Pilz PMCprotego S1 User manual

Operating Manual — No. 1001431-EN-06
Safety Card - Servo amplifiers
OperatingManualPMCprotegoS1OperatingManualPMCprotegoS1
PMCprotego S1

This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Co ies may be made
for internal ur oses.
Suggestions and comments for im roving this documentation will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS ®, SafetyEYE®,
SafetyNET ®, the s irit of safety® are registered and rotected trademarks of
Pilz GmbH & Co. KG in some countries.
SD means Secure Digital.
Preface

1
Contents
ContentsContents Page
Chapter 1 Introduction
1.1Validityofdocumentation1-11.1.1Retainingthedocumentation1-11.2Overviewofdocumentation1-21.3Definitionofsymbols1-3Chapter 2 Overview
2.1Unitstructure2-12.1.1Unitfeatures2-12.2Frontview2-3Chapter 3 Safety
3.1Intendeduse3-13.1.1Permittedmotortypes3-23.1.2Permittedmotorencodertypes3-23.1.3Useofqualifiedpersonnel3-23.1.4Warrantyandliability3-33.1.5Disposal3-33.2Standards3-4Chapter 4 Function Description
4.1Overview4-14.2Inputsandoutputs4-34.2.1Inputs4-34.2.2Outputs4-34.2.2.1Single-poleoutputs4-34.2.2.2Dual-poleoutputs4-54.2.2.3Outputtest4-54.3Safetyfunctions4-84.3.1Safetorqueoff-STO4-84.3.2Safestop1-SS14-104.3.3Safestop2-SS24-144.3.4Safeoperatingstop-SOS4-164.3.5Safelylimitedspeed-SLS4-184.3.6Safespeedrange-SSR4-224.3.7Safedirection-SDI4-254.3.8Safebrakecontrol-SBC4-284.3.9Safebraketest-SBT4-304.4Operatingmodeoftheservoamplifier4-344.5Reactiontimes4-364.6Configuration4-38

Contents
2Chapter 5 Installation
5.1Generalrequirements5-15.2Dimensions5-25.3Installingthesafetycard5-3Chapter 6 Wiring
6.1Generalwiringguidelines6-16.2Connectorpinassignment6-26.3Shielding6-36.4Digitalinputs6-46.5Digitaloutputs6-56.5.1Supplyvoltage6-56.5.2Single-poleoutputs6-66.5.3Dual-poleoutputs6-76.6Encoder6-96.6.1Supplyvoltage6-96.6.2IncrementalencoderwithTTLsignal6-9Chapter 7 Commissioning
7.1Safetyguidelines7-17.2Initialcommissioning7-27.3Recommissioning7-57.3.1Recommissioningatarestart7-57.3.2Recommissioningaftererror7-67.3.2.1Switchingtheinputs"SS1Activate"or"SS1SIL3/Reset"7-67.3.2.2Command"CLRFAULT"7-77.3.3Swapsafetycard7-87.3.3.1DownloadconfigurationfromConfiguratortosafetycard7-97.3.3.2DownloadconfigurationtoSDcard7-107.3.3.3DownloadconfigurationfromSDcardtosafetycard7-117.4Safetychecks7-13Chapter 8 Operation
8.1Operatingstates8-28.2Testingthesafepulsedisabler8-48.3Displayelements8-58.4Messages8-6Chapter 9 Technical Details
9.1TechnicalDetails9-19.2Safetycharacteristicdata9-39.2.1Safeactuatorwithoneencoder9-3

3
Contents
9.2.1.1MTTF>=10years9-39.2.1.2MTTF>=57years9-39.2.2Safeactuatorwithtwoencoders9-4Chapter 10 Glossary

Contents
4

1-11.1 Validity of documentation
1 Introduction
11000IntroductionIntroduction1-1.1Validityofdocumentation1100Validityofdocumentation1-EinfGltigkeitderDokumentationThisdocumentationisvalidfortheproductPMCprotego S1.Itisvaliduntilnewdocumentationispublished.][BA_Einfhrung_EinleitungThisoperatingmanualexplainsthefunctionandoperation,describestheinstallationandprovidesguidelinesonhowtoconnecttheproductPMCprotego S1.Einf_DokumentePleasealsorefertothefollowingdocumentsfromthemotioncontrolrange:TheconfigurationoftheexpansioncardisdescribedintheonlinehelpfortheConfiguratorPASconfigSDrive.TheservoamplifierPMCprotegoDisdescribedinthe"PMCprotegoDoperatingmanual".Detailsofhowtosettheparametersfortheservoamplifierarede-scribedintheonlinehelpforthePDrivecommissioningsoftware.AllthesemanualscanbefoundonthesuppliedCD-ROM:"MotionCon-trol".Youwillneedtobeconversantwiththeinformationinthesedocumentsinordertofullyunderstandthismanual.1.1.1 Retaining the documentation
Retainingthedocumentation1-EinfAufbewahrenThisdocumentationisintendedforinstructionandshouldberetainedforfuturereference.

1.2 Overview of documentation
1 Introduction
1-21.2Overviewofdocumentation1200Overviewofdocumentation1-Einf_Uebersicht_Doku1 Introduction
Theintroductionisdesignedtofamiliariseyouwiththecontents,struc-tureandspecificorderofthismanual.2 Overview
Thischapterprovidesinformationontheproduct'smostimportantfea-tures.3 Safety
Thischaptermustbereadasitcontainsimportantinformationonsafetyandintendeduse.4 Function Description
Thischapterdescribestheproduct'sindividualfunctions.5 Installation
Thischapterexplainshowtoinstalltheproduct.6 Wiring
Thischapterdescribestheproduct'swiring.7 Commissioning
Thischapterdescribeshowtocommissiontheproduct.8 Operation
Thischapterdescribesthedisplayelements,explainingtheiroperationanddiagnostics.9 Technical Details
10 Glossary

1-31.3 Definition of symbols
1 Introduction
1.3Definitionofsymbols1300Definitionofsymbols1-EinfhrungZeichenInformationthatisparticularlyimportantisidentifiedasfollows:DANGER!
Thiswarningmustbeheeded!Itwarnsofahazardoussituationthatposesanimmediatethreatofseriousinjuryanddeathandindicatespreventivemeasuresthatcanbetaken.WARNING!
Thiswarningmustbeheeded!Itwarnsofahazardoussituationthatcouldleadtoseriousinjuryanddeathandindicatespreven-tivemeasuresthatcanbetaken.CAUTION!
Thisreferstoahazardthatcanleadtoalessseriousorminorinjuryplusmaterialdamage,andalsoprovidesinformationonpreventivemeasuresthatcanbetaken.NOTICE
Thisdescribesasituationinwhichtheunit(s)couldbedamagedandalsoprovidesinformationonpreventivemeasuresthatcanbetaken.Italsohighlightsareaswithinthetextthatareofpartic-ularimportance.INFORMATION
Thisgivesadviceonapplicationsandprovidesinformationonspecialfeatures.

1.3 Definition of symbols
1 Introduction
1-4

2-12.1 Unit structure
2 Overview
22000OverviewOverview2-2.1Unitstructure2100Unitstructure2-Uebersicht_MerkmaleThesafetycardPMCprotego S1isanexpansionoftheservoamplifierPMCprotegoD.Itisusedforsafemotionmonitoring,whichisachievedinconjunctionwiththestandardmotorencoderandservoamplifier.Intheeventofanerror,theservoamplifier'spowerelementshutsdownthepowerquicklyandsafely.2.1.1 Unit features
Unitfeatures2-Uebersicht_Merkmale_EinlThesafetycardhasthefollowingfeatures:Uebersicht_Merkmale_Ein_Anzahl9single-pole,digitalinputstoactivatethesafetyfunctionsinaccord-ancewithEN61800-5-2:Funkt_Sicherheitsfunktion_BasisSafestop1(SS1)Safestop2(SS2)Safeoperatingstop(SOS)Safespeedrange(SSR)Safelylimitedspeed(SLS)Safedirection(SDI)Funkt_Sicherheitsfunktion_SBTSafebraketest(SBT)(notdefinedinEN61800-5-2)Uebersicht_Merkmal_Eing_SIL3_ResetAdditionalsafeinputtoachieveSIL3andresetthesafetycardafteranerrorUebersicht_Merkmale_Geber_S11inputforincrementalencoderUebersicht_Merkmale_Aus_einpolig_Anzahl7single-pole,digitaloutputsforthestatusofthesafetyfunctionsplustheoperatingstatus:Uebersicht_Merkmale_Aus_einpolig_BasisSafetorqueoff(STO)Safeoperatingstop(SOS)Saferange(SRA)Safedirection(SDI)SafetycardreadyUebersicht_Merkmale_Aus_einpolig_SBTSafebraketest(SBT)Uebersicht_Merkmale_Aus_einpolig_zweiter_AbschaltwegSecondshutdownroute(STOSIL3)Uebersicht_Merkmale_Aus_zweipolig_Anzahl1dual-poledigitaloutputforFunkt_Sicherheitsfunktion_SBCSafebrakecontrol(SBC)Uebersicht_Merkmale_VersorgungsspannungSupplyvoltage24VDCfordigitaloutputsUebersicht_Merkmale_LED

2.1 Unit structure
2 Overview
2-2LEDsforSupplyvoltage(POWER)Systemstatus(RUN)Downloadofconfigurationdata(CONFIG)Fault(FAULT)

2-32.2 Front view
2 Overview
2.2Frontview2200Frontview2-Uebersicht_Front_VollUebersicht_Front_Legende_BasisKey:
1:Screwforattachmenttotheservoamplifier2:LEDstodisplayoperatingstates3:Inputs/outputsandsupplyvoltage4:Labellingstripwith:–Ordernumber–Serialnumber–Numberofdeviceversion5:2DcodeUebersicht_Front_Legende_Voll6:Connectionforencoder
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
RUN
POWER
FAULT
CONFIG
X30
X31
8176105 12
100001
1
3
4
5
6
2
1
3

2 Overview
2-4

3-13.1 Intended use
3 Safety
33000SafetySafety3-3.1Intendeduse3100Intendeduse3-][BA_Sicherheit_Bestimmung_FSThesafetycardPMCprotego S1isanexpansionoftheservoamplifierPMCprotegoD.Itisdesignedforuseinsafety-relatedapplications.Sicherheit_Bestimm_prot_SItmeetstherequirementsforsafetyfunctionsinaccordancewithEN61800-5-2,withregardtosafemotionmonitoring.Sicherheit_Impulssperre_S1ThesafetycardmeetstherequirementsofENIEC61508uptoSIL3andENISO13849-1uptoPLe.ToachievecategorySIL3orPLe,theoperatormustensurethatthefunctionofthesafepulsedisableristestedperiodically,after8hoursatthelatest,bytriggeringsafetyfunctionsSS1orSTO:ByrestartingaftersafetyfunctionsSS1orSTOhavebeentriggeredasaconditionofoperationorByrestartingaftersafetyfunctionSS1hasbeentriggeredbytheop-eratorSicherheit_Impulssperre_InfoSicherheit_Bestimmung_Ausschluss_S1_S2Thefollowingisdeemedimproperuse:Anycomponent,technicalorelectricalmodificationtotheservoam-plifierUseoftheservoamplifieroutsidetheareasdescribedinthismanualUseoftheservoamplifieroutsidethedocumentedtechnicaldetails(seechapterentitled“TechnicalDetails”)IntendeduseincludesmakingtheinstallationandwiringEMC-compli-ant.Sicherheit_Bestimm_DokumenteIntendedusealsoincludescompliancewiththeOperatingmanualforthePMCprotegoDOnlinehelpfortheconfigurationtoolPASconfigSDrive.Sicherheit_Bestimm_ProdukteINFORMATION
Totestthesafepulsedisablerthroughdeliberateoperatoraction,seethesectionentitled"Operation",under"Testingthesafepulsedisabler".

3.1 Intended use
3 Safety
3-2ThesafetycardPMCprotego S1fromVersion1.0mayonlybeusedinconjunctionwiththefollowingservoamplifiers:PMCprotegoD.01fromVersion1.1PMCprotegoD.03fromVersion1.1PMCprotegoD.06fromVersion1.1PMCprotegoD.12fromVersion1.1PMCprotegoD.24fromVersion1.1PMCprotegoD.48fromVersion1.1PMCprotegoD.72fromVersion1.13.1.1 Permitted motor types
Permittedmotortypes3-Sicherheit_Bestimm_MotortypenThefollowingmotortypesareapprovedforusewiththesafetycard:RotarysynchronousmotorsLinearsynchronousmotorsPleasenote:Theuseofsynchronousmotorswithoutmotorencoder(sensorlessoperation)isnotpermitted.Workisinprogressforusewith:Asynchronousmotors3.1.2 Permitted motor encoder types
Permittedmotorencodertypes3-Sicherheit_Bestimm_MotorgebertypenThefollowingmotorencodertypesareapprovedforusewiththesafetycard:Encoder type Feedback type (parameter
FBTYPE) in the servo am-
plifier's commissioning
software
Status for operation
with safety card
Resolver0EnabledSinCosencoderwithHiperfaceinterface2EnabledSinCosencoderwithEnDat2.1interface(analogue)4EnabledSinCosencoder5Vwithwake&shake7EnabledSinCosencoderwithBiSSinterface5V(digital)20EnabledSinCosencoderwithBiSSinterface12V(digital)22EnabledSinCosencoderwithEnDat2.2interface5V(digital)32EnabledSinCosencoderwithEnDat2.2interface12V(digital)34Enabled

3-33.1 Intended use
3 Safety
3.1.3 Use of qualified personnel
Useofqualifiedpersonnel3-SichQualif.PersonalTheproductsmayonlybeassembled,installed,programmed,commis-sioned,operated,maintainedanddecommissionedbycompetentper-sons.Acompetentpersonissomeonewho,becauseoftheirtraining,experi-enceandcurrentprofessionalactivity,hasthespecialistknowledgere-quiredtotest,assessandoperatetheworkequipment,devices,systems,plantandmachineryinaccordancewiththegeneralstandardsandguidelinesforsafetytechnology.Itisthecompany'sresponsibilityonlytoemploypersonnelwho:Arefamiliarwiththebasicregulationsconcerninghealthandsafety/accidentpreventionHavereadandunderstoodthesafetyguidelinesgiveninthisdescrip-tionHaveagoodknowledgeofthegenericandspecialiststandardsap-plicabletothespecificapplication.3.1.4 Warranty and liability
Warrantyandliability3-SichGewhrleistungAllclaimstowarrantyandliabilitywillberenderedinvalidif:TheproductwasusedcontrarytothepurposeforwhichitisintendedDamagecanbeattributedtonothavingfollowedtheguidelinesinthemanualOperatingpersonnelarenotsuitablyqualifiedAnytypeofmodificationhasbeenmade(e.g.exchangingcompo-nentsonthePCBboards,solderingworketc.).3.1.5 Disposal
Disposal3-SichEntsorgungInsafety-relatedapplications,pleasecomplywiththemissiontimetMinthesafety-relatedcharacteristicdata.Whendecommissioning,pleasecomplywithlocalregulationsregard-ingthedisposalofelectronicdevices(e.g.ElectricalandElectronicEquipmentAct).

3.2 Standards
3 Safety
3-43.2Standards3200Standards3-Sicherheit_Normen_SicherheitskarteKnowledgeofandcompliancewiththerelevantstandardsanddirec-tivesareaprerequisiteforusingthesafetycard.Thefollowingstandardsarerelevant:EN61326-3-1:2008:Electricalequipmentformeasurement,controlandlaboratoryuse-EMCrequirementsEN61800-3:2004:AdjustablespeedelectricaldrivesEN61800-5-2:2007:Adjustablespeedelectricalpowerdrivesystems–Part5-2:Safetyrequirements.FunctionalENISO13849-1:2008:Safetyofmachinery–Safety-relatedpartsofcontrolsystems–Part1:Generalprinciplesfordesign,Part2:Valida-tionEN61508:1998:Functionalsafetyofsafety-relatedelectrical/elec-tronic/programmableelectroniccontrolsystems,Parts1,3,4EN61508-2:2000:Requirementsforsafety-relatedelectrical/elec-tronic/programmableelectronicsystemsEN60204-1:2007:Safetyofmachinery–Electricalequipmentofma-chines–Part1:GeneralrequirementsEN62061:2005:Safetyofmachinery–Functionalsafetyofsafety-re-latedelectrical,electronicandprogrammableelectroniccontrolsys-temsPleasenotethisisnotanexhaustivelistofsafetystandardsanddirec-tives.

4-14.1 Overview
4 Function Description
44000FunctionDescriptionFunctionDescription4-4.1Overview4100Overview4-Funkt_Uebersicht_allgThesafetycardmonitorssafetyfunctionsinaccordancewithEN61800-5-2.Itmonitorssafemotionsequencesondrives,whicharesafelybroughttoastopandshutdownintheeventofanerror.ThesafetycardisbuiltintoaservoamplifierPMCprotegoD.Thiscon-vertstheservoamplifierintoasafeservoamplifier.Funkt_Uebersicht_AntriebssystemAsafe drive systemfromPilzconsistsofthefollowing:Servoamplifier(PMCprotegoD)SafetycardPMCprotegoSbuiltintotheservoamplifierServomotor(synchronousmotor)with–Standardencodersystem(feedback)–Brake(optional,notsafety-related)SafetycontrolsystemFunkt_Uebersicht_Antriebssystem_S1Fig.4-1:SafedrivesystemFunkt_Uebersicht_SichKarteSafety card
PMCprotego S
Servo amplifier
PMCprotego D
Digit l outputs:
St tus of s fety functions
Oper tion l re diness
Safe servo amplifier PMCprotego DS
Safety control system
PSS
PNOZmulti
...
Digit l inputs:
S fety functions
S fe pulse
dis bler
M3
Intern l
supply volt ge
Extern l br ke
Motor br ke
St rt-up
dis bler
Motor
encoder
Extern l encoder
24 VDC
Second
shutdown route
Safety devices
e.g.
E-STOP
Oper ting mode
Light grid
Configurator
PASconfig SDrive

4.1 Overview
4 Function Description
4-2Thesafety card
ActivatessafetyfunctionsMonitorssafemotionsequencesSignalsthestatusofsafetyfunctionstothesafetycontrolsystemIntheeventofanerror,activatesthesafepulsedisablerwhichisin-tegratedwithintheservoamplifierandshutsdownthepowertothemotorPassesthebrakecommandtotheservoamplifierthatisexecutingthetravelcommand.Funkt_Uebersicht_SichKarte_vollHasasecondshutdownrouteinordertoimplementcategoriesSIL3orPLe.Hasadual-poleoutputtocontrolanexternalholdingbrake.Thebrakecanbetestedusingthesafetyfunction"safebraketestSBT".Hasaconnectionforanexternalencoder(incrementalencoderoren-coderwithSSIsignalscanbeselected).Fordetailsofthesafety-re-latedassessmentwhenusinganexternalencoderseeChapter8"TechnicalDetails",under"Safety-relatedcharacteristicdata".Funkt_Uebersicht_ServoverstTheservo amplifier
Removesthepowertothemotor,ifthesafepulsedisablerisactivat-ed,switchesthemotortotorque-freeandcanalsocontrolaninternalmotorbrake.Funkt_Uebersicht_SteuerungThesafety control system
ActivatesthesafetyfunctionsviainputsonthesafetycardEvaluatessignalsfromsafetydevices,suchas:–E-STOPpushbuttons–Safetygates–Lightbeamdevices–Two-handbuttonsProcessesthesafetycard'sstatusoutputsSafeinterconnectionbetweensafetycardandsafetycontrolsystemFaultdetection(shortsacrosscontacts,shortcircuits)onsignalsbe-tweenthesafetycontrolsystemandsafetycard,andinitiationofmeasuresFunkt_Uebersicht_Konfigurator_PilzConfigurator PASconfig SDrive
Funkt_Uebersicht_KonfiguratorConfigurationandparameterisationofthesafetycardSafeuploadanddownloadoftheconfigurationfileOnlinedisplayofthestatusofthesafetyfunctionsDisplayoferrorstackAbilitytosavetheconfigurationtoSDcard
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