Carlo gavazzi Certus User manual

CERTUS Installation Manual

CARLO GAVAZZI

Automation Components

(Copy of the original instructions)

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CERTUS Installation Manual

Specifications are subject to change without notice. Pictures are just an example. For special features and/or customization, please ask to our sales network. 07/18

CERTUS Installation Manual

Dispose of the product in an eco-compatible manner and in accordance with national legislation.

For Countries in the European Union:

Pursuant to the Directive no. 2012/19/EU on waste electrical and electronic equipment (WEEE)

The crossed out wheelie-bin symbol on the equipment or its packaging means that when the product reaches the end of its

useful life it must be collected separately from other waste.

Proper separate collection of the discarded equipment for later environment-friendly recycling, processing and disposal,

helps to avoid any negative impact on the environment and health and encourages re-use and recycling of the materials the

equipment is made of.

In each individual Member State of the European Union this product is required to be disposed of in accordance with

Directive 2012/19/EU as implemented in the Member State where the product is disposed of.

For further information please contact Carlo Gavazzi or your local dealer.

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Introduction ............................................................. 8

Contents of this handbook ................................................ 8

Important safety instructions .............................................. 8

Abbreviations and symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Applicable standards .................................................... 9

Overview............................................................... 10

Product Composition .................................................... 11

Installation ............................................................. 12

Mechanical fastening ................................................... 12

Calculation of safety distance of an ESPE connected to CERTUS ................ 13

Electrical connections................................................... 13

Instructions concerning connection cables .................................. 14

USB input ............................................................ 15

Certus Configuration Memory (CMC) ....................................... 15

Multiple load function ................................................... 15

Restore function ....................................................... 15

Encoder connections with RJ45 connector (C ES1, C ES2) ..................... 21

Example of connection of Certus to the machine control system ................. 22

Checklist after installation................................................ 22

Operating diagram ..................................................... 23

Input .................................................................. 24

Master enable ......................................................... 24

Node Sel ............................................................. 24

Proximuty input for speed controller C ES2.................................. 25

Configuration with interleaved proximity .................................... 25

Restart_FBK .......................................................... 26

Outputs .............................................................. 27

Out Status............................................................ 27

Out Test ............................................................. 27

OSSD (CMM, C 8I 2O) .................................................. 27

OSSD (C 2OSSD, C 4OSSD) ............................................. 27

Characteristics of the output circuit ........................................ 28

C 2R / C 4R internal contacts diagram ..................................... 28

Example of C 2R module connection with static OSSD outputs of a module CMM. . . 29

Switching operation timing diagram........................................ 29

Technical features....................................................... 30

General system characteristics............................................ 30

Safety level parametrs .................................................. 30

General data .......................................................... 30

Enclosure ............................................................ 31

CMM module ......................................................... 31

C 8I 2O module........................................................ 31

C 8I - C 16I modules.................................................... 32

C 12I 8TO module...................................................... 32

CONTENTS

CERTUS Installation Manual

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C 2OSSD - C 4OSSD modules............................................ 32

C 2R - C 4R modules ................................................... 32

CPSS, CES1 and CES2 modules .......................................... 33

Mechanical Dimensions ................................................. 34

Signals............................................................... 35

Master CMM (Figure 10)............................................... 35

C 8I 2O (Figure 11) ................................................... 36

C 8I (Figure 12) ...................................................... 37

C 16I (Figure 14) ..................................................... 38

C 2OSSD (Figure 15) ................................................. 39

C 4OSSD (Figure 16) ................................................. 40

C 2R (Figure 17) / C 4R (Figure 18) ...................................... 41

Master CMM (Figure 19)............................................... 42

C 8I 2O (Figure 20) ................................................... 43

C 8I (Figure 21) ...................................................... 44

C 12I 8TO (Figure 22) ................................................. 45

C 16I (Figure 23 - C 16I) ............................................... 46

C 2R / C 4R (Figure 24) ............................................... 47

C ES1, C ES2 ....................................................... 48

C PSS, C ES1 and C ES2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Certus Safety Designer Software .......................................... 50

Installing the software................................................... 50

PC HARDWARE requirements ............................................ 50

PC SOFTWARE requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

How to install CSS ..................................................... 50

Fundamentals ......................................................... 51

Standard tool bar ...................................................... 52

Textual tool bar ........................................................ 53

Create a new project (configure the Certus system) ........................... 53

Edit configuration (composition of the various modules) ........................ 54

Change user parameters ................................................ 54

Objects - Operator - Configuration tool bars ................................. 55

Creating the diagram (Fig. 16) ............................................ 56

Example of a project.................................................... 57

Connect to Certus ................................................... 59

Sending the configuration to the Certus .................................. 59

Download a configuration file (project) from Certus CMM..................... 59

Configuration LOG ................................................... 59

System composition.................................................. 60

CERTUS Installation Manual

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CERTUS Installation Manual

MONITOR (I/O status in real time - textual) ................................ 61

MONITOR (I/O status in real time - textual - graphic) ........................ 61

Password protection.................................................... 62

Level 1 password .................................................... 62

Level 2 password .................................................... 62

Password Change ................................................... 62

TESTING the system ................................................. 63

Object Function Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Output Object ....................................................... 64

OSSD (safety output) ................................................. 64

STATUS (signal output) ............................................... 65

FIELDBUS PROBE ................................................... 65

INPUT OBJECTS ...................................................... 66

E STOP (emergency stop) ............................................. 66

E-GATE (safety gate device)............................................ 67

ENABLE (enable key) ................................................. 70

ESPE (optoelectronic safety light curtain / laser scanner) ..................... 71

FOOTSWITCH (safety pedal) ........................................... 73

MOD-SEL (safety selector) ............................................. 74

PHOTOCELL (safety photocell) ......................................... 75

TWO-HAND (bimanual control).......................................... 76

SENSOR ........................................................... 76

S-MAT (safety mat)................................................... 78

SWITCH ........................................................... 79

ENABLING GRIP SWITCH ............................................. 80

TESTABLE SAFETY DEVICE ........................................... 81

SOLID STATE DEVICE ................................................ 83

FIELDBUS INPUT .................................................... 84

COMMENTS ........................................................ 84

TITLE.............................................................. 84

SPEED CONTROL TYPE FUNCTION BLOCKS ............................... 85

SPEED CONTROL ................................................... 85

WINDOW SPEED CONTROL ........................................... 88

STAND STILL ....................................................... 90

STAND STILL AND SPEED CONTROL ................................... 92

OPERATOR FUNCTION BLOCKS ......................................... 95

LOGICAL OPERATORS ............................................... 95

AND............................................................... 95

NAND ............................................................. 95

NOT............................................................... 96

OR................................................................ 96

NOR .............................................................. 96

XOR............................................................... 97

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CERTUS Installation Manual

XNOR ............................................................. 97

MULTIPLEXER ...................................................... 98

Memory Operators ..................................................... 98

D FLIP FLOP (max number = 16) ........................................ 98

SR FLIP FLOP....................................................... 99

USER RESTART MANUAL (max number = 16 with RESTART MONITORED) ..... 99

USER RESTART MONITORED (max number = 16 with RESTART MANUAL) ..... 99

COUNTER OPERATORS ............................................. 102

COUNTER (max number = 16) ........................................... 102

TIMER OPERATORS (max number = 16)................................. 103

CLOCKING .......................................................... 103

MONOSTABLE ..................................................... 104

PASSING MAKE CONTACT ........................................... 105

DELAY............................................................ 106

MUTING FUNCTION................................................... 107

MUTING OPERATORS (max number = 4) .................................. 107

MUTING “L” ....................................................... 109

MUTING “T” ....................................................... 112

MUTING OVERRIDE (max number = 16) ................................. 113

MISCELLANEOUS FUNCTION BLOCKS ................................. 115

SPECIAL APPLICATIONS............................................... 120

Output delay with manual............................................. 120

ACCESSORIES AND SPARE PARTS ...................................... 122

WARRANTY ......................................................... 123

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CERTUS Installation Manual

Introduction

Contents of this Handbook

This handbook describes how to use the Certus programmable safety module and its

expansion units (“SLAVES”); it includes:

• a description of the system

• method of installation

• connections

• signals

• troubleshooting

• use of the configuration software

Important safety instructions

The Certus is built to the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4 in

accordance with the applicable standards. However, the definitive SIL and PL of the

application will depend on the number of safety components, their parameters and the

connections that are made, as per the risk analysis.

Read the “Applicable Standards” section carefully.

Perform an in-depth risk analysis to determine the appropriate safety level for your

specific application, on the basis of all the applicable standards.

Programming/configuration of the Certus is the sole responsibility of the installer or user.

The device must be programmed/configured in accordance with the application specific

risk analysis and all the applicable standards.

Once you have programmed/configured and installed the Certus and all the relative

devices, run a complete application safety test (see “TESTING the system”, page 57).

Always test the complete system whenever new safety components are added (see the

“TESTING the system” section, page 57).

Carlo Gavazzi is not responsible for these operations or any risks in connection there

with.

Reference should be made to the handbooks and the relative product and/or

application standards to ensure correct use of devices connected to the Certus within

the specific application.

The ambient temperature in the place where the system is installed must be compatible

with the operating temperature parameters stated on the product label and in the

specifications.

For all matters concerning safety, if necessary, contact your country’s competent safety

authorities or the competent trade association.

This safety alert symbol indicates a potential personal safety hazard. Failure to comply

with instructions bearing this symbol could pose a very serious risk to personnel.

⇒This symbol indicates an important instruction

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Abbreviations and Symbols

CMC = CERTUS Configuration Memory Card: memory chip for CERTUS CMM (accessory)

SCC = CERTUS Safety Communication: proprietary bus for expansion units

CCS = CERTUS Configuration Software: CERTUS configuration SW running in Windows

OSSD = Output Signal Switching Device: solid state safety output

MTTFd = Mean Time to Dangerous Failure

PL = Performance Level

PFHd = Probability of a dangerous failure per Hour

SIL = Safety Integrity Level

SILCL = Safety Integrity Level Claim Limit

SW = Software

Applicable Standards

Certus complies with the following European Directives:

• 2006/42/EC “Machinery Directive”

• 2004/108/EC “Electromagnetic Compatibility Directive”

• 2006/95/EC “Low Voltage Directive”

and is built to the following standards:

CEI EN 61131-2 Programmable controllers, part 2:

Equipment requirements and tests

ISO 13489-1 Safety of machinery:

Safety related parts of control systems. General principles for design

EN61496-1 Safety of machinery: Electro-sensitive protective equipment. Part 1: General requirements

and tests.

IEC 61508-1 Functional safety of electrical/electronic/programmable electronic safety-related systems:

General requirements.

IEC 61508-2 Functional safety of electrical/electronic/programmable electronic safety-related systems:

Requirements for electrical/electronic/programmable electronic safety-related systems.

IEC 61508-3 Functional safety of electrical/electronic/programmable electronic safety-related systems:

Software requirements.

IEC 61784-3 Digital data communication for measurement and control: Functional safety fieldbuses.

IEC62061 Safety of machinery. Functional safety of safety-related electrical, electronic and programmable

electronic control systems

CERTUS Installation Manual

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CERTUS Installation Manual

Overview

Certus is a modular safety controller. It consists of a master unit (CMM), which can be

configured using the CCS graphic interface, and a number of expansion units connected to

the CMM via the proprietary SCC bus.

The CMM can also be used as a stand-alone device. It has 8 safety inputs and 2

independent programmable dual channel outputs.

⇒The following expansions are available:

• Input/Output expansions (C 8I 2O, C 12I 8TO)

• Input expansions (C 8I, C 16I, C PSS, C ES1 and C ES2)

• Output expansions (C 2OSSD and C 4OSSD)

• Guided contact safety relay output modules (C 2R and C 4R) and

• Data and diagnostic communication expansion units to the main fieldbuses:

C PDP (Profibus DP), C CAN (CANOpen), C DNE (DeviceNET), C EIP (Ethernet IP), C PFN

(PROFINET), C ECA (EtherCAT).

Certus is capable of monitoring the following safety sensors and commands:

• Optoelectronic sensors (safety light curtains, scanners, safety photocells), mechanical

switches, safety mats, emergency stops, two-hand controls, all managed by a single

flexible and expandable device.

• The system must consist of just one Master module CMM and a number of electronic

expansions that can range from 0 to a maximum of 14, not more than 4 of which of the

same type. There is no limit to the number of relay modules that can be installed.

• With 14 expansions, the system can have up to 128 inputs, 16 dual channel safety outputs

and 16 status outputs. The MASTER and its SLAVE units communicate via the 5-way SCC

bus (Carlo Gavazzi proprietary bus), physically arranged on the rear panel of each unit.

• Furthermore 8 inputs and 16 outputs probe controllable (by Fieldbus) are available.

• The CCS software is capable of creating complex logics, using logical operators and

safety functions such as muting, timer, counters, etc.

• All this is performed through an easy and intuitive graphic interface.

The configuration performed on the PC is sent to the CMM via USB connection; the

file resides in the CMM and can also be saved on the proprietary CMC memory chip

(accessory). The configuration can therefore quickly be copied to another CMM unit.

⇒The Certus system is certified to the maximum safety level envisaged by the applicable

industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4).

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Product Composition

The Certus CMM is supplied with:

• CD-ROM containing the free CCS SW, this PDF multi-language handbook and other

product literature.

• Multi-language installation sheet.

CERTUS Installation Manual

The expansion units are supplied with:

• Multilingual Installation sheet.

• Carlo Gavazzi panel SCC connector (not present in the C 2R and C 4R which are

connected via terminal blocks only)

⇒NB: the rear panel SCC connector and CMC memory can be ordered separately as

accessories.

⇒NB: to install an expansion unit (excluding relays) you will need the SCC connector

supplied with the unit plus another SCC for the connection to the CMM. This can be

ordered separately as an accessory.

The C PSS, C ES1 and C ES2 CERTUS expansion units can be used to control the following

(up to PLe):

• Zero speed, Max. speed, Speed range;

• Direction of movement, rotation/translation;

Up to 4 speed thresholds can be set for each logic output (axis).

Each unit incorporates two logic outputs that can be configured using the MSD software and

is thus capable of controlling up to two independent axes.

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Installation

CERTUS Installation Manual

Mechanical Fastening

Fix the Certus system units to a 35mm DIN rail as follows:

1. Connect the same number of “SCC” 5-pole rear panel connectors as the number of units

to be installed.

2. Fix the train of connectors thus obtained to the DIN 35mm (EN 5022) rail (hooking them

at the top first).

3. Fasten the units to the rail, arranging the contacts on the base of the unit on the respective

connector. Press the unit gently until you feel it snap into place.

4. To remove a unit, use a screwdriver to pull down the locking latch on the back of the unit;

then lift the unit upwards and pull.

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Calculation of Safety Distance of an ESPE Connected to Certus

CERTUS Installation Manual

The European standard:

- ISO 13855:2010- (EN 999:2008) Safety of machinery - Positioning of safeguards with

respect to the approach speeds of parts of the human body.1

provides the elements to calculate the proper safety distance.

Carefully read the installation manual of each device for specific information on the

correct positioning.

Remember that the total response time depends on:

Certus response time + ESPE response time + response time of the machine (i.e. the

time taken by the machine to stop the dangerous movement from the moment in

which the stop signal is transmitted).

Any Electro-Sensitive Protective Equipment device connected to Certus, must be positioned at

a distance equal to or greater than the minimum safety distance S so that the dangerous point

can be reached only after stopping the dangerous movement of the machine.

Electrical Connections

The Certus system units are provided with terminal blocks for the

electrical connections. Each unit can have 8, 16 or 24 terminals.

Each unit alsohas a rearpanel plug-in connector(for communication

with the master and with the other expansion units).

The C 2R and C 4R are connected via terminal

blocks only.

⇒Terminal tightening torque: 5÷7lb-in (0,6÷0,7 Nm).

Install safety units in an enclosure with a protection class of at least IP54.

Connect the module when it is not powered.

The supply voltage to the units must be 24Vdc ±20% (PELV, in compliance with the

standard EN 60204-1 (Chapter 6.4).

Do not use the Certus to supply external devices.

The same ground connection (0VDC) must be used for all system components

1”Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point for

the safety devices, particularly Electro-sensitive devices (eg. light curtains), safety-mats or pressure sensitive floors and bimanual

control. It contains a rule to determine the placement of safety devices based on approach speed and the stopping time of the

machine, which can reasonably be extrapolated so that it also includes the interlocking guards without guard locking.”

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Instructions Concerning Connection Cables

CERTUS Installation Manual

⇒Wire size range: AWG 12÷30, (solid/stranded) (UL).

⇒Use 60/75°C copper (Cu) conductor only.

⇒ We recommend the use of separate power supplies for the safety module and for other

electrical power equipment (electric motors, inverters, frequency converters) or other

sources of disturbance.

⇒Cables used for connections of longer than 50m must have a cross-section of at least

1mm2(AWG16).

Connectionis of each single Certus system unit are listed in the table below:

Master CMM

Terminal Signal Type Description Operation

1 24VDC - 24VDC power supply -

2 MASTER_ENABLE2 Input Master Enable 1 Input (“type B” according to EN61131-2)

3 MASTER_ENABLE2 Input Master Enable 2 Input (“type B” according to EN 61131-2)

4 GND - 0VDC power supply PNP active high

5 OSSD2_A Output Static output 1 PNP active high

6 OSSD1_B Output PNP active high

7 RESTART_FBK1 Input Feedback/Restart Input according to EN61131-21

8 OUT_STATUS1 Output Programmable digital output PNP active high

9 OSSD2_A Output Static output 2 PNP active high

10 OSSD2_B Output PNP active high

11 RESTART_FBK2 Input Feedback/Restart 2 Input according to EN61131-2

12 OUT_STATUS2 Output Programmable digital output PNP active high

13 OUT_TEST1 Output Short circuit detected output PNP active high

14 OUT_TEST2 Output Short circuit detected output PNP active high

15 OUT_TEST3 Output Short circuit detected output PNP active high

16 OUT_TEST4 Output Short circuit detected output PNP active high

17 INPUT1 Input Digital input 1 Input according to EN61131-2

18 INPUT2 Input Digital input 2 Input according to EN61131-2

19 INPUT3 Input Digital input 3 Input according to EN61131-2

20 INPUT4 Input Digital input 4 Input according to EN61131-2

21 INPUT5 Input Digital input 5 Input according to EN61131-2

22 INPUT6 Input Digital input 6 Input according to EN61131-2

23 INPUT7 Input Digital input 7 Input according to EN61131-2

24 INPUT8 Input Digital input 8 Input according to EN61131-2

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CERTUS Installation Manual

USB Input

The Certus master CMM includes a USB 2.0

connector for connection to a Personal Computer

where the CCS (Certus Configuration Software)

configuration SW resides.

A USB cable of the correct size is available as an

accessory (CSU).

Certus Configuration Memory (CMC)

A backup memory, called CMC (optional)

can be installed in the Certus master CMM

and used to save the SW configuration

parameters.

The CMC is written each time a new project

is sent from the PC to the CMM.

⇒Always switch the CMM off before

logging on to/logging off from the CMC.

Insert the card in the slot in the rear panel of

the CMM (in the direction shown in Figure 3

- CMC).

MULTIPLE LOAD function

To perform the configuration of several CMM modules without using a PC and the USB

connector, you can save the desired configuration on a single CMC and then use it to download

data on the modules CMM to be configured.

If the file contained in the CMC is not identical to the one contained in CMM, an

overwrite operation that will permanently delete the configuration data contained in

CMM will be performed.

WARNING: ALL DATA PREVIOUSLY CONTAINED IN CMM WILL BE LOST.

RESTORE function

If the CMM unit is damaged, you can replace it with a new one; having already saved all the

configurations on the CMC, all you need to do is insert the CMC in the new CMM and switch

on the Certus system, that will immediately load the backup configuration. In this way, the

work interruptions will be minimized.

Technical Data Label

CMC Label

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CERTUS Installation Manual

⇒The LOAD and RESTORE functions can be disabled via SW. (see Figure 29)

⇒In order to be used, the expansion units must be addressed at the time of installation

(see the NODE SEL section).

Each time CMC is used, carefully check that the chosen configuration is the one that

was planned for that particular system. Try again a fully functional test of the system

composed of Certus plus all devices connected to it (see the TESTING the system

section).

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CERTUS Installation Manual

C 8I 2O Expansion Module

Terminal Signal Type Description Operation

1 24VDC - 24VDC power supply -

2 NODE_SEL0 Input Node selection Input (“type B” according to EN61131-2)

3 NODE_SEL1 Input Input (“type B” according to EN 61131-2)

4 GND - 0VDC power supply -

5 OSSD1_A Output Static output 1 PNP active high