Pilz Intern PMC SR6 User manual

Pilz
PMC SR6 safety module
Manual-1005344-en-US-01
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Table of contents
Manual PMC SR6 safety module
1005344-en-US-01
Pilz | ii
Table of contents
1 Foreword ..........................................................................................................................................................4
2 User information ..............................................................................................................................................5
2.1 Storage and transfer ..........................................................................................................................................5
2.2 Described product..............................................................................................................................................5
2.3 Timeliness..........................................................................................................................................................5
2.4 Original language...............................................................................................................................................5
2.5 Limitation of liability............................................................................................................................................5
2.6 Formatting conventions .....................................................................................................................................6
2.6.1 Use of symbols ..................................................................................................................................................6
2.6.2 Markup of text elements ....................................................................................................................................7
2.6.3 Mathematics and formulas.................................................................................................................................7
3 General safety instructions ............................................................................................................................8
3.1 Standards ..........................................................................................................................................................8
3.2 Qualified personnel............................................................................................................................................8
3.3 Intended use ......................................................................................................................................................9
3.4 Decommissioning ..............................................................................................................................................9
4 Safety module PMC SR6 ...............................................................................................................................10
5 System design and function.........................................................................................................................11
6 Technical data................................................................................................................................................13
6.1 Safety-related variables ...................................................................................................................................13
6.2 System times ...................................................................................................................................................14
6.3 Interface classification .....................................................................................................................................15
7 Connection .....................................................................................................................................................16
7.1 Connection compliant with EMC......................................................................................................................16
7.2 X12 terminal.....................................................................................................................................................16
7.3 Parallel connection ..........................................................................................................................................19
8 Commissioning..............................................................................................................................................20
8.1 Putting the safety module and drive controller into operation..........................................................................20
8.2 Activating STO.................................................................................................................................................21
8.3 Deactivating STO.............................................................................................................................................21
9 PMC SR6 and SS1 .........................................................................................................................................22
10 Diagnostics ....................................................................................................................................................23
10.1 Parameters ......................................................................................................................................................23
10.1.1 E53 | Required safety module | G6 | V3 ..........................................................................................................23
10.1.2 E54 | Information safety module | G6 | V0 .......................................................................................................23
10.1.3 E67 | STO active | G6 | V0...............................................................................................................................23
10.2 Events..............................................................................................................................................................24
10.2.1 Event 50: Safety module..................................................................................................................................24
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Table of contents
Manual PMC SR6 safety module
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Pilz | iii
11 More on safety technology and PMC SR6?.................................................................................................25
11.1 SRP/CS: Processing a typical safety function .................................................................................................25
11.2 Monitoring the connection wiring .....................................................................................................................26
11.2.1 Monitoring by a safety relay.............................................................................................................................26
11.2.2 Fault exclusion for lines/connections in accordance with DINEN13849 ........................................................27
11.2.3 Monitoring by means of plausibility check of the signals ................................................................................27
11.2.3.1 STO function test .............................................................................................................................................28
11.3 Calculation of suitable protective measures – Examples ................................................................................30
11.3.1 STO – Creating schematic and block diagrams ..............................................................................................31
11.3.1.1 Generating a schematic diagram.....................................................................................................................31
11.3.1.2 Creating block diagrams ..................................................................................................................................32
11.3.2 SS1 – Creating schematic and block diagrams ...............................................................................................34
11.3.2.1 Generating a schematic diagram.....................................................................................................................34
11.3.2.2 Creating block diagrams ..................................................................................................................................35
11.3.3 Determining the safety figures .........................................................................................................................37
11.3.3.1 Subsystem SB1 ...............................................................................................................................................37
11.3.3.2 Subsystem SB2 ...............................................................................................................................................38
11.3.3.3 Subsystem SB3 ...............................................................................................................................................39
11.3.3.4 Wiring the subsystems.....................................................................................................................................39
11.3.3.5 Safety figures for the entire system .................................................................................................................39
11.4 PMC SR6 in accordance with interface classification (ZVEI) ..........................................................................40
12 Appendix ........................................................................................................................................................42
12.1 Detailed information.........................................................................................................................................42
12.2 Formula symbols .............................................................................................................................................44
12.3 Abbreviations ...................................................................................................................................................45
Glossary .........................................................................................................................................................46
List of figures .................................................................................................................................................48
List of tables...................................................................................................................................................49
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Foreword
Manual PMC SR6 safety module
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1 Foreword
The PMC SR6 safety module adds the Safe Torque Off (STO) safety function (described as standard
in DIN EN 61800-5-2) to Pilz drive controllers of the PMC SC6 or PMC SI6 series.
STO prevents an electrical rotating magnetic field, needed for the operation of synchronous or
asynchronous motors, from being generated in a drive controller. Additional safety functions can be
built upon the STO function with the suitable external wiring, such as Safe Stop 1 (SS1-t).
Different interfaces are available for activating STO in a drive controller, including the terminal-based
PMC SR6 safety module.
PMC SR6 is a fast and wear-free fully electronic solution. In addition, the safety module is designed
so that regular system tests that interrupt operation are eliminated.
In practical terms, this means increased availability of machines and systems. The often complex
planning and documentation of function tests are also eliminated.
Drive controllers with an integrated safety module can be used in systems with high safety
requirements up to SIL 3, PL e, category 4. Compliance with standard requirements is ensured by an
external testing institute as part of type testing.
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User information
Manual PMC SR6 safety module
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2 User information
This documentation provides all information on the intended use of the drive controller in combination
with the PMC SR6 safety module.
2.1 Storage and transfer
As this documentation contains important information for handling the product safely and efficiently, it
must be stored in the immediate vicinity of the product until product disposal and be accessible to
qualified personnel at all times.
Also pass on this documentation if the product is transferred or sold to a third party.
2.2 Described product
This documentation is binding for:
Drive controllers of the PMC SC6 or PMC SI6 series in combination with the PMC SR6 safety module
and DriveControlSuite (DS6) software in V 6.4-E or later and associated firmware in V 6.4-E or later.
2.3 Timeliness
Check whether this document is the most up-to-date version of the documentation. We make the
latest document versions for our products available for download on our website:
https://www.pilz.com/en-INT.
2.4 Original language
The original language of this documentation is German; all other language versions are derived from
the original language.
2.5 Limitation of liability
This documentation was created taking into account the applicable standards and regulations as well
as the current state of technology.
No warranty or liability claims for damage shall result from failure to comply with the documentation or
from use that deviates from the intended use of the product. This is especially true for damage
caused by individual technical modifications to the product or the project configuration and operation
of the product by unqualified personnel.
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User information
Manual PMC SR6 safety module
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2.6 Formatting conventions
Orientation guides in the form of signal words, symbols and special text markups are used to
emphasize specific information so that you are able identify it in this documentation quickly.
2.6.1 Use of symbols
Safety instructions are identified with the following symbols. They indicate special risks when handling
the product and are accompanied by relevant signal words that express the extent of the risk.
Furthermore, useful tips and recommendations for efficient, error-free operation are specially
highlighted.
ATTENTION!
Notice indicates that damage to property may occur
▪ if the stated precautionary measures are not taken.
CAUTION!
Caution with a warning triangle indicates that minor personal injury may occur
▪ if the stated precautionary measures are not taken.
WARNING!
Warning with a warning triangle means there may be a considerable risk of fatal
injury
▪ if the stated precautionary measures are not taken.
DANGER!
Danger with a warning triangle indicates that there is a considerable risk of fatal
injury
▪ if the stated precautionary measures are not taken.
Information
Information indicates important information about the product or serves to
emphasize a section in the documentation that deserves special attention from the
reader.
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User information
Manual PMC SR6 safety module
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2.6.2 Markup of text elements
Certain elements of the continuous text are distinguished as follows.
Important information Words or expressions with a special meaning
Interpolated position mode Optional: File or product name or other name
Detailed information Internal cross-reference
http://www.samplelink.com External cross-reference
Interpretation of parameter identification
Parameter identification consists of the following elements, where short forms are also possible,
i.e. only specifying a coordinate or the combination of coordinate and name.
E50 V0
Coordinate Name Version
Drive controller G6
Drive controller
generation/series
2.6.3 Mathematics and formulas
The following signs are used to represent mathematical relationships and formulas.
- Subtraction
+ Addition
× Multiplication
÷ Division
| | Amount
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General safety instructions
Manual PMC SR6 safety module
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3 General safety instructions
There are risks associated with the product described in this documentation that can be prevented by
complying with the described warning and safety instructions as well as the included technical rules
and regulations.
3.1 Standards
The following standards are relevant to the product specified in this documentation:
}DIN EN ISO 13849-1:2016
}DIN EN ISO 13849-2:2013
}DIN EN 61800-5-2:2017-11
}DIN EN 61508-x:2011
}DIN EN 60204-1:2007
}DIN EN 62061:2016
Subsequent references to the standards do not specify the respective year in order to improve
readability.
3.2 Qualified personnel
In order to be able to perform the tasks described in this documentation, the persons instructed to
perform them must have the appropriate professional qualification and be able to assess the risks and
residual hazards when handling the products. For this reason, all work on the products as well as
their operation and disposal may be performed only by professionally qualified personnel.
Qualified personal are persons who have acquired authorization to perform these tasks either through
training to become a specialist and/or instruction by specialists.
Furthermore, valid regulations, legal requirements, applicable basic rules, this documentation and the
safety instructions included in it must be carefully read, understood and observed.
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General safety instructions
Manual PMC SR6 safety module
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3.3 Intended use
The PMC SR6 safety module can be combined with Pilz drive controllers of the PMC SC6 or PMC
SI6 series. The module must be wired compliant for EMC.
If a drive controller with the integrated PMC SR6 safety module is used in a safety-related application,
the safety module must be activated by a safety relay or a safety controller.
DANGER!
Electrical voltage! Risk of fatal injury due to electric shock!
An active STO safety function only means that generation of the rotating magnetic
field at the motor has been interrupted. The motor may still be energized with
dangerous high voltages.
▪ Make sure that persons cannot come into contact with conductive parts.
▪If the supply voltage must be switched off, observe the requirements of
DIN EN 60204-1.
Improper use
The safety module may not be operated outside of the drive controller or operated not in compliance
with the applicable technical specifications.
Information
An emergency off in accordance with DINEN60204-1 is not possible with the
PMC SR6 safety module!
Observe this standard regarding the difference between emergency off and
emergency stop in conjunction with Safe Torque Off.
Modification
As the user, you may not make any technical or electrical modifications to the PMC SR6 safety
module.
Maintenance
The safety module does not require maintenance.
Take appropriate measures to detect or prevent possible errors in the connecting wiring (see the
chapter Monitoring the connection wiring).
Product life span
A drive controller with integrated safety module must be taken out of operation 20 years after the
production date. The production date of the drive controller is found on the accompanying nameplate.
3.4 Decommissioning
In safety-oriented applications, note the mission time TM = 20 years in the safety-relevant key
performance indicators.
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Safety module PMC SR6
Manual PMC SR6 safety module
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4 Safety module PMC SR6
The PMC SR6 safety module adds the STO (Safe Torque Off) safety function to the drive controller .
In the event of an error or by external request, STO prevents the formation of a rotating magnetic field
in the power unit of the drive controller. The safety module switches the drive controller to the STO
state.
Additional safety functions can be built upon the STO function with suitable external wiring, such as
SS1-t (Safe Stop 1).
Features
}Two one-pole digital inputs for activating the safety functions:
• Safe Torque Off – STO in accordance with DIN EN 61800-5-2
• Stop category 0 in accordance with DIN EN 60204-1
}STO switch-off time <20ms
}Wear-free
Certifications in accordance with DIN EN61800-5-2 and DIN ENISO13849-1
}Safety Integrity Level (SIL) (SIL) 3
}Performance Level (PL) (PL) e
}Category 4
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