Pilz PMCprotego S1--2 User manual

PMCprotegoS12(C)
OperatingManual1002528EN03
PMCprotegoSafeMotion

Preface
Thisdocumentistheoriginaldocument.
AllrightstothisdocumentationarereservedbyPilzGmbH&Co.KG.Copiesmaybemade
forinternalpurposes.Suggestionsandcommentsforimprovingthisdocumentationwillbe
gratefullyreceived.
Pilz®,PIT®,PMI®,PNOZ®,Primo®,PSEN®,PSS®,PVIS®,SafetyBUSp®,
SafetyEYE®,SafetyNETp®,thespiritofsafety®areregisteredandprotectedtrademarks
ofPilzGmbH&Co.KGinsomecountries.
SDmeansSecureDigital

Content
OperatingManualPMCprotegoS12(C)
1002528EN03 3
Section1 Introduction 5
1.1 Validityofdocumentation 5
1.1.1 Retainingthedocumentation 5
1.2 Definitionofsymbols 5
Section2 Overview 7
2.1 Unitstructure 7
2.1.1 Unitfeatures 7
2.2 Frontview 8
Section3 Safety 9
3.1 Intendeduse 9
3.1.1 Permittedmotortypes 10
3.1.2 Permittedmotorencodertypes 10
3.1.3 Useofqualifiedpersonnel 11
3.1.4 Warrantyandliability 11
3.1.5 Disposal 11
3.2 Standards 12
Section4 Functiondescription 13
4.1 Overview 13
4.2 Inputsandoutputs 14
4.2.1 Inputs 15
4.2.2 Outputs 16
4.2.2.1 Singlepoleoutputs 16
4.2.2.2 Dualpoleoutputs 18
4.2.2.3 Outputtest 18
4.3 Safetyfunctions 20
4.3.1 SafeTorqueOffSTO 20
4.3.2 SafeStop1SS1 22
4.3.3 SafeStop2SS2 26
4.3.4 SafeOperatingStopSOS 28
4.3.5 SafelyLimitedSpeedSLS 30
4.3.6 SafeSpeedRangeSSR 34
4.3.7 SafeDirectionSDI 37
4.3.8 SafelyLimitedIncrementSLI 41
4.3.9 SafelyLimitedPositionSLP 44
4.3.10 SafeBrakeControlSBC 46
4.3.11 SafeBrakeTestSBT 50
4.4 Operatingmodeoftheservoamplifier 52
4.5 Reactiontimes 54
4.6 Configuration 55
Section5 Installation 56
5.1 Generalrequirements 56
5.2 Dimensions 56
5.3 Installingthesafetycard 57

Content
OperatingManualPMCprotegoS12(C)
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Section6 Wiring 58
6.1 Generalwiringguidelines 58
6.2 Connectorpinassignment 59
6.3 Shielding 59
6.4 Digitalinputs 60
6.5 Digitaloutputs 61
6.5.1 Supplyvoltage 61
6.5.2 Singlepoleoutputs 63
6.5.3 Dualpoleoutputs 64
6.6 Encoder 65
6.6.1 Supplyvoltage 65
6.6.2 IncrementalencoderwithTTLsignal 66
6.6.3 AbsoluteencoderwithSSIinterface 67
Section7 Commissioning 69
7.1 Safetyguidelines 69
7.2 Initialcommissioning 69
7.3 Recommissioning 72
7.3.1 Recommissioningatarestart 72
7.3.2 Recommissioningaftererror 73
7.3.2.1 Switchingtheinputs"SS1Activate"or"SS1SIL3/Reset" 73
7.3.2.2 Command"CLRFAULT" 74
7.3.3 Swapsafetycard 75
7.3.3.1 DownloadconfigurationfromConfiguratortosafetycard 76
7.3.3.2 DownloadconfigurationtoSDcard 77
7.3.3.3 DownloadconfigurationfromSDcardtosafetycard 78
7.4 Safetychecks 79
Section8 Operation 80
8.1 Operatingstates 80
8.2 Testingthesafepulsedisabler 81
8.3 Displayelements 83
8.4 Messages 84
Section9 Technicaldetails 85
9.1 Safetycharacteristicdata 88
9.1.1 Safeactuatorwithoneencoder 88
9.1.1.1 MTTF>=10years 88
9.1.1.2 MTTF>=57years 89
9.1.2 Safeactuatorwithtwoencoders 89
Section10 Orderreference 91
Section Glossary 92

Introduction
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1 Introduction
1.1 Validityofdocumentation
ThisdocumentationisvalidfortheproductsPMCprotegoS12andPMCprotegoS12C.It
isvaliduntilnewdocumentationispublished.
Thisoperatingmanualexplainsthefunctionandoperation,describestheinstallationand
providesguidelinesonhowtoconnecttheproductPMCprotegoS12(C).
Pleasealsorefertothefollowingdocumentsfromthemotioncontrolrange:
}TheconfigurationoftheexpansioncardisdescribedintheonlinehelpfortheConfigur
atorPASconfigSDrive.
}TheservoamplifierPMCprotegoDisdescribedinthe"PMCprotegoDoperating
manual".
}Detailsofhowtosettheparametersfortheservoamplifieraredescribedinthehelpfor
thecommissioningsoftwarePASmotion.
AllthesemanualscanbefoundonthesuppliedCDROM:"MotionControl"
Youwillneedtobeconversantwiththeinformationinthesedocumentsinordertofullyun
derstandthismanual.
1.1.1 Retainingthedocumentation
Thisdocumentationisintendedforinstructionandshouldberetainedforfuturereference.
1.2 Definitionofsymbols
Informationthatisparticularlyimportantisidentifiedasfollows:
DANGER!
Thiswarningmustbeheeded!Itwarnsofahazardoussituationthatposes
animmediatethreatofseriousinjuryanddeathandindicatespreventive
measuresthatcanbetaken.
WARNING!
Thiswarningmustbeheeded!Itwarnsofahazardoussituationthatcould
leadtoseriousinjuryanddeathandindicatespreventivemeasuresthatcan
betaken.

Introduction
OperatingManualPMCprotegoS12(C)
1002528EN03 6
CAUTION!
Thisreferstoahazardthatcanleadtoalessseriousorminorinjuryplus
materialdamage,andalsoprovidesinformationonpreventivemeasures
thatcanbetaken.
NOTICE
Thisdescribesasituationinwhichtheproductordevicescouldbedam
agedandalsoprovidesinformationonpreventivemeasuresthatcanbe
taken.Italsohighlightsareaswithinthetextthatareofparticularimport
ance.
INFORMATION
Thisgivesadviceonapplicationsandprovidesinformationonspecialfea
tures.

Overview
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2 Overview
2.1 Unitstructure
ThesafetycardPMCprotegoS12(C)isanexpansionoftheservoamplifierPMCprot
egoD.Itisusedforsafemotionmonitoring,whichisachievedinconjunctionwiththe
standardmotorencoderandservoamplifier.Intheeventofanerror,theservoamplifier's
powerelementshutsdownthepowerquicklyandsafely.
2.1.1 Unitfeatures
Thesafetycardhasthefollowingfeatures:
2singlepoledigitalinputstoactivatethesafetyfunctionSafeStop1(SS1)inaccordance
withEN6180052(fixedassignment):
}SafetyfunctionSafeStop1(SS1)
}InputtoachieveSIL3andtoresetthesafetycardafteranerror
7singlepoledigitalinputs,whichcanbeassignedthefollowingsafetyfunctionsinaccord
ancewithEN6180052inthesafetycards'sConfigurator:
}SafeStop2(SS2)
}SafeOperatingStop(SOS)
}SafeSpeedRange(SSR)
}SafelyLimitedSpeed(SLS)
}SafeDirection(SDI)
}SafeBrakeTest(SBT)(notdefinedinEN6180052)
}SafelyLimitedIncrement(SLI)
}SafelyLimitedPosition(SLP)
3singlepoledigitaloutputswithfixedfunction:
}SafeTorqueOff(STO)
}Safetycardready
}Secondshutdownroute(STOSIL3)
4singlepoledigitaloutputs,whichcanbefreelyassignedthestatusofsafetyfunctions.
1dualpoledigitaloutputfor
}SafeBrakeControl(SBC)
1inputforincrementalencoderorencoderwithSSIsignal
Supplyvoltage
}24VDCfordigitaloutputs
LEDsfor
}Supplyvoltage(POWER)
}Systemstatus(RUN)
}Downloadofconfigurationdata(CONFIG)
}Faultordrivetorquefree(STO)

Overview
OperatingManualPMCprotegoS12(C)
1002528EN03 8
Ctype:
}PMCprotegoS12C:Coatedcircuitboard
2.2 Frontview
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
RUN
POWER
STO
CONFIG
X30
X31
8176105 12
100001
1
3
4
5
6
2
1
3
Key:
}1:Screwforattachmenttotheservoamplifier
}2:LEDstodisplayoperatingstates
}3:Inputs/outputsandsupplyvoltage
}4:Labellingstripwith:
– Ordernumber
– Serialnumber
– Numberofdeviceversion
}5:2Dcode
}6:Connectionforencoder

Safety
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3 Safety
3.1 Intendeduse
ThesafetycardPMCprotegoS12(C)isanexpansionoftheservoamplifierPMCprot
egoD.Itisdesignedforuseinsafetyrelatedapplications.
ItmeetstherequirementsforsafetyfunctionsinaccordancewithEN6180052,withre
gardtosafemotionmonitoring.
ThesafetycardmeetstherequirementsofENIEC61508uptoSIL3andENISO138491
uptoPLe.
ToachievecategorySIL3orPLe,theoperatormustensurethatthefunctionofthesafe
pulsedisableristestedperiodically,after8hoursatthelatest,bytriggeringsafetyfunctions
SS1orSTO:
}ByrestartingaftersafetyfunctionsSS1orSTOhavebeentriggeredasaconditionof
operation
or
}ByrestartingaftersafetyfunctionSS1hasbeentriggeredbytheoperator
INFORMATION
Totestthesafepulsedisablerthroughdeliberateoperatoraction,seethe
sectionentitled"Operation",under"Testingthesafepulsedisabler".
Thefollowingisdeemedimproperuse:
}Anycomponent,technicalorelectricalmodificationtotheservoamplifier
}Useoftheservoamplifieroutsidetheareasdescribedinthismanual
}Useoftheservoamplifieroutsidethedocumentedtechnicaldetails(seechapteren
titled“TechnicalDetails”)
IntendeduseincludesmakingtheinstallationandwiringEMCcompliant.
Intendedusealsoincludescompliancewiththe
}OperatingmanualforthePMCprotegoD
}OnlinehelpfortheconfigurationtoolPASconfigSDrive.
INFORMATION
FortheuseofthesafetycardinaPMCprotegoD,theapprovalsoftherel
evantservoamplifierapply(seeTechnicalDetailsintheoperatingmanual
oftheservoamplifiers).
ThesafetycardPMCprotegoS12(C)fromVersion1.0mayonlybeusedinconjunction
withthefollowingservoamplifiers:
}PMCprotegoD.01fromVersion1.1
}PMCprotegoD.03fromVersion1.1
}PMCprotegoD.06fromVersion1.1

Safety
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1002528EN03 10
}PMCprotegoD.12fromVersion1.1
}PMCprotegoD.24fromVersion1.1
}PMCprotegoD.48fromVersion1.1
}PMCprotegoD.72fromVersion1.1
3.1.1 Permittedmotortypes
Thefollowingmotortypesareapprovedforusewiththesafetycard:
}Rotarysynchronousmotors
}Linearsynchronousmotors
Pleasenote:Theuseofsynchronousmotorswithoutmotorencoder(sensorlessoperation)
isnotpermitted.
Workisinprogressforusewith:
}Asynchronousmotors
Pleasenotethefollowingfaultdetectionguidelines:
Whenthedriveisoperatedwithanencoder(standardmotorencoderontheservoampli
fier),afaultontheencodersystemisdetectedbythesafetycardasfollows:
}Rotarysynchronousmotors
Detectedwithinonemechanicalrevolutionofthemotor.
}Linearsynchronousmotors
Detectedwithinthedistancetravelled,inaccordancewiththefollowingformula:
Distance=(Numberofpoles/2)·Polepairpitch
Commandsintheservoamplifier:
– Numberofpoles:MPOLES
– Polepairpitch:MPITCH
3.1.2 Permittedmotorencodertypes
Themotorencoderisconnectedtoaninputontheservoamplifier.Thefollowingmotoren
codertypesareapprovedforusewiththesafetycard:
Encodertype
Feedbacktype
(parameter
FBTYPE)inthe
servoamplifier's
commissioning
software
Connectionto
theservoampli
fier
Statusforopera
tionwithsafety
card
Resolver 0 X2 Enabled
Hiperface(Stegmann) 2 X1 Enabled
EnDat(Heidenhain) 4 X1 Enabled
SinCos5VwithW&S 7 X1 Enabled
RS42224V 12 X3 Enabled
ROD5VwithHall 15 X1 Enabled