog sensors 110
10.2.3.1. Exemplary connection of analog sensors 111
10.2.3.1.1.Voltage and current sensor 111
10.2.3.1.2.Voltage sensor with test pulse 112
10.2.3.1.3.Current sensor with test pulse 112
10.3. Safety related characteristic data and wiring of the outputs 113
10.3.1. Charakteristic of output elements 113
10.3.2. Diagnoses in the cut-off circuit 115
10.3.2.1. Diagnostic functions 115
10.3.2.2. Overview DC with respect to the chosen diagnostic functions 116
10.3.3. Permissable capacitive and inductive load at safe outputs 117
10.3.4. Digital outputs 118
10.3.4.1. Characteristic data of the basic outputs 118
10.3.4.2. Wiring examples basic outputs 120
10.3.4.2.1.Single-channel switching relay or semi-conductor output
without test 120
10.3.4.2.2.Single-channel switching relay or semi-conductor output
with external switching amplifier and testing 121
10.3.4.2.3.Single-channel switching relay or semi-conductor output
with dual-channel external circuit with testing 122
10.3.4.2.4.Dual-channel switching relay output with external monitoring
- group feedback 124
10.3.4.2.5.Dual-channel output with relay output and semi-conductor output
–external control circuit with monitoring 125
10.3.4.2.6.Dual-channel output with relay output and external control
circuit in PL e 126
10.3.4.2.7.Dual-channel output with semi-conductor output and external control
circuit in PL e 126
10.3.4.2.8.Wiring of a auxiliary output 127

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10.3.5. Digital outputs I/Os (IQx) 128
10.3.5.1. Classification of the I/Os (IQx) when used as output 128
10.3.5.2. Wiring examples for safe digital outputs I/O ‘s (IQx) 129
10.3.5.2.1.Wiring single-channel without testing 129
10.3.5.2.2.Wiring single-channel with testing 130
10.3.5.2.3.Wiring with safe cut-off circuit 131
10.3.5.2.4.Wiring in connection with two-channel switching cut-off 131
10.3.5.2.5.Redundant two-channel output 132
10.3.5.2.5.1.Wiring dual-channel in the same group 132
10.3.5.2.5.2.Wiring dual-channel in diffrent groups 133
10.3.5.3. Overview of achievable PL for digital safety outputs 134
11. Commissioning and start......................................................................137
11.1. Switch-on sequence 137
11.2. Reset behaviour 138
11.2.1. Types of Reset and triggering events 138
11.2.2. Timing of Reset 139
11.2.3. Reset functions 140
11.3. LED displays 142
11.4. Parametrization 143
11.5. Regular function test 143
11.6. Validation 143
11.6.1. Process 144
11.6.2. Configuration report 145
11.6.2.1. Structure of the configuration report 145
11.6.2.2. Creating a configuration report 145
11.6.2.3. Filling in the configuration report 145
12. Safety inspection .................................................................................147
13. Maintenance.........................................................................................148
14. Failure and troubleshooting .................................................................148
15. Replacing an assembly.........................................................................148
16. Decommissioning / disassembly / disposal .........................................149
17. Setting as EtherCAT Slave with TwinCAT3............................................150
17.1. Installing the program 150
17.2. Creating a new project / Creating a new EtherCAT network 150
17.3. EoE settings in TwinCAT (EtherCAT settings) 159
18. Information for design, programming, validation and test...................161
18.1. Risk analysis 161
18.2. Necessary technical documents 164
18.3. Necessary steps –design, realization and test 165

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18.3.1. Specification of the safety requirements 167
18.3.2. Specification of the safety system 169
18.3.3. Software specification 171
18.3.4. Hardware specification 171
18.3.5. Selection of the SRP/CS and selection of the equipment 171
18.3.6. Consideration of systematic failures 172
18.3.7. Fault exclusions 173
18.3.8. Hardware design and software design 174
18.3.8.1. Testing of the hardware design 174
18.3.8.2. Analysis of the circuit diagram 174
18.3.8.3. Iterative test of the achieved safety level 175
18.3.8.4. Verification of the software and parameters 175
18.3.8.5. Validation of the functional scheme against the Instruction List (AWL)
and parameters via a validation report 175
18.3.8.6. Execution of system tests / FIT (Fault Injection Test) 175
19. List of abbreviaions..............................................................................176

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1.2. Table of illustrations
Fig. 1: rating plated SCU-2-EC/NM............................................................................ 28
Fig. 2:Network EtherCAT ......................................................................................... 32
Fig. 3:example FSoE Netzwerk FSoE ......................................................................... 33
Fig. 4: strucutre of SCU-2-EC/NM ............................................................................ 35
Fig 5: structure of SCU-1-EC ................................................................................... 35
Fig. 6: structure of SDU-11-PXV ............................................................................... 36
Fig. 7: structure of SDU-22A .................................................................................... 37
Fig. 8: structure SIO-2 ............................................................................................ 38
Fig. 9: structure of SSB-6-x* ................................................................................... 39
Fig. 10: mounting of the top-hat rail ......................................................................... 47
Fig. 11: 2-channel architecture................................................................................. 83
Fig. 12: total architecture ........................................................................................ 83
Fig. 13: Digital sensor 2-channel parallel ................................................................... 85
Fig. 14: Digital sensor 2-channel serial...................................................................... 85
Fig. 15: digital sensor one-channel ........................................................................... 86
Fig. 16: Single-Channel sensor, without cross-shorting test ......................................... 92
Fig. 17: Single-channel sensor with cross-shorting test ............................................... 92
Fig. 18: dual-channel sensor homogenous without cycling, with positive disconnection.... 94
Fig. 19: dual-channel input element heterogeneous, without cycling ............................. 94
Fig. 20 dual-channel sensor homogenous with clock.................................................... 96
Fig. 21: dual-channel sensor system with separate signal processing ............................ 99
Fig. 22: Sensor system with single-/dual-channel partial system .................................. 99
Fig. 23 Course of fault in V-detection .......................................................................105
Fig. 24: Single-channel switching P-output................................................................120
Fig. 25: Single-channel switching relay output...........................................................120
Fig. 26: Single-channel relay output with testing .......................................................121
Fig 27: Single-channel switching outout QX00_PP with dual-channel external circuit
and monitoring at output 13 as group feedback.........................................................122
Fig. 28: Single-channel switching output QX00_PP with dual-channel external circuit as
combination of electro-mechanical element and hydraulic/pneumatic valve and
monitoring at two inputs.........................................................................................123
Fig. 29: Two-channel switching relay output with external monitoring –group feedback.124
Fig. 30: Dual-channel output with relay output and semi-conductor output –external
control circuit with monitoring .................................................................................125
Fig. 31: Dual-channel output with relay output –external control circuit in PL e ............126
Fig. 32: Dual-channel output with semi-conductor output and external control
circuit in PL e ........................................................................................................126
Fig. 33 wiring of a notification output .......................................................................127
Fig. 34: Two-channel output with single-channel wiring without testing ........................129
Fig. 35: Two-channel output with single-channel wiring with testing.............................130
Fig. 36: two-channel output in connection with a device with examined disconnection....131
Fig. 37: two-channel output in connection with two-channel cut-off circuit with testing ..131
Fig. 38: Redundant two-channel outputs in the same group in connection with
two-channel cut-off circuit ......................................................................................132
Fig. 39: Redundant two-channel outputs in different groups in connection with
two-channel switching-off circuit..............................................................................133
Fig. 40: Timing of Reset .........................................................................................139
Fig. 41: Reset function 1 ........................................................................................140
Fig. 42: Reset function 2 ........................................................................................140
Fig. 43: Reset function 3 ........................................................................................141
Fig. 44: starting TwinCAT .......................................................................................151
Fig. 45: TwinCAT –Geräte einfügen [TwinCAT - insert devices] ...................................151
Fig. 46: TwinCAT - Master einfügen [TwinCAT –insert Master] ....................................152
Fig..47: TwinCAT –SCU einfügen [TwinCAT - insert SCU] ...........................................152
Fig .48: TwinCAT –IO devices.................................................................................153
Fig. 49: TwinCAT –IO devices.................................................................................154