Pilz PMCprotego S2-2 Operating Manual

Safe motion

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PMCprotego S2-2(-C)

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PMCprotego - Safe Motion

Operating Manual-1002529-EN-04

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Summary of Contents for Pilz PMCprotego S2-2

Page 1 PMCprotego S2-2(-C) PMCprotego - Safe Motion Operating Manual-1002529-EN-04...
Page 2 Preface This document is a translation of 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.
Page 3: Table Of Contents
Safe direction - SDI 4.3.8 Safely Limited Increment - SLI Operating mode of the servo amplifier Reaction times Configuration Section 5 Installation General requirements Dimensions Installing the safety card Section 6 Wiring General wiring guidelines Connector pin assignment Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 4 Operation Operating states Testing the safe pulse disabler Display elements Messages Section 9 Technical details Safety characteristic data 9.1.1 Safe actuator with one encoder 9.1.1.1 MTTF >= 10 years Section 10 Order reference Section Glossary Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 5: Introduction
Introduction Introduction Validity of the documentation This documentation is valid for the products PMCprotego S2-2 and PMCprotego S2-2-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 S2-2(-C).
Page 6 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. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 7: Overview
Overview Unit structure The safety card PMCprotego S2-2(-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.
Page 8: Front View
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 Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 9: Safety
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 S2-2(-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...
Page 10: Permitted Motor Types
Feedback types with one-cable connection (power and feedback in one cable) Hiperface DSL SFD3 Feedback types with two-cable connection (power and feedback in two cables) Resolver Hiperface (Stegmann) EnDat (Heidenhain) SinCos 5 V with W&S RS422 24V ROD 5 V with Hall Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 11: Use Of Qualified Personnel
In safety-related applications, please comply with the mission time T in the safety-re- lated characteristic data. When decommissioning, please comply with local regulations regarding the disposal of electronic devices (e.g. Electrical and Electronic Equipment Act). Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 12: Standards
EN 62061: Safety of machinery – Functional safety of safety-related electrical, elec- tronic and programmable electronic control systems Please note this is not an exhaustive list of safety standards and directives. Where standards are undated, the 2009-03 latest editions shall apply. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 13: Function Description
The safety card is built into a servo amplifier PMCprotego D. This converts the servo ampli- fier into a safe servo amplifier. A safe drive system from Pilz consists of the following: Servo amplifier (PMCprotego D) Safety card PMCprotego S built into the servo amplifier Servo motor (synchronous motor) with –...
Page 14: Inputs And Outputs
Inputs I0 to I6 can be used to activate the safety functions. Outputs O0 to O3 can be used to acknowledge the status of the safety functions. Inputs and outputs are assigned to the safety functions in the safety card's Configurator. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 15: Inputs
"1"-signal (+24 V) at the input: – Safety function is not activated NOTICE Inputs "SS1 Activate" and "Reset" must always be connected. In the case of all inputs, only tested outputs from a safety control system may be connected. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 16: Outputs
SRA Safe Range Acknowledge – 1: Drive is moving within the permitted limit values for speed or position. – 0: Drive is moving outside the permitted limit values for speed or position, or monit- oring is not activated. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 17: Output Test
Outputs that are switched off are switched on for the duration of the test pulse. – The load must not switch on because of the test. Testing for shorts A test is regularly carried out to check for shorts between the outputs. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 18 0: "0" signal Pulse duration on on test (see Technical details) Scan time of power-up test under normal circumstances (ca. 200 ms) Characteristic: Output capacitance C dependent on load current I C [µF] I [A] Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 19: Safety Functions
To prevent the drive running down in an uncontrolled manner, in normal operation the safety function STO is activated via the safety function SS1. STO is only activated directly when – there is an internal error on the servo amplifier or safety card Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 20 The drive is switched to torque-free "STO Acknowledge" output: “1” Signal If any external forces influence the motor axis (e.g. suspended loads), additional measures (e.g. a safety holding brake) are required in order to eliminate hazards. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 21: Safe Stop 1 - Ss1
In the Configurator, the braking ramp is specified and monitoring is activated. The brak- ing period depends on the speed of the motor when braking is started. The braking ramp can be monitored via a maximum position error specified in the Con- figurator. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 22 "0". The safety function "STO" is activated once the STO delay time has elapsed. The safety function "STO" is activated immediately if the second input is also set to "0". The safety function "STO" is always activated when both the inputs "SS1 Activate" and "Reset" are set to "0". Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 23 "safe torque off" (STO). The motor becomes torque-free. "STO Acknowledge" output: “1” Signal If any external forces influence the motor axis (e.g. suspended loads), additional measures (e.g. a safety holding brake) are required in order to eliminate hazards. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 24 Braking ramp Tolerance window Braking ramp Limit value Standstill detection STO delay time Fig.: Safety function SS1 : Activation of safety function SS1 : Activation of safety function STO SS1 Activate: Input for safety function SS1 Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 25: Safe Stop 2 - Ss2
SSA Safe Standstill Acknowledge Prerequisites for normal operation: Input "SS1 Activate" and "Reset": "1" Signal (+24 VDC) "Ready" output: "1" Signal (+24 VDC). The safety card is ready for operation. "STO Acknowledge" output: “0” Signal Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 26 Drive-activated braking ramp Controller-activated braking ramp Reaction: Controlled braking of the drive, with the configured braking ramp. The drive remains in a controlled standstill and is monitored for "safe standstill". Output "SSA Safe Standstill Acknowledge": "1" signal Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 27: Safe Operating Stop - Sos
An error will activate safety function SS1 (E-STOP braking ramp). Features of the safety function: The drive’s control functions are maintained in the standstill position. Power to the motor is not shut down. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 28 Output "SSA Safe Standstill Acknowledge": "1" signal Safety function SS1 (E-STOP braking ramp) shuts the drive down safely if the limit value for the standstill position is exceeded. An error is registered. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 29 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SSA Safe Standstill Acknowledge: Output for feedback from limit value monitoring Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 30: Safely Limited Speed - Sls
The tolerance range becomes active the first time the speed limit value is exceeded (see flowchart). Reaction: If the tolerance range is exceeded, the safety function SS1 (E-STOP braking ramp) is activated. The following diagrams illustrate the sequences, with and without the tolerance range activ- ated. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 31 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 32 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 33: Safe Speed Range - Ssr
The tolerance range becomes active the first time the speed limit value is exceeded (see flowchart). Reaction: If the tolerance range is exceeded, the safety function SS1 (E-STOP braking ramp) is activated. The following diagrams illustrate the sequences, with and without the tolerance range activ- ated. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 34 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 35 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 36: Safe Direction - Sdi
Once the SDI delay time has elapsed, the direction of rotation is monitored Output "SDA Safe Direction Acknowledge": "1" signal If the direction of rotation is violated, safety function SS1 (E-STOP braking ramp) is ac- tivated. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 37 (See Case A in the illustration). If an SDI delay time t has been configured, it will start when the new direction of rotation monitoring is activated. In A, the SDI delay time t shown = 0. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 38 The safety function SS1 will trigger if monitoring in both directions is activated simultaneously. SDI Neg Activate SDI Neg Activate SDI Pos Activate SDI Pos Activate t m = 0 Fig.: Changing the direction of rotation Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 39 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SDA Safe Direction Acknowledge: Output for feedback from safety function SDI Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 40: Safely Limited Increment - Sli
While this monitoring function is carried out, the output "SSA Safe Standstill Acknowledge" = "1". – A tolerance window may be specified for standstill monitoring. If the value is ex- ceeded, safety function SS1 (E-STOP braking ramp) is activated. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 41 Ready: Output for operating status of safety card and second output for feedback from safety function STO STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 42 STO Acknowledge: Output for feedback from safety function STO SRA Safe Range Acknowledge: Output for monitoring the limit value on the motor SSA Safe Standstill Acknowledge: Output for feedback from monitoring the standstill limit value Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 43: Operating Mode Of The Servo Amplifier
With the drive-activated safety function "safe stop 2" (SS2), the movement is ultimately continued. The status of the safety card (SS2 activated) is transmitted to the servo amplifier. As a result, the information is available to a higher level control system (status word). Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 44: Reaction Times
Please also refer to the operating manual for the servo amplifier. Reaction times The reaction times refer exclusively to the inputs and outputs on a servo amplifier with safety card when: The signal at the inputs changes Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 45 CYCLE PULSE PMCprotego Sx PMCprotego Dx Input Controller Output Pulse disabler Power element CYCLE PULSE t (ms) Error reaction time = 3 ms Response time = 5 ms Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 46: Configuration
Save safety card configuration to SD card in the servo amplifier. The feasibility of the configuration is checked as it is uploaded. INFORMATION Further information on the configuration and parameter settings for the safety functions is available in the safety card configurator's online help. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 47: Installation
Electrostatic discharge can damage components. Ensure discharge before touching the safety card, e.g. by touching an earthed, conductive surface or by wearing an earthed armband. Dimensions 103 (4.06") 18,5 87,5 (3.45") (0.73") POWER CONFIG Fig.: Dimensions stated in mm (") Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 48: Installing The Safety Card
2. Break the middle link 3. Break the top link and lever out the cover plate 5. Plug in the safety card 4. Using suitable pliers, pull out the blank in the safety card and tighten the screws plug Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 49: Wiring
DIN 46228/4 0.5 mm [H 0.5/16D] metrical. Ferrule length 10 mm, stripping length 12 mm Max. cable lengths – Supply voltage: Max. 30 m – Digital inputs and outputs: Max. 30 m Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 50 Not connected n. c. Not connected n. c. Not connected Reset Input for reset 0 V Supply Supply voltage for digital outputs (0 DC) 0 V Supply Supply voltage for digital outputs (0 DC) Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 51: Shielding
Alternatively you can use the shielded con- nection terminals (3) (available as an ac- cessory). These hook into the bottom shielding plate and guarantee optimum con- tact between the shield and the shielding plate. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 52: Digital Inputs
24 V I/O-GND Shield Servo Amplifier Shield Connection Digital outputs 6.5.1 Supply voltage The digital outputs need a 24 VDC supply. When selecting the power supply, please refer to the requirements stated under “Tech- nical Details”. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 53 Servo Amplifier XGND Noise suppression filter in- tegrated within the safety card *) Please note the follow- ing: Link X30, Pin 21 or 22 to XGND on the servo ampli- fier Connection *) XGND: Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 54: Single-Pole Outputs
STO Acknowledge DI 1 Max. cable length: 30 m DI 2 DI 3 24 VDC DI 4 Referenced to earth: 0V DI 5 Supply X30 Pin 21 Ready DI 6 I/O-GND Shield Servo Amplifier Shield Connection Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 55: Commissioning
[AENA]" is set in the commissioning software PASconfig SDrive: – after the safety card has run-up – when recommissioning after a fault Appropriate measures should be taken so that the start of the machine does not create a hazardous situation. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 56: Initial Commissioning
You will know when the servo amplifier and safety card are ready for operation by the display elements on the individual components. The display elements on the safety card are described in this manual, under "Operation". Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 57 (O0 … O3) have a "0 signal" in the STARTUP phase. If the self test is successful, the servo amplifier's power element is enabled. The "Ready" output has a "1" signal. The "RUN" LED is lit. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 58 The dynamic program display in the safety card's Configurator the commissioning software PASmotion INFORMATION Please note the following in the STARTUP state: The activation inputs of all the safety functions configured in the tool must be switched to +24 VDC. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 59: Recommissioning
4 > 100 ms Enable U, V, W Motor n Legend: Servo amplifier – 24 V: Supply voltage – BTB/RTO: Relay contact for operational readiness, servo amplifier – L1, L2, L3: Mains voltage – X8: Intermediate circuit Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 60: Recommissioning After Error
The activation inputs of all the safety functions configured in the tool must be switched to +24 VDC. 7.3.2.1 Switching the inputs "SS1 Activate" or "Reset" 1. Switch input "SS1 Activate" or "Reset" to 0 V Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 61: Command "Clrfault
(e.g. IN4MODE=30 on input DIGITAL-IN4). INFORMATION Further information on the command can be found in the online help for the servo amplifier. Please also refer to the operating manual for the servo amplifier. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 62: Swap Safety Card
You can download the configuration data to the safety card as follows: From the Configurator to the safety card via the servo amplifier's communications in- terface (RS 232 or Ethernet). From an SD card in the servo amplifier to the safety card. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 63: Download Configuration From Configurator To Safety Card
Connection is established between the PC and servo amplifier (RS 232 or Ethernet). Procedure: Select Online Mode -> Download Project in the safety card's Configurator. INFORMATION Further information is available in the safety card Configurator's online help. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 64: Download Configuration To Sd Card
Further information is available in the safety card Configurator's online help. 7.3.3.3 Download configuration from SD card to safety card Before carrying out the steps described in this section, please note the following safety guidelines: Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 65 7. Wait until "dis" (= drive integrated safety) appears on the display. a Note: You must then press the left-hand operator key on the servo amplifier within 60 seconds (see step 8). 8. Press the left-hand operator key for at least 2 seconds. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 66: Safety Checks
You must comply with the requirements of the applicable national regulations. The intervals you select will depend on the application, the overall system and the associ- ated risk analysis. The test interval should not exceed one year. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 67: Operation
The motor is switched volt free in the CONFIG operating state (STO is active) NORMAL OPERATION No safety function activated Transition to state of STO: Internal error Transition to SAFE OPERATION: A safety function is activated Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 68: Testing The Safe Pulse Disabler
The safety card switches to a "STARTUP" condition. The device and the safe pulse dis- abler are tested. The "RUN" LED flashes. The safety card switches to a "RUN" condition. The "RUN" LED is lit continuously. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 69 : At least 2 ms; time during which SS1 Activate or Reset must have a "0" signal : Approx. 2 s, safety card's run-up time SS1 Activate: Input for safety function SS1 Reset: Input for reset STO Acknowledge: Output for feedback from safety function STO "RUN" LED: System is ready Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 70: Display Elements
- - - No error occurred, safety function SS1 not triggered, oper- ating status STO is inactive Error occurred or safety function SS1 triggered, operating status STO is active Legend LED on LED off LED flashes Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 71: Messages
Safety card status messages and error messages (error stack) – States of safety card inputs and outputs The expanded diagnostics system PVIS displays errors, messages and the correspond- ing remedies only in conjunction with a PMCprimo controller. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 72: Technical Details
DIN EN 60721-3-3 Temperature range 0 - 40 °C 0 - 40 °C Storage temperature In accordance with the standard DIN EN 60721-3-1 DIN EN 60721-3-1 Temperature range -25 - 55 °C -25 - 55 °C Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 73 Mounting type plug-in plug-in Dimensions Height 142,0 mm 142,0 mm Width 18,5 mm 18,5 mm Depth 103,0 mm 103,0 mm Weight 150 g 150 g Where standards are undated, the 2009-03 latest editions shall apply. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 74: Safety Characteristic Data
PMCprotego S2 Motor encoder with MTTF ³ 10 years The safety-related characteristic data is valid for all safety functions. All the units used within a safety function must be considered when calculating the safety characteristic data. Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 75: Order Reference
Order reference Order reference Order reference Product type Features Order no. PMCprotego S2-2 Safety Card 680 006 PMCprotego S2-2-C Safety card with coated circuit board 680 009 Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 76: Glossary
SOS function if the motor speed drops below a defined limit value, or c) Initiates the motor delay and then initiates the SOS function after an application-specific time delay." Operating Manual PMCprotego S2-2(-C) 1002529-EN-04...
Page 77 Front cover Support Technical support is available from Pilz round the clock. Americas Australia Scandinavia Brazil +61 3 95600621 +45 74436332 +55 11 97569-2804 Spain Canada Europe +34 938497433 +1 888-315-PILZ (315-7459) Austria Switzerland Mexico +43 1 7986263-0 +41 62 88979-30...

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