Kollmorgen KSM31R User manual

Installation Manual
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Installation Manual
for
KSM31R

Installation Manual
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Installation Manual for Extension Module KSM 31R.
Note:
The German version is the original version of the installation manual
Status: 09/2015
Valid from FW release 2.0.2.31
Subject to change without prior notification
The contents of this documentation has been collated with greatest care and corresponds
with our present status of information.
However, we would like to point out, that this document cannot always be updated at the
same time as the technical further development of the products.
Information and specifications can be changed at any time. Please keep yourself informed
about the current version under www.kollmorgen.com.
Devices of the
Kollmorgen Europe GmbH
Pempelfurtstraße 1
DE-40880 Ratingen

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Table of Contents
1IMPORTANT NOTES .......................................................................................... 4
1.1 Definitions ........................................................................................................................................... 4
1.2 Co-valid documents ............................................................................................................................. 4
1.3 Abbreviations used.............................................................................................................................. 5
2SAFETY REGULATIONS.................................................................................... 6
2.1 Operation and service ......................................................................................................................... 6
2.2 Transportation / storage ..................................................................................................................... 6
3DEVICE TYPES................................................................................................... 7
3.1 Characteristic data of device................................................................................................................ 7
3.2 Identification ....................................................................................................................................... 8
3.3 Scope of delivery ................................................................................................................................. 8
4CONNECTION AND INSTALLATION................................................................. 9
4.1 General notes on installation............................................................................................................... 9
4.2 Installation and assembly of the KSM module ................................................................................... 10
4.3 Installation of backplane bus system ................................................................................................. 10
4.4 Assembling the modules.................................................................................................................... 11
4.4.1 Assembly on C-rail............................................................................................................. 11
4.4.2 Assembly on backplane bus.............................................................................................. 12
4.5 Terminal assignment ......................................................................................................................... 14
5SAFETY RELATED WIRING OF OUTPUTS..................................................... 16
5.1 General specifications for wiring and testing..................................................................................... 16
5.2 Wiring of the relay outputs................................................................................................................ 17
5.2.1 Single-pole switching relay output without testing............................................................. 17
5.2.2 Single-pole switching relay with external switching amplifier and testing ......................... 18
5.2.3 Dual-channel switching relay output with external monitoring group feedback ................ 19
5.2.4 Two-channel relay output – external control circuit with monitoring.................................. 20
5.2.5 Dual-channel relay output with external control circuit in PL e.......................................... 21
6CONFIGURING THE KSM31R.......................................................................... 22
6.1.1 Basic configuration ............................................................................................................ 22
6.1.2 Step 2 ................................................................................................................................ 23
6.1.3 Step 3 ................................................................................................................................ 23
6.1.4 Step 4 ................................................................................................................................ 24
7MAINTENANCE ................................................................................................ 25
7.1 Modification / handling changes to the device .................................................................................. 25
7.2 Exchanging a module......................................................................................................................... 25
7.3 Maintenance intervals....................................................................................................................... 25
8TECHNICAL DATA ........................................................................................... 26
8.1 Environmental conditions.................................................................................................................. 26
8.2 Load carrying capacity of outputs...................................................................................................... 26
8.3 Technical data of switching relay....................................................................................................... 26
8.4 Safety-related characteristic data...................................................................................................... 27
8.4.1 Single-channel use of the relay output according to 5.2.2 ................................................ 27
8.4.2 Dual-channel use of the relay output according to 5.2.3, 5.2.4 or 5.2.5............................ 27

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1 Important notes
Definition of individual target groups
Project engineers for secure drive systems:
Engineers and technicians
Assembly, electric installation, maintenance and replacement of devices
Maintenance electricians and service technicians
Commissioning, operation and configuration:
Technicians and engineers
1.1 Definitions
The designation KSM is used as generic term for all derivatives from the KSM product range.
Wherever this description refers to a certain derivative, the complete designation is used.
The term “safe” used in the following text in any case refers to the classification as a safe
function for application up to Pl e acc. to EN ISO 13849-1 or SIL3 acc. to EN 61508.
The system software “SafePLC” serves the purpose of configuring and programming
KSM modules.
The modules of the KSM series are internally built up of two independent processing units.
In the following these are referred to as system A and system B.
1.2 Co-valid documents
Description
Reference
Installation manual for KSM module
series KSM10/11/12
HB-37350-810-01-xxF-DE KSM
Installation manual
Acceptance test
TÜV certificate for product modules
KSM31R
Note:
•Thoroughly read the manuals before you start the installation and the commissioning
of the KSM module.
•Paying attention to the documentation is a prerequisite for trouble-free operation and
fulfilment of possible warranty claims.

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1.3 Abbreviations used
Abbreviation
Meaning
AC
Alternating voltage
IL
Instruction list
ELIA
Employer's liability insurance association
CLK
Clock (cycle)
CPU
Central Processing Unit
DC
Direct voltage
DI1..DI14
Digital Input
DIN
Deutsches Institut für Normung (German Institute for Standardization)
DO
Digital Output
EMU
Emergency Monitoring Unit
EMC
Electromagnetic compatibility
ELC
Emergency Limit Control
EN
European Standard
HISIDE
Output with 24 VDC nominal level switching to plus
IP20
Degree of protection for housing
ISO
International Organisation for Standardisation
LED
Light Emitting Diode
LOSIDE
Output switching to reference potential
OLC
Operational Limit Control
PIA
Process image of outputs
PII
Process image of inputs
P1,P2
Pulse outputs
PLC
Programmable Logic Controller
POR
Power on Reset
PSC
Position Supervision Control
SELV
Safety Extra Low Voltage
SSI
Synchronous Serial Interface
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik e. V.
(association for electrical engineering, electronics and information
technology)

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2 Safety regulations
Intended use
You can only operate the KSM31R module with a basic module. This means that the same
safety regulations apply as for the KSM10/11/12 modules.
2.1 Operation and service
The module must always be de-energized before installation and removal, or before
disconnecting signal lines.
When installing or removing the module appropriate measures must be applied to prevent
electrostatic discharge to the externally arranged terminal and plug connections.
2.2 Transportation / storage
Information concerning transport, storage and proper handling must be strictly followed.
The climate related specifications in chapter “Technical data” must be complied with.

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3 Device types
3.1 Characteristic data of device
Type designation
Device design
Design of module with the following periphery:
12 digital inputs (DI 1-4 and DI8-12 OSSD)
2 I/Os optionally configurable as input or output
4 secure relay outputs
2 pulse outputs
2 signal outputs
12 status LEDs for inputs
10 status LEDs for I/O/relay output
1 backplane bus interface

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3.2 Identification
The type plate is located on the left side wall of the module and contains the following
information:
Type designation
Part number
Serial number
Identification of hardware release
Identification of software release
Safety category
Input characteristics
Output characteristics
Type plate KSM31R (image enlarged)
3.3 Scope of delivery
The scope of delivery contains:
KSM31R module:
•A plug for all the signal terminals
•A backplane bus connector

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4 Connection and installation
4.1 General notes on installation
Strictly follow the safety regulations when installing!
Type of protection IP20
Route all signal lines for the interfacing of digital inputs and contact monitoring separately.
In any case isolate 230 VAC voltages from low voltage lines, if these voltages are used in
connection with the application.
The cable lengths for digital inputs and outputs must not exceed 30 m.
Measures concerning the electromagnetic compatibility (EMC)
The KSM module is intended for use in the drive environment and meets the
EMC-requirements mentioned above.
It is also assumed that the electromagnetic compatibility of the overall system is ensured by
application of appropriate measures.
Safety note:
Electric power supply lines of the KSM and “discontinuous-action lines” of the power
converter must be isolated from each other.
Signal lines and power lines of the power converter must be routed through separate cable
ducts. The distance between the cable ducts should be minimum 10 mm.
Only shielded cables must be used to connect the position and speed sensors. The signal
transmission cable must be RS-485-standard compliant (lines twisted in pairs).
Care must be taken to ensure that the shielding is correctly connected in the 9-pin
SUB-D plugs of the position and speed sensors. Only metal or metal coated plugs are
permitted.
The shielding on the sensor side must comply with appropriate methods.
EMC-compliant installation of the power converter technology in the environment of the
KSM module must be assured. Special attention must be paid to the routing of cables, the
shielding of motor cables and the connection of the braking resistor. Strict compliance with
the installation instructions of the power converter manufacturer is mandatory.
All contactors in the environment of the power converter must be equipped with appropriate
suppressor circuits.
Suitable measures to protect against overvoltages must be applied.

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4.2 Installation and assembly of the KSM module
The module is solely to be installed in control cabinets,with a degree of protection of at
least IP54.
The modules must be vertically fastened on a top hat rail
The ventilation slots must be kept unobstructed, to ensure adequate air circulation inside
the module.
4.3 Installation of backplane bus system
The KSM31R module is connected to the base unit via the backplane bus.
Example: KSM11 + KSM31R + KSM5x
(Base unit + KSM31R + communication module)
The KSM31R module is supplied with power via the backplane bus from the base unit.
The digital outputs are supplied with power via plug connector X11 on the KSM31R module.
Note:
•A maximum of 2 extension modules can be connected to a base unit.
(Excl. bus module)
•You must not connect several base units with extension modules to one backplane
bus connection.
KSM5x
KSM31R
KSM11

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4.4 Assembling the modules
The modules are mounted on C-standard rails by means of snap-on latches.
4.4.1 Assembly on C-rail
The devices are inserted into the rail under an oblique angle and then snapped on downwards.
For disassembling use a screwdriver, insert it into the slot of the downwards pointing latch
and then move it up.

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4.4.2 Assembly on backplane bus
After assembling the backplane bus, you can install the device. For this purpose insert the
module from above into the plug connection under a oblique angle and snap it onto the C-rail.
Insert the module from above under an oblique angle.
Snap-on downwards on to the C-rail.

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The backplane plug connection can later be extended. The system configuration can thus be
extended by additional modules.
Snap the backplane bus element into the C-rail and insert it into the counter-piece by sliding
it sideways.

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4.5 Terminal assignment
Terminal
Designation
Function
X07:1
X07:2
X07:3
X07:4
K1/11
K1/12
K2/11
K2/12
Readback contact relay 1
Readback contact relay 1
Readback contact relay 2
Readback contact relay 2
X08:1
X08:2
X08:3
X08:4
K3/11
K3/12
K4/11
K4/12
Readback contact relay 3
Readback contact relay 3
Readback contact relay 4
Readback contact relay 4
X09:1
X09:2
X09:3
X09:4
K5/11
K5/12
K6/11
K6/12
Readback contact relay 5
Readback contact relay 5
Readback contact relay 6
Readback contact relay 6
X10:1
X10:2
X10:3
X10:4
K7/11
K7/12
K8/11
K8/12
Readback contact relay 7
Readback contact relay 7
Readback contact relay 8
Readback contact relay 8
X11:1
X11:2
X11:3
X11;4
U24 external
U24 external
GND external
GND external
IO voltage supply device +24 VDC
IO voltage supply device +24 VDC
IO voltage supply device 0 VDC
IO voltage supply device 0 VDC
X12:1
X12:2
X12:3
X12:4
IO01
IO02
P1
P2
I/O extension 1 (EAEx.1 / EAAx.1)
I/O extension 2 (EAEx.2 / EAAx.2)
Pulse output P1
Pulse output P2
X13:1
X13:2
X13:3
X13:4
Ax.1
Ax.2
Not used
Not used
Semi-conductor output Ax.1 (not a safety output)
Semi-conductor output Ax.2 (not a safety output)
X14:1
X14:2
X14:3
X14:4
Digital IN01
Digital IN02
Digital IN03
Digital IN04
Digital input 01 (Ex.1)
Digital input 02 (Ex.2)
Digital input 03 (Ex.3)
Digital input 04 (Ex.4)
X17:1
X17:2
X17:3
X17:4
K1.1
K1.2
K2.1
K2.2
Relay output 1
Relay output 1
Relay output 2
Relay output 2
X18:1
X18:2
X18:3
X18:4
K3.1
K3.2
K4.1
K4.2
Relay output 3
Relay output 3
Relay output 4
Relay output 4

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X19:1
X19:2
X19:3
X19:4
K5.1
K5.2
K6.1
K6.2
Relay output 5
Relay output 5
Relay output 6
Relay output 6
X20:1
X20:2
X20:3
X20:4
K7.1
K7.2
K8.1
K8.2
Relay output 7
Relay output 7
Relay output 8
Relay output 8
X21:1
X21:2
X21:3
X21:4
Not used
Not used
Not used
Not used
X22:1
X22:2
X22:3
X22:4
Not used
Not used
Not used
Not used
X23:1
X23:2
X23:3
X23:4
Digital IN05
Digital IN06
Digital IN07
Digital IN08
Digital input 05 (Ex.5)
Digital input 06 (Ex.6)
Digital input 07 (Ex.7)
Digital input 08 (Ex.8)
X24:1
X24:2
X24:3
X24:4
Digital IN09
Digital IN10
Digital IN11
Digital IN12
Digital input 09 (Ex.9) (OSSD)
Digital input 10 (Ex.10) (OSSD)
Digital input 11 (Ex.11) (OSSD)
Digital input 12 (Ex.12) (OSSD)
Note)
X: 1-> KSM31R device 1
2-> KSM31R device 2

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5 Safety related wiring of outputs
5.1 General specifications for wiring and testing
The wiring suggestions below show both the options for functional use of the relay outputs
and the wiring that is necessary for diagnostics in each case. Diagnosis must always be
carried out in the case of any safety-relevant use of the relay outputs. Apart from the wiring,
diagnostics requires integration into the application program of the monitoring function for
secure outputs “EMU” – For more details on this topic, refer to the programming manual.
Safety note:
•When using the relay outputs for safety-relevant functions, you must observe the
information below, in particular the specifications on wiring diagnostics.
•The diagnostics for achieving the respective Pl and SIL in accordance with the wiring
suggestions below, require you to integrate an associated diagnostics function into
the application program – For more details on this topic, refer to the programming
manual.
•For applications with frequent safety shut-down requests, these tests should be
performed more frequently, e.g. at the beginning of the shift, 1 × per week. However,
a test should at least be carried out cyclically 1 × year.
•You must parameterize the HISIDE outputs of the KSM31R module as safety outputs
(see configuration of KSM31R)
Wiring example relay with feedback:
X14
DI1
DI2
DI3
DI4
EA1
EA2
P1
P2
X12
K1/11
K1/12
K2/11
K2/12
X07
Fig.: Feedback of AK1

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5.2 Wiring of the relay outputs
5.2.1 Single-pole switching relay output without testing
For a single-pole connection without external testing, bear in mind that the KSM31R module
will not recognize bonding of the internal relay or of one or more external contacts. The
following circuit example is only suitable for safety applications on a limited basis; at
a maximum, Pl b according to EN 13849-1 can be achieved!
K1
K2
L+
L-
X17
X17.1
X17.2
X17.3
X17.4
Fig.: Single-pole switching relay output.
Safety note:
Not recommended for safety applications!
In this context see also the notes in EN 13849-1 concerning the application and the required
fault exclusions.

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5.2.2 Single-pole switching relay with external switching amplifier and testing
If you are using only one relay output, you will need a set-up to test the complete chain,
i.e. including all the downstream electro-mechanical, pneumatic or hydraulic components as
well as a message / warning device if faults are detected to achieve PL c or above.
You need positively guided auxiliary contacts for downstream electro-mechanical devices or
failsafe alarm contacts for the valve position for the hydraulic or pneumatic components.
The message / warning device must ensure that the operator recognizes the dangerous
situation immediately.
The achievable PI mainly depends on the test rate, PI d acc. to EM 13849-1 can be achieved
at a maximum.
X17
X14
K1
K2
IO01
IO02
P1
P2
X12
DI01
DI02
DI03
DI04
L +
L -
X17.1
X17.2
X17.3
X17.4
X14.1
X14.2
X14.3
X14.4
X12.1
X12.2
X12.3
X12.4
X7
K1/11
K1/12
K2/11
K2/12
X7.1
X7.2
X7.3
X7.4
Fig.: Single-pole relay output with testing
Safety note:
Only conditionally recommended for safety applications! In this context see also the
notes in EN 13849-1 concerning the application and the required fault exclusions.
For PL c or above, a test rate > 100 * request rate is necessary. For Pl d, you must
carry out testing at least once a year.
For PL c and above, a message / warning feature is required that informs the
operator immediately about a dangerous situation.

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5.2.3 Dual-channel switching relay output with external monitoring group feedback
For safety-related applications from Pl d onwards according to EN ISO 13849-1, two relays
on the KSM31R module and two external power contactors are used.
X17
X14
K1
K2
IO01
IO02
P1
P2
X12
DI01
DI02
DI03
DI04
L +
L -
X17.1
X17.2
X17.3
X17.4
X14.1
X14.2
X14.3
X14.4
X12.1
X12.2
X12.3
X12.4
X7
K1/11
K1/12
K2/11
K2/12
X7.1
X7.2
X7.3
X7.4
Fig.: Two-channel switching relay output with external monitoring – group feedback
The two external monitoring contacts are switched in series, supplied by clock signal P1 and
read-in from DI01 (configured as an EMU input). In the case of higher requirements, you
must consider that at least one switching process must take place every 24 hours.
Safety note:
To achieve PI d and above according to EN ISO 13849-1, a sufficiently high testing
rate is required.
For applications with frequent safety shut-down requests, these tests should be
performed more frequently, e.g. at the beginning of the shift, 1 × per week.
For Pl d, you must carry out a cyclical test at least once a year; to achieve Pl e this
test is needed at least once per month.

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5.2.4 Two-channel relay output – external control circuit with monitoring
For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is
controlled in dual-channel mode via two relay outputs. Each of the two external cutout paths
is monitored. For PL e acc. to EN ISO 13849-1 a sufficiently high testing rate
(see the remarks) and MTTFD= high is required for the external circuit.
X17
X14
K1
K2
IO01
IO02
P1
P2
X12
DI01
DI02
DI03
DI04
L +
L -
X17.1
X17.2
X17.3
X17.4
X14.1
X14.2
X14.3
X14.4
X12.1
X12.2
X12.3
X12.4
X7
K1/11
K1/12
K2/11
K2/12
X7.1
X7.2
X7.3
X7.4
P
N
Abschaltkanal 1
Abschaltkanal 2
Safety note:
To achieve PI d and above according to EN ISO 13849-1, a sufficiently high testing
rate is required.
For applications with frequent safety shut-down requests, these tests should be
performed more frequently, e.g. at the beginning of the shift, 1 × per week.
For Pl d, you must carry out a cyclical test at least once a year; to achieve Pl e this
test is needed at least once per month.
Shut-down circuit 1
Shut-down circuit 2