CARLO GAVAZZI CERTUS User manual

CERTUS Installation Manual
CARLO GAVAZZI
Automation Components
(Copy of the original instructions)

2 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

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 3
CERTUS Installation Manual
© Copyright - Carlo Gavazzi – All rights reserved - Revision. R02
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.

4 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
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

8 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
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

10 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
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).