Baumuller BM5-O-SAF-000 Operating Instructions Manual
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Baumuller BM5-O-SAF-000 Operating Instructions Manual

Baumuller BM5-O-SAF-000 Operating Instructions Manual

Safety module for b maxx 5000
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Operation Manual
English
Language
Translation
Document No. 5.09013.07
Part No.
432449
Date
Nov. 19, 2018
E
5.09013.07
Read the Operating Instructions before beginning!
BM5-O-SAF-000/-001
Safety Module for b maXX 5000

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Summary of Contents for Baumuller BM5-O-SAF-000

  • Page 1 Operation Manual English Language Translation Document No. 5.09013.07 Part No. 432449 Date Nov. 19, 2018   BM5-O-SAF-000/-001 Safety Module for b maXX 5000  Read the Operating Instructions before beginning! 5.09013.07...
  • Page 2  Baumüller Nürnberg GmbH Ostendstr. 80 - 90 90482 Nürnberg Germany +49 9 11 54 32 - 0  Tel. Fax: +49 9 11 54 32 - 1 30 E-Mail: mail@baumueller.de Internet: www.baumueller.de...

  • Page 3: Table Of Contents

    Compatibility list ............Working principle parameter module (BM5-O-SAF-000-000-000)....
  • Page 4 General safety regulations ..........71 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07...
  • Page 5 Index ..............Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07...
  • Page 6 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 7: Document History

    Safety Module SAF-001-001-001 (Safe Stop 1) added Chap. 8.1.2 SAF-001-001-001 added Chap. 8.2.2 Compatibility list SAF-001-001-001 added Chap. 8.4.2 Working principle SAF-001-001-001 added Chap. 8.14 Type code SAF-001-001-001 added Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 8 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 9: General

    The operation manual is a component of the product and must be kept accessible in the immediate vicinity of the device at all times. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07...

  • Page 10: Legend

    ..notifies of a potentially dangerous situation which can lead to property damage if not avoided. Recommenda- tions NOTICE! ..draws attention to useful tips and recommendations as well as information for efficient and trouble-free operation. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 11: Limitation Of Liability

    (reviewed by Baumüller) information. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 12: Copyright

    If no return or disposal agreement has been made, dismantled components can be taken for recycling after proper disassembly. ZDisposal– See also on page 95. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 13: Warranty And Liability

    TÜV Rheinland. EC Type Examination Certificate Number: 01/205/5563.03/18 Test report no.: 968/FSP 1400.03/18 Notified Body: 0035 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 14: Approvals, Directives And Standards

    - Part 5-2: Safety requirements - Functional EN 61131-2 Programmable controllers - Part 2: Equipment requirements and tests EN 60204-1 Electrical equipment of machines Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 15: Use Of This Manual

    Planning n Installation/Assembly n Commissioning n Validation n Operation n Modification/Retrofitting n Troubleshooting n Maintenance/Repair n Disassembly Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 16 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 17: Safety

    In order to avoid hazards and ensure optimum performance, neither alterations, additions nor rebuilding work may be conducted on the device unless explicitly authorized by the manufacturer. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 18: Intended Use

    Only operate the plug-in module if it is in technically faultless condition. m Only use the plug-in module in combination with components approved by Baumüller Nürnberg GmbH. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 19: Operator Responsibility

    The device may only be operated in technically faultless condition and must be safe for operation. Protective equipment When installed in the converter, the plug-in module complies with the protective category IP20. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 20: Personnel Training

    Qualified personnel is educated or trained in the maintenance and use of suitable safety equipment in accordance with the respective local safety engineering standards. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 21: Personnel Protective Equipment

    To be worn during special work Protective glasses to protect the eyes from flying parts and spraying liquids. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 22: Special Dangers

    Electric shock can occur if a conductive fire extinguishing medium is used. Therefore: m Use the following fire extinguishing medium:  ABC-Pulver / CO 2<Default Font> Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 23: Electric Safety

    Safety is only ensured if the safety equipment is intact. Therefore: m Check to make sure that the safety equipment is functional and installed properly before beginning work. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 24: Conduct In The Event Of Danger And Accidents

    Electric current Only qualified personnel may work in work spaces with this marking. Unauthorized persons may not touch work equipment bearing this marking. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 25: Functional Safety

    20 years. The user cannot perform a proof test. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 26: Saf-001-000-Xxx

    This values lies within the permissible tolerance of 5% according to EN ISO 13849-1 for the classification HIGH. No proof test is necessary during the expected life cycle of the device of up to 20 years. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 27: Saf-001-001-Xxx

    Parameters in accordance with EN ISO 13849-1 n Performance Level PL e n Category: Kat 4 n MTTF HIGH (751 a) n Diagnostic Coverage DC: HIGH (99 %) Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 28 Safety-related parameters Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 29: Packaging And Shipping

    Therefore: m Follow the rules and instructions on handling components sensitive to electrostatic discharge when handling the plug-in module. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 30: Disposing Of The Packaging

    ZAppendix C - Technical data– Make sure that the shipping conditions (see from page 103 onward) are consistently fulfilled throughout the entire shipping process. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 31: Description Of The Default And Parameter Module

    If the converter was previously equipped with a module with a higher safety level (SAF-001/002/003), the parameter storage of the converter must be reset with the Reset- Module. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 32: Working Principle Parameter Module (Bm5-O-Saf-000-000-000)

    RAM with all the parameters,  was loaded in the flash memory of the b maXX 5000 again. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 33: Setting Of The Switch-On Behavior

    This behavior assures, that the parameters are only in the case of service written back from the module to the axis unit. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 34 Setting of the switch-on behavior Figure 2: Flow diagram switch-on behavior Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 35: Operation Manual Safety Module For B Maxx 5000 Bm5-O-Saf-000/-001

    The third and fourth digit of the serial number provide information on the year of pro- duction. Example: Serial number „S310045208“ corresponds to production year 2010. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 36 BM5 - O - SAF - 000 - xxx - xxx - Safety level (identification for the compatibility between converter and safety module) Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 37: Description Of The Safety Module (Saf-001)

    The module SAF-001-001-001 carries out the safety function "Safe Stop 1 (SS1)" (safe stop 1 with time control according to EN61800-5-2), exclusively. After the expiry of the Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 38: Compatibility List

    WARNING! A converter b maXX 5000 with a firmware version V01.14.00 or higher must be used for the Safety Module with SS1 function (SAF-001-001-001). Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 39: Compatibility List Saf-001-000-002 With Automatic Restart

    Ensure by the use of the external safety components that an unexpected start-up is prevented during commissioning. Therefore: m Maintain an adequate distance from moving machine parts/line parts or from the moving machine/line. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 40: Working Principle

    SS1 is running. The drive enable is only possible if there was no voltage at both channels at the same time after reaching STO and the 24 V are applied again. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...
  • Page 41 (such as "stop at the current limit"). The module SAF-001-001-001 is also displayed in parameter 200.1 (SAF module version) from the controller FW V01.15 (value 28): Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 42: Input Circuitry

    Baumüller Safety I/O terminal SO4000. WARNING! The power supply unit for generating the 24 Volt electrical supply must meet the requirements for PELV according to EN 60204-1. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 43 STO_2A_24V (X1-07) STO_1A_24V (X1-08) Internal STO_1B_24V (X1-09) connections FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12) FS_2_24V (X1-13) STO_1A_24V (X1-14) Figure 6: Safety Module (SAF-001-000-xxx) with emergency stop device Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 44 Internal STO_1B_24V (X1-09) connections FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12) FS_2_24V (X1-13) STO_1A_24V (X1-14) Figure 7: Safety Module (SAF-001-000-xxx) with safety light curtain Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 45 SO4000 STO_2A_24V (X1-07) STO_1A_24V (X1-08) Internal STO_1B_24V (X1-09) connections FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12) FS_2_24V (X1-13) STO_1A_24V (X1-14) Figure 8: Safety Module (SAF-001-000-xxx) with SO4000 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 46: Saf-001-001-Xxx

    Internal STO_1B_24V (X1-09) connections reserved (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12) reserved (X1-13) STO_1A_24V (X1-14) Figure 9: Safety Module (SAF-001-001-xxx) with emergency stop device Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 47 STO_2A_24V (X1-07) STO_1A_24V (X1-08) Internal STO_1B_24V (X1-09) connections reserved (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12) reserved (X1-13) STO_1A_24V (X1-14) Figure 10: Safety Module (SAF-001-001-xxx) with safety light curtain Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 48: Structure

    A = Button S1 B = LED H1 - green C = LED H2 - red D = Connector X1 Figure 11: Safety Module (SAF-001-000-xxx) Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 49: Structure Of The Safety Module (Saf-001-001-000)

    Structure of the Safety Module (SAF-001-001-000) Connector X1 Figure 12: Safety Module (SAF-001-001-000) 8.6.3 Structure of the Safety Module (SAF-001-001-001) Time 200 ms Connector X1 Figure 13: Safety Module (SAF-001-001-001) Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 50: Pin Assignment

    +24V safety device axis 2 / channel B FS_2_24V +24V input restart axis 2 STO_1A_24V +24V safety device axis 1 / channel A Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 51: Pin Assignment Of Connector X1 (Saf-001-001-Xxx)

    +24V safety device axis 2 / channel A STO_2B_24V +24V safety device axis 2 / channel B Reserved STO_1A_24V +24V safety device axis 1 / channel A Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 52: Switching Thresholds For Voltage And Current

    Inputs FS_1_24V and FS_2_24V (restart axis 1 and 2) The inputs FS_1_24V and FS_2_24V (restart axis 1 and 2) are in the normal range for digital inputs according to type 1 (EN 61131-2). Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 53: Maximum Response Time

    RAM with all the parameters,  was loaded in the flash memory of the b maXX 5000 again. The Safety Module (SAF-001-001-xxx) has no parameter memory. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 54: Operation And Display Elements

    Safety Module (SAF-001) by pressing the button S1 (long - short - short - long). The Safety Module (SAF-001-001-xxx) has no LEDs. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 55: Button For Verification Purposes

    ZExchanging the module– from page 79 onward). Button S1 Type plate Figure 17: Button S1 on the Safety Module (SAF-001-000-xxx) The Safety Module (SAF-001-001-xxx) has no button. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 56: Restart Inhibit (Saf-001-000-Xxx)

    0 ms 30 ms The controller is operational at once and the safety function STO is not active, when t and t = 0. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 57 The restart inputs may in no case be used for the safety-related shut down of the driver supply. A safe activation of the safety function STO is only permitted by the STO inputs and the connected safety components. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 58: Automatic Restart (Saf-001-000-002 And Saf-001-001-Xxx)

    The safety function STO is already canceled by resetting the safety component which has triggered the function STO. From that point on, the machine can be restarted. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 59: Marking Of The Safety Module (Saf-001) - Type Code

    SS1 time (= 200 ms) BM5 - O - SAF - 001 - xxx - xxx - #xx Safety level (identification for the compatibility between converter and safety module) Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 60 8.14 Marking of the Safety Module (SAF-001) - type code Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 61: Description Of The Reset-Module

    Safety Module. An operation of the converter with the Reset-Module is not possible, because the module does not provide supply for the converter’s drivers. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 62: Structure Of The Reset-Module (Bm5-O-Saf-100)

    For a list of the converters compatible with the Safety Module refer to the chapter ZCompatibility list SAF-001-000-xxx– on page 38. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 63: Mode Of Operation Module Replacement

    (P200.008 := 0) Error message (error number 2423) rive state: No error Failure (P108.006 = 15) Command processing Command processing Figure 23: Mode of operation module replacement BM5-O-SAF-100 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 64 Mode of operation module replacement Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 65: Resetting Of The Safety Level By The Controller

    3 This code must be written in parameter 200.020.0.0 (reset code). 4 After 15 seconds the voltage supply can be switched off and slot A can be equipped with the required module. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 66 10.2 Operation mode of the reset command Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 67: Planning Of A Safety-Oriented Control System

    As machine manufacturer, the applicable machine guidelines obligate you to conduct a risk assessment in order to establish the dangers associated with the machine and reduce the residual risk to a justifiable minimum. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 68 Risk estimation: Estimation of the risks for each hazard identified Risk assessment: Assessment of the risks and establishment of risk reduction measures Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 69: Installation And Wiring Plan

    ZCompatibility list SAF-001-000-002 with automatic restart– xxx– on page 38 and page 39). m Adequate supply of the converter by the connected power supply unit or safety components. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 70 11.3 Course of the planning phase Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 71: Assembly And Installation

    Make sure that the system components do not come into contact with aggressive substances (such as acids, bases, transmission oil). Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 72: Requirements On The Personnel Conducting The Work

    Make sure that power to the device and surrounding area is shut off before beginning work. m Follow the applicable safety regulations when handling devices carrying high voltages. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 73 1 Plug the plug-in module into the mounting opening of the frequency converter. 2 Secure the module against unintentional falling out with the torx screw. Figure 25: Assembly of plug-in module Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 74: Installation

    Prevent a short circuit between inputs and outputs. A short circuit between inputs and outputs can destroy the plug-in module. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 75: Requirements On The Connection Cable

    Make sure that the connection cable is routed in an EMC-compatible manner. 12.4.2 Requirements on the connection cable The connection cable must be selected in accordance with the EN 60204-1 standard. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 76 12.4 Installation Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 77: Commissioning And Exchange Of The Module

    Please take note of from page 87 for rectifying errors during the commissioning process. 13.1 General safety regulations h Follow the chapter ZSafety– from page 17 . Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 78: Requirements On The Personnel Conducting The Work

    The machine/line or parts of the machine or line can be started during the commissioning of the Safety Module. Therefore: m Maintain an adequate distance from moving machine parts/line parts or from the moving machine/line. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 79: Exchanging The Module

    Module) in parameter 100.010.0.0 (Safety Module state). By acceptance with button S1 (long-short-short-long) by the user, the parameters are copied from the controller to the Safety Module. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 80 Course of the module exchange process CAUTION! Once the module has been exchanged, a complete function test for the system has to be conducted and documented accordingly. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 81 (see the chapter ZRepair– from page 91 ). Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 82 13.3 Exchanging the module Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 83: System Validation

    2 Conduct a complete function test with all sensors (initiators), switches, actuators and drives. To conduct the function tests, trigger all safety functions sequentially and document the system's reaction. Check whether their action corresponds with the expected behavior. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 84 14.1 Function test Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 85: Operation

    Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 86 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 87: Troubleshooting And Rectification

    Do not put a defective safety-oriented system back into operation as long as the cause of the error is unknown to you or an error has not been rectified. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07...

  • Page 88: Detecting Errors In The Periphery

    In the safe status, the Safety Module (SAF-001) safely shuts off the driver supply of the converter. Thus, the actuation of the power output module of the converter is already interrupted. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 89: Maintenance

    Take organizational measures to make sure that the interval for the repeat testing of ZSafety-related parameters– all system components (proof test interval, see from page 25 onward) is complied with. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 90 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 91: Repair

    EPAIR You cannot repair a defective plug-in module. Please contact Baumüller Nürnberg GmbH for a replacement. CAUTION! Defective components may only be repaired by the manufacturer. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 92 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 93: Disassembly, Storage

    Only disassemble the connections and remove the connection once you are completely certain that the component assembly is not under power. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 94: Requirements On The Personnel Conducting The Work

    If you want to put the plug-in module back into operation, observe the specifications under ZCommissioning and exchange of the module– „Storage conditions“. Then conduct the from page 77 onward again. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 95: Disposal

    Observe the applicable regulations in doing so. Plastic The housing is made of plastic. Plastic must be put into the cycle of potential recyclables for plastics. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 96: Recycling Collection Center/Offices

    In the event of uncertainty, contact the industrial inspectorate responsible for your company or the environmental agency. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH...

  • Page 97: Appendixa - Abbreviations

    Probability of Failure per Hour Safety module Safety Integrity Level Safe Failure Fraction (fraction of failures which lead to safe status) Safe Torque Off Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 98 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 99: Appendixb - Checklists

    Do all safety-oriented system components meet the requirements of the established SIL (IEC 61508), performance levels and safety category (DIN EN ISO 13849-1)? Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 100 Has computational evidence been provided? 1.12 Is the system protected from mechanical overloading? 1.13 Is the system protected from corrosive substances? Date Name Signature Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 101: Installation Checklist

    Does the system fulfill the required type of protection? 2.12 Is degree of pollution 2 complied with? 2.13 Is the system protected from corrosive substances? Date Name Signature Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 102: Commissioning And Validation Checklist

    Are the calculated reaction times still complied with after the modification/ retrofitting? Proof is required! Has a complete function test been conducted and documented? Date Name Signature Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 103: Appendix C - Technical Data

    Climate classification (EN 60721-3-2) Installation height Up to 2000 m above sea level WARNING! The operating conditions specified in the table above may not be exceeded at any time. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 104: Pin Assignment Of Safety Module (Saf-001-000-Xxx) Connector X1

    Pin assignment of Safety Module (SAF-001-000-xxx) connector X1 Pin no. Assignment STO_1A_GND STO_1B_GND FS_1_GND STO_2A_GND STO_2B_GND FS_2_GND STO_2A_24V STO_1A_24V STO_1B_24V FS_1_24V STO_2A_24V STO_2B_24V FS_2_24V STO_1A_24V Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 105: C.4 Pin Assignment Of Safety Module (Saf-001-001-Xxx And Saf-001-000-002) Connector X1

    Pin assignment of Safety Module (SAF-001-001-xxx and SAF-001-000-002) connector X1 Pin no. Assignment STO_1A_GND STO_1B_GND Reserved STO_2A_GND STO_2B_GND Reserved STO_2A_24V STO_1A_24V STO_1B_24V Reserved STO_2A_24V STO_2B_24V Reserved STO_1A_24V Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 106: C.4 Pin Assignment Of Safety Module (Saf-001-001-Xxx And Saf-001-000-002) Connector X1

    Pin assignment of Safety Module (SAF-001-001-xxx and SAF-001-000-002) connector X1 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 107: Appendixd - Declaration Of Conformity

    D - D PPENDIX ECLARATION OF CONFORMITY Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 108 Machinery Directive 2006/42/EC. Nuremberg / 17.05.2017 Location / Date Subject to change of this declaration of EC conformity without notice. Actual valid edition on request. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 109 Attention should be paid to the safety instructions in the manual. Nuremberg / 17.05.2017 Location / Date Subject to change of this declaration of EC conformity without notice. Actual valid edition on request. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 110 Machinery Directive 2006/42/EC. Nuremberg / 24.09.2018 Location / Date Subject to change of this declaration of EC conformity without notice. Actual valid edition on request. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 111 Attention should be paid to the safety instructions in the manual. Nuremberg / 24.09.2018 Location / Date Subject to change of this declaration of EC conformity without notice. Actual valid edition on request. Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...
  • Page 112 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...

  • Page 113: Index

    Switching thresholds Limitation of liability Inputs FS_1_24V, FS_2_24V Inputs STO_1A_24V, STO_1B_24V, STO_2A_24V, STO_2B_24V Mean Time To Failure (MTTFd) switch-on behavior Mechanical properties Module type 36, 59 Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 of 114...

  • Page 114: Document No.: 5.09013.07 Of

    Technical data Terms Definition Type code Module Type plate Warning notices, general Warranty and liability Wiring plan Pin assignment Switching thresholds of inputs Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH of 114...
  • Page 116 Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg Tel: +49(0)911-5432-0 Fax: +49(0)911-5432-130 www.baumueller.de All the information in these Operating Instructions is non-binding customer information; it is subject to ongoing further development and is updated on a continuous basis by our permanent change management system.

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