Lenze c250-S User manual

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Operating Instructions
Translation
EN
c250−S C25BAYA42, C25BAYA82,
C25BAYA160, C25BAYA164
c250−S Safety I/O−module
l

Safety I/O-module
EDBC250SIO | 2.0 2
Information Safety I/O-module C25BAYA42
The operatin instructions be in on pa e 3.
Information Safety-I/O-Module C25BAYA82, C25BAYA16 ,
C25BAYA164
The operatin instructions be in on pa e 113.
ATTENTION: There are si nificant deviations from the Safety I/O Module
C25BAYA42 in some Technical Data.
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Safety I/O-module
EDBC250SIO | 2.0 3
1 Version Details ........................................................................................................... 7
1.1 Revision .............................................................................................................. 7
1.1.1 Manual .............................................................................................. 7
1.1.2 Safety I/O-module (C25BAYA42) .......................................................... 7
2 Preface ...................................................................................................................... 8
2.1 About this Operatin Instructions ....................................................................... 8
2.1.1 Limitation of Liability ............................................................................ 8
2.1.2 Terms of Delivery ................................................................................. 8
2.1.3 Copyri ht .............................................................................................. 8
2.1.4 Warranty .............................................................................................. 9
2.2 Reliability, Safety ................................................................................................. 9
2.2.1 Applicability .......................................................................................... 9
2.2.2 Tar et Group ........................................................................................ 9
2.2.3 Reliability .............................................................................................. 9
2.2.4 Hazard and Other Warnin s ............................................................... 10
2.2.5 Other Notices ..................................................................................... 10
2.2.6 Safety ............................................................................................ 11
2.2.7 Project Plannin and Installation ....................................................... 11
2.2.8 Maintenance and Servicin ................................................................ 11
2.2.9 General Notes on Installation ............................................................ 12
3 System Description .................................................................................................. 14
3.1 EtherCAT® – Ethernet Control ........................................................................... 14
3.2 c250-S Safety System ......................................................................................... 14
3.2.1 Safety over EtherCAT (FSoE) .............................................................. 15
3.2.2 Safety controller c250-S ..................................................................... 15
3.2.3 Safety I/O-module .............................................................................. 15
3.2.4 PLCDesi ner Safety............................................................................. 15
3.2.5 PLCDesi ner SafetyPLCopen Library .................................................. 16
4 Product Description ................................................................................................. 17
4.1 General Description ........................................................................................... 17
4.2 Application ......................................................................................................... 18
4.2.1 Intended Use ...................................................................................... 18
4.2.2 Qualified Persons ............................................................................... 18
4.2.3 Disclaimer of Liability ......................................................................... 19
4.3 Safe State ........................................................................................................... 20
4.3.1 Safe Functional State ......................................................................... 20
4.3.2 Fail-Safe State – External Fault........................................................... 20
4.3.3 Fail-Safe State – Internal Fault ........................................................... 20
4.3.4 Traceability ......................................................................................... 21

Safety I/O-module
EDBC250SIO | 2.0 4
4.4 Useful Lifetime ................................................................................................... 21
4.5 Technical Data ................................................................................................... 21
4.5.1 General Specifications ........................................................................ 21
4.5.2 Safe Di ital Inputs .............................................................................. 23
4.5.3 Safe Di ital Test Pulse Outputs .......................................................... 23
4.5.4 Safe Di ital Outputs ........................................................................... 24
4.6 Safety-related Input Ratin s .............................................................................. 25
4.6.1 Safety-related Ratin s of a Sin le-channel Application ..................... 25
4.6.2 Safety-related Ratin s of a Two-channel Application ........................ 26
4.7 Safety-related Output Ratin s ........................................................................... 27
4.7.1 Safety-related Ratin s of a Sin le-channel Application ..................... 27
4.7.2 Safety-related Ratin s of a Two-channel Application ........................ 28
4.8 Response Time................................................................................................... 29
4.9 Dimensions ........................................................................................................ 31
4.10 Transport and Stora e ....................................................................................... 31
5 Construction and Functionality ................................................................................. 32
5.1 Labellin and Identification ............................................................................... 32
5.1.1 Imprinted Texts and Symbols ............................................................. 32
5.1.2 Serial Number .................................................................................... 32
5.2 Contents of Packa e .......................................................................................... 33
5.3 Connectors......................................................................................................... 34
5.3.1 E-bus and Module Lock ...................................................................... 34
5.3.2 Sprin -assisted Combi Plu X1 ........................................................... 35
5.3.3 Wirin Example .................................................................................. 37
5.3.4 Safety I/O-module Supply .................................................................. 38
5.4 Indicators and Controls ..................................................................................... 40
5.4.1 LED "EtherCAT Run" ........................................................................... 40
5.4.2 LED "Safe Status"................................................................................ 40
5.4.3 LED "Power" ....................................................................................... 40
5.4.4 LEDs "Channel" ................................................................................... 41
5.5 Operatin Software ........................................................................................... 42
Installation and Operation ........................................................................................ 43
6.1 Mechanical Installation ..................................................................................... 43
6.1.1 Mountin Position .............................................................................. 44
6.1.2 To Snap on a Sin le Module ............................................................... 45
6.1.3 To Interconnect Two Modules ........................................................... 45
6.1.4 To Disconnect Two Modules .............................................................. 46
6.1.5 To Take Down a Sin le Module .......................................................... 46

Safety I/O-module
EDBC250SIO | 2.0 5
6.2 Electrical Installation ......................................................................................... 47
6.2.1 Earth ............................................................................................ 47
6.2.2 Module Interconnection .................................................................... 48
6.2.3 System Power Supply ......................................................................... 48
6.2.4 Safety I/O-module Supply .................................................................. 49
6.2.5 Sensor and Actuator Power Supply .................................................... 50
6.2.6 Power Supply Wirin Example ........................................................... 51
6.2.7 Sensor Connection ............................................................................. 52
6.2.8 Actuator Connection .......................................................................... 58
6.2.9 Multiple socket connector (MSC)....................................................... 62
6.3 Confi uration ..................................................................................................... 63
6.3.1 Address Setup .................................................................................... 63
6.3.2 FSoE Parameters ................................................................................ 65
6.3.3 Input Parameters ............................................................................... 71
6.3.4 Output Parameters ............................................................................ 72
6.4 Puttin into Service ........................................................................................... 74
6.5 Dia nosis ............................................................................................................ 75
6.5.1 Self-test ............................................................................................ 75
6.5.2 Safety I/O-module Module Faults ...................................................... 75
6.5.3 Wron Wirin ..................................................................................... 75
6.5.4 Temperature Faults ............................................................................ 76
6.5.5 Wron Supply Volta e ........................................................................ 76
6.5.6 Table of Faults .................................................................................... 76
6.5.7 Error Codes ......................................................................................... 77
6.5.8 EtherCAT Link Lost.............................................................................. 78
6.5.9 Wron FSoE Address .......................................................................... 79
6.5.10 Wron Confi uration of the Safety I/O-Module ................................ 79
6.6 Reset / Acknowled e Error ................................................................................ 80
6.7 Maintenance / Servicin .................................................................................... 81
6.7.1 General ............................................................................................ 81
6.7.2 Servicin ............................................................................................ 81
6.7.3 Preventive Maintenance .................................................................... 81
6.8 Replacin a Safety I/O-module .......................................................................... 82
6.9 Durability ........................................................................................................... 83
6.9.1 Repairs / Customer Service ................................................................ 83
6.9.2 Warranty ............................................................................................ 83
6.9.3 Takin out of Service .......................................................................... 84
6.9.4 Disposal ............................................................................................ 84

Safety I/O-module
EDBC250SIO | 2.0 6
7 Connection Examples ............................................................................................... 85
7.1 Safety Function with Sin le-channel Input ........................................................ 86
7.2 Safety Function with Two-channel Input .......................................................... 87
7.3 Two-hand Actuation .......................................................................................... 88
7.4 Mode Selector, Rotary Table ............................................................................. 90
7.5 Safety Mats, Connectin Blocks and Bumpers .................................................. 92
7.6 Connectin Two Actuators with Internal GND Reference ................................. 94
7.7 Connectin Two Parallel Actuators to One Safe Output ................................... 95
8 Appendix ................................................................................................................. 97
8.1 Object Dictionary ............................................................................................... 97
8.1.1 Type 1000
h
......................................................................................... 97
8.1.2 Error Re ister 1001
h
........................................................................... 97
8.1.3 Name 1008
h
........................................................................................ 98
8.1.4 Hardware Version 1009
h
.................................................................... 98
8.1.5 Software Version 100A
h
..................................................................... 98
8.1.6 Identification 1018
h
............................................................................ 99
8.1.7 24V Volta e CPU 1: 2001
h
and CPU 2: 2011
h
................................... 100
8.1.8 Output 0/1 Current CPU 1: 2005
h
and CPU 2: 2015
h
....................... 100
8.1.9 CPU 1: External Temperature Sensor 2006
h
.................................... 101
8.1.10 Errorcode CPU 1: 2007
h
and CPU 2: 2017
h
....................................... 102
8.1.11 Errorline CPU 1: 2008
h
and CPU 2: 2018
h
......................................... 107
8.1.12 Errormodule CPU 1: 2009
h
and CPU 2: 2019
h
.................................. 107
8.1.13 Errorclass CPU 1: 200A
h
and CPU 2: 201A
h
...................................... 109
8.1.14 System Uptime [s] 200C
h
.................................................................. 109
8.1.15 Temperature Warnin 2016
h
........................................................... 109
8.1.16 Objects - For Internal Use Only ........................................................ 110
8.2 Standards Complied With ................................................................................ 111
8.2.1 Product Standard Applied ................................................................ 111
8.2.2 Safety Standards and Directives ...................................................... 111
8.2.3 EMC Standards ................................................................................. 111
8.3 Re ulations and Declarations .......................................................................... 111
8.3.1 Mark of Conformity .......................................................................... 111
8.4 Permits .......................................................................................................... 112
8.5 Order Specifications ........................................................................................ 112
8.5.1 Basic Units ........................................................................................ 112
8.5.2 Accessories ....................................................................................... 112
8.5.3 Spare Parts ....................................................................................... 112

1 Version Details
EDBC250SIO | 2.0 7
1Version Details
1.1 Revision
1.1.1 Manual
Manual History
Version
Date
Comments / modification
1.0
0
1/
3
1/2017
C
reation
1.1
0
4
/0
5
/
2017
R
elease
1.2
0
8
/
0
2
/2017
C
orrections
1.
3
0
8
/
2
9
/
2017
C
orrections
2.0
0
9
/
2
7
/2019
C
orrections
1.1.2 Safety I/O-module (C25BAYA42)
The table below summarises the module releases, manual versions, production dates and the
chan es to the functionality.
Modul release
Version
Manual
Date
Comments / modifications
V1.0 1.0 01/31/2017
Applies to module release
V1.0
(Softwareversion V1.0x, Hardwareversion V2.1)
V1.0 1.1 04/05/2017
A
pplies to module release
V1.0
(Softwareversion V1.0x, Hardwareversion V2.1)
V1.0 1.2 08/02/2017
A
pplies to module release V1.0
(Softwareversion V1.0x, Hardwareversion V2.1)
V1.0 1.3 08/29/2017
A
pplies to module release
V1.0
(Softwareversion V1.0x, Hardwareversion V2.1)
V1.0 2.0 09/27/2019
A
pplies
to module release V1.0
(Softwareversion V1.0x, Hardwareversion V2.1)

Safety I/O-module
EDBC250SIO | 2.0 8
2Preface
2.1 About this Operating Instructions
This document is the ori inal Operatin Instructions to Safety I/O-module, order number
C25BAYA42. Your module work should always be based on the correct Operatin Instructions
version ► 1.1.1 Manual.
This document is primarily directed to system desi ners and project en ineers. It does not
contain any availability information. We reserve the ri hts for errors, omissions and
modifications. Pictures are similar.
Information
Always
use
the current version of the manual.
Information and Tools about the Lenze Products can be found in the Internet
httP://www.lenze.com
►
Download
2.1.1 Limitation of Liability
Specifications are for description only and are not to be understood as uaranteed product
properties in a le al sense. Exact properties and characteristics shall be a reed in the specific
contract. Claims for dama es a ainst us - on whatever rounds - are excluded, except in
instances of deliberate intent or ross ne li ence on our part.
2.1.2 Terms of Delivery
The eneral conditions of sales and service of Lenze Automation GmbH shall apply.
2.1.3 Copyri ht
Microsoft®, Windows® and the Windows® lo o are re istered trademarks of Microsoft Corp. in
the USA and other countries.
EtherCAT® is a re istered brand and patented technolo y, licenced by Beckhoff Automation
GmbH, Germany.
Safety over EtherCAT is a re istered trademark and patented technolo y, licenced by Beckhoff
Automation GmbH, Germany
Further information about the PLCopen or anisation is available at www.plcopen.or . CiA® and
CANopen® are re istered joint brands of CAN in Automation e.V. Title to all companies and
company names mentioned herein as well as to products and product names is held by the
respective enterprises.
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2 Preface
EDBC250SIO | 2.0 9
2.1.4 Warranty
Warranty is subject to the provisions of the conditions of sale of Lenze or any contractual
a reements between the parties.
The warranty will be voided by:
•improper assembly and use
•repairs or inadmissible servicin
•modifications or renderin the serial number ille ible or removin it
2.2 Reliability, Safety
2.2.1 Applicability
This Operatin Instructions contains all information necessary for the use of the described
product (control device, control terminal, software, etc.) accordin to instructions.
2.2.2 Tar et Group
The Operatin Instructions is written for desi n, project plannin , servicin and commissionin
experts. For proper understandin and error-free application of technical descriptions,
instructions for use and particularly of notes of dan er and warnin , extensive knowled e of
automation technolo y and functional safety is compulsory.
2.2.3 Reliability
Reliability of Lenze products is brou ht to the hi hest possible standards by extensive and cost-
effective means in their desi n and manufacture.
These include:
•selectin hi h-quality components,
•quality a reements with our suppliers,
•actions to avoid static char es when handlin MOS circuits,
•worst case plannin and desi n of all circuits,
•visual inspections at various sta es of fabrication,
•computer-aided tests of all assemblies and their interaction in the circuit,
•statistical assessment of the quality of fabrication and of all returned oods for the
immediate takin of appropriate corrective actions.
•standardised returns handlin process
•ISO 9001:2015 certification

2 Preface
EDBC250SIO | 2.0 10
2.2.4 Hazard and Other Warnin s
Despite the actions described in section 2.2.3 Reliability , the occurrence of faults or errors in
electronic control units - even if most hi hly improbable - must be taken into consideration.
Please pay particular attention to the additional notices which we have marked by symbols
throu hout this Operatin Instructions. While some of these notices make you aware of
possible dan ers, others are intended as a means of orientation. They are described further
down below in descendin order of importance.
Every alert and hazard warnin is made up as follows:
•Type and source of risk
•Potential consequences of non-observance
•Preventive measures
DANGER
A DANGER warnin makes you aware of an immediately hazardous situation
which WILL cause a serious or fatal accident if not observed.
WARNING
A WARNING makes you aware of a potentially hazardous situation which MAY
cause a serious or fatal accident or dama e to this or other devices if not
observed.
CAUTION
A CAUTION alert makes you aware of a potentially hazardous situation which
MAY cause an accident or dama e to this or other devices if not observed.
ATTENTION
An ATTENTION notice makes
you aware of a potentially hazardous situation
which MAY cause dama e to this or other devices if not observed.
2.2.5 Other Notices
Note, information
This symbol draws your attention to additional information concernin the use
of the described product. This may include cross references to information
found elsewhere (e. . in other manuals).
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