Page 1 Installation manual Installation Manual SMX series SMX Compact and SMX Compact, 2nd Generation (SMXGen2) HB-37350-810-01-51F-EN SMX Installation manual.docx Page 1 of 234 Version: 50F...
Page 2 Installation manual Installation manual for devices SMX 10 (/4x) SMX 10A (/4x) SMX 10R (/4x) SMX 10AR (/4x) SMX 11 (/4x) SMX 11-2 (/4x) SMX 12/12A (/4x) SMX 12-2 (/4x) SMX 12-2A (/4x) of the series SMX 10/11/12 and their extension modules SMX 31 SMX 31R SMX 5x (see section 3).
Page 3 However, we would like to point out, that this document cannot always be updated at the same time as the technical further development of the products. Information and specifications can be changed at any time. Please keep yourself informed about the current version under www.bbh-products.de. Devices of the BBH Products GmbH Böttgerstraße 40...
Page 4: Table Of Contents
Installation manual Inhalt IMPORTANT NOTES ..................... 8 Definitions .............................. 8 Co-valid documents ..........................9 Abbreviations used ..........................11 SAFETY REGULATIONS ..................13 Intended use ............................13 Use in regions with UL/CSA requirements .................... 13 General safety regulations ........................14 Operation and service .......................... 15 Transport/storage ..........................
Page 5 Installation manual 4.3.4 Digital outputs ........................86 4.3.4.1 Characteristic data of the basic outputs ................86 4.3.4.2 Wiring examples basic outputs ..................88 Digital outputs I/O’s (IQQx) ....................95 4.3.5 Classification of the I/O‘s (IQQx) when used as output ............ 95 4.3.5.1 Wiring examples for safe digital outputs I/O's I/O’s (IQQx) ..........
Page 6 Installation manual 5.12.1 General description of encoder configuration ..............172 5.12.2 Sensor type ......................... 172 5.12.2.1 Absolute encoder: ....................... 172 5.12.2.2 Incremental encoder: ....................174 SinusCosinus encoder – standard mode ..............174 5.12.2.3 SinusCosinus encoder – high resolution mode: ............174 5.12.2.4 5.12.2.5 Proxi - switch ......................
Page 7 Installation manual 12.3.9 Performance of the system test / FIT (fault injection test) ..........226 APPENDIX ........................ 227 Appendix A – Classification of switch types ..................... 227 Appendix B – CE-Declaration ........................... 230 HB-37350-810-01-51F-EN SMX Installation manual.docx Page 7 of 234 Version: 50F...
Page 8: Important Notes
The system software "SafePLC", “Safe PLC2” serves the purpose of configuring and programming SMX modules. The modules of the SMX series are internally built up of two independent processing units. In the following these are referred to as system A and system B.
Page 9: Co-Valid Documents
Installation manual 1.2 Co-valid documents Description Referenz Configuration of the SMX module for SafePLC programming manual stand-alone applications without field- (System CD) bus interfacing with the program "SafePLC" Validation report for implemented Safety inspection with acceptance parameterization and PLC-program protocol Acceptance for general safety relevant Certificate for type approval test as applications...
Page 10 Installation manual Description Referenz Acceptance for applications in the Certificate for type approval test as elevator technology PESSRAL acc. to EN 81-20/-50 resp. EN (validity range EN 81) 81-1/-2 for the product groups SMX10P SMX11P Options: - Standard field bus - Standard field bus and safety protocol - Universal communication interface - Decentral expansion module...
Page 11: Abbreviations Used
Installation manual 1.3 Abbreviations used Abbreviation Meaning Alternating voltage Instruction list ELIA Employer's liability insurance association Clock (cycle) Central Processing Unit Direct voltage I1..I14 Digital Input Deutsches Institut für Normung (German Institut for Standardization) Digital Output Emergency Monitoring Unit Electromagnetic compatibility Emergency Limit Control European Standard HISIDE...
Page 12 Installation manual Abbreviation Meaning Verband der Elektrotechnik, Elektronik und Informationstechnik e. V. (association for electrical engineering, electronics and information technology) Yx.y Auxiliary Output G.P. General purpose (Gerneral use) x = 0 ….. 2 (1) Module address y = 1 ….. 40 Channel address HB-37350-810-01-51F-EN SMX Installation manual.docx Page 12 of 234...
Page 13: Safety Regulations
See appendix "EC Declaration of Conformity" 2.2 Use in regions with UL/CSA requirements In case of modules of SMX series, which do not have UL/CSA approval, these modules can be used in USA and Canada under the following conditions: the switching voltage of the output relays must be limited to max. 24 V.
Page 14: General Safety Regulations
Installation manual 2.3 General safety regulations Safety note: • In order to avoid damage to persons and property only qualified personnel is entitled to work on the device. The term qualified personnel refers to persons who have successfully completed electrotechnical training and are fully familiar with the applicable rules and standards of electrical engineering.
Page 15: Operation And Service
Using our devices contrary to the rules and conditions specified hereunder can lead to injuries or fatalities as well as damage to connected devices and machines! This will also cause the loss of all warranty and compensation claims against BBH. 2.4 Operation and service The module must always be de-energized before installation and removal, or before disconnecting signal lines.
Page 16: Device Types
Installation manual 3 Device types The series SMX10/11/12 consists of Basic devices SMX10/11/12 Extension modules SMX3x decentralised expansion modules SMX32x communication modules with standard field bus SMX5x integrated communication modules with safe field bus SMXxx-x(/2, /4x, /x) Basic devices Series SMX10/11/12 is a compact fail-safe control system with optionally integrated drive monitoring for one (SMX11/11-2) or two (SMX12/12-2) axes.
Page 17 Installation manual SMXGen2 of the above-mentioned device types The distinguishing of the device types takes place through the SMXGen2 characterization (/2). (e.g.: SMX10/2) The following characteristics distinguish the two versions: Switchable outputs on the base devices; See technical data. Higher nominal loads of the outputs on the base devices. See technical data. Higher nominal loads of the outputs on the I/O expansion modules See technical data.
Page 18: Module Overview
Installation manual 3.1 Module overview Basic units Extension units Designation SMX32-0/2/D, 10/10A/10 SMX12/12A/ SMX31/31R/31R- SMX32-1/2/D, R/10AR 11/11-2(/2, 12-2/12-2A(/2, SMX5x 4(/2) SMX32-0R/2/D, (/2, /4x, /4x, /x /4x, /x SMX32-1R/2/D General data Max. no. of expansion modules Safe digital inputs Safe digital I/O 10/2 0 / 10 Safe digital outputs pn-...
Page 19: Characteristic Data Of Device
Installation manual 3.2 Characteristic data of device 3.2.1 Basic modules 3.2.1.1 SMX10/10A/10R/10AR (/2, /4x, /x Type designation Device design Design of module with the following periphery: Digital inputs Pulse outputs Relay outputs (6x SMX10R, SMX10AR) pn- or pp- switching outputs Auxiliary outputs Analog inputs (SMX10A, SMX10AR) diagnostic- and configuration interface...
Page 20 Installation manual o Standard and safe field bus protocols for communication with a higher level controller o Safe cross communication (SMMC) for data exchange between multiple base devices o Safe remote I/O communication for data exchange with distributed I/O systems See: Chapter 3.2.4.3 Optional universal communikation interface •...
Page 21 Installation manual Technical characteristic data SMX10/A/R/AR (/2, /4x, /x Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 plus in SMX10R, SMX10AR 1-channel per Rel 20 FIT max. 4) 2-channel per Rel 1,0 FIT max.
Page 22 Installation manual Temperature rating 24 VDC; 1,8A (G.P.) 50°C pp-switching Temperature rating 24 VDC; 2A (G.P.) 30°C Temperature rating 24 VDC; 1,8A (G.P.) 50°C Max. total current (pn or pp) Auxiliary outputs 24 VDC; 250mA (G.P.) Rated data Normally open 24 VDC;...
Page 23: Smx11(/2, /4X, /X )
Installation manual 3.2.1.2 SMX11(/2, /4x, /x Type designation Device design Design of module with the following periphery: Axis Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp- switching outputs Auxiliary outputs Diagnostic- and configuration interface Function button 7-segment display status-LED status LEDs for inputs status-LEDs für Pulse outputs...
Page 24 Installation manual • Switchable safe semi-conductor outputs pn-, pp- switching for safety-relevant functions • Complete speed and position-based safety functions for drive monitoring in accordance with IEC 61800-5-2 are integrated in firmware o Spatial functions for safe speed and are monitoring are possible •...
Page 25 Installation manual Technical characteristic data SMX11(/2, /4x,/x Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operating period General data Max.
Page 26 Installation manual Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Degree of pollution Mechanical data Dimensions SMX11(/2) = 100x115x45 (HxDxW [mm]) SMX11(/2)(4x, /x = 100x115x67,5 Weight SMX11(/2)
Page 27: Smx11-2(/2, /4X, /X )
Installation manual 3.2.1.3 SMX11-2(/2, /4x, /x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces Digital Inputs Pulse outputs Relay outputs pn- or pp- switching outputs Auxiliary outputs Diagnostic and configuration interface Function button 7-segment display status-LED status LEDs for inputs status-LEDs für Pulse outputs...
Page 28 Installation manual • Monitored relay outputs for safety relevant functions • Switchable safe outputs pn-, pp-switching for safety-relevant functions • Complete speed and position-based safety functions for drive monitoring in accordance with IEC 61800-5-2 are integrated in firmware o Spatial functions for safe speed and are monitoring are possible •...
Page 29 Installation manual Technical characteristic data SMX11-2(/4x, /x Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /CaT 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operation period General data Max.
Page 30 Installation manual Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Degree of pollution Mechanical data Dimensions SMX11-2(/2) = 100x115x67,5...
Page 31: Smx12/12A
Installation manual 3.2.1.4 SMX12/12A(/2, /4x, /x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp- switching outputs Auxiliary outputs Analogue inputs (SMX12A) Diagnostic- and configuration interface Function button 7-segment display status-LED...
Page 32 Installation manual • Switchable safe semi-conductor outputs pn-, pp- switching for safety-relevant functions • Parameter management for expansion modules in base device • Comprehensive diagnostics functions integrated • Coded status display via front-side 7 segment display and status LEDs • Multifunction buttons (quit, start, reset) can be operated from the front side •...
Page 33 Installation manual Technical characteristic data SMX12/12A(/2, /4x, /x Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operation period General data Max.
Page 34 Installation manual 0°C … +50°C operation Temperature -25C° … +70C° storage and transport Class of protection IP 20 Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m...
Page 35: Smx12-2/12-2A
Installation manual 3.2.1.5 SMX12-2/12-2A(/2, /4x, /x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp- switching outputs Auxiliary outputs Analogue inputs Diagnostic- and configuration interface Function button 7-segment display status-LED status LEDs for inputs...
Page 36 Installation manual • Switchable safe semi-conductor outputs pn-, pp- switching for safety-relevant functions • Parameter management for expansion modules in base device • Comprehensive diagnostics functions integrated • Coded status display via front-side 7 segment display and status LEDs • Multifunction buttons (quit, start, reset) can be operated from the front side •...
Page 37 Installation manual Technical characteristic data 12-2/12-2A(/2, /4x, /x Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operation period General data Max.
Page 38 Installation manual (Read back contact) Environmental data 0°C … +50°C operation Temperature -25C° … +70C° storage and transport Class of protection IP 20 Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude...
Page 39: Central Expansion Modules
Installation manual 3.2.2 Central expansion modules 3.2.2.1 SMX31/31R/31R-4(/2) Type designation Device design Design of module with the following periphery: Digital inputs Digitale I/Os Pulse outputs Auxiliary outputs Relay outputs (SMX31x) status LEDs for inputs Status-LEDs für I/O Characteristics of the module: •...
Page 40 Installation manual Technical characteristic data SMX31/31R/31R-4(/2) Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 9,2 FIT /Cat 4 plus in SMX31R/31R-4 1-channel per Rel 20 FIT max. 8) 2-channel per Rel 1,0 FIT max.
Page 41 Installation manual EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Degree of pollution Mechanical data Dimensions SMX31(/2) = 100x115x45 (HxDxW [mm]) SMX31R(/2) = 100x115x90 SMX31R-4(2) = 100x115x67,5 Weight SMX31(/2) = 300 SMX31R(/2) = 680 SMX31R-4(/2)
Page 42: Decentralized Expansion Modules
Installation manual 3.2.3 Decentralized expansion modules 3.2.3.1 SMX32-x/2/D, SMX32-xR/2/D Type designation Device design Design of module with the following periphery: Digital inputs Digitale I/Os configurable Pulse outputs Relay outputs pn- or pp- switching outputs Auxiliary outputs 7-segment display status-LED status LEDs for inputs status-LEDs for pulse outputs status-LEDs for relay outputs status LEDs for outputs...
Page 43 Installation manual Technical characteristic data SMX32-x/2/D, SMX32-xR/2/D Safety related characteristic data Pl acc. to EN ISO 13849-1 PL e PFH / architecture 9,2 FIT /Cat 4 plus in SMX32-xR/2/D 1-channel per Rel 20 FIT (max. 8) 2-channel per Rel 1,0 FIT max.
Page 44 Installation manual 06 – 10 Temperature rating 24 VDC; 2A (G.P.) 30°C Temperature rating 24 VDC; 1,8A (G.P.) 50°C Max. total current (I/O) Rated data Normally open 24 VDC; 2A (Pilot Duty relays 120 VAC; 2A (Pilot Duty Normally closed 24 VDC;...
Page 45: Communication Interface
Installation manual 3.2.4 Communication interface 3.2.4.1 SMX5x Type designation Device design Designs of the module with following peripherals: SMX51 CAN 2.0 oder SMX52 Profibus oder SMX53 Profinet oder SMX54 CANopen oder SMX55 EtherCAT oder SMX57 Devicenet backplane bus interface status LED for operating status status LED CAN- communication Characteristics of the module: •...
Page 46 Installation manual Technical characteristic data SMX5x Safety related characteristic data Pl acc. to EN ISO 13849-1 n.a. PFH / architecture n.a. SIL acc. to IEC 61508 n.a. Proof test interval n.a. General data Fieldbus interface Type of connection Standard acc. to field bus type Max.
Page 47: Smx1X/4X
Installation manual 3.2.4.2 SMX1x/4x Type designation Device design SMX1x/43 Designs of the module with following peripherals: SMX1x/45 SMX1x/43 PROFISAFE over Profinet SMX1x/45 FSoE FailSafe over EtherCAT status LED for operating status status LED internal SPI communication status LED field bus Characteristics of the module: •...
Page 48 Installation manual Technical characteristic data SMX1x/4x Safety related characteristic data Pl acc. to EN ISO 13849-1 n.a. PFH / architecture n.a. SIL acc. to IEC 61508 n.a. Proof test interval n.a. General data Fieldbus interface Type of connection Standard acc. to field bus type Max.
Page 49: Optional Universal Communication Interface
Storage medium for safety program Properties of the universal communication interface: • Optional specification of the SMX series communication interface • Subsequent expansion capability of standard to safe field bus via additional Mini SD card on the back side of the module is possible. (/xNx and /xBx) •...
Page 50 Installation manual Technical characteristic data: Optional universal communication interface Safety related characteristic data Pl acc. to EN ISO 13849-1 n.a. PFH / architecture n.a. SIL acc. to IEC 61508 n.a. Proof test interval n.a. General data Decentralised communication interfaces 2x RJ 45* Field bus interfaces 2x RJ 45** 1x Sub-D***...
Page 51: Encoder Specifications
Installation manual 3.2.5 Encoder specifications Physical Layer RS-422 compatible Measuring signal A/B Track with 90 degree phase difference Max. frequency of input cycles (X31, 250 kHz / 500 kHz X32 / X33, X34) Type of connection D-SUB 9pol Sin / Cos Physical Layer RS-422 compatible Measuring signal A/B...
Page 52: Derating Outputs
Installation manual 3.3 Derating outputs Maximum current load based on temperature. This derating should be considered for all 2A outputs (IO-Board and REL-Board)! 2A outputs can be fully loaded at an ambient temperature of up to 30°C. From a ambient temperature from 30°C to maximum 50°C, the 2A outputs can be loaded to a maximum of 1.8A.
Page 53: Type Plate Smxgen2 (/2)
Installation manual 3.4.2 Type plate SMXGen2 (/2) The type plate is located on the left side wall of the module and contains the following information: Type designation Part number Serial number Identification of hardware release Identification of software release Safety category Input characteristics Output characteristics Date of manufacture (week/year)
Page 54: Scope Of Delivery
Installation manual 3.4.3 Scope of delivery The scope of delivery contains: SMX module: • Plug for all signal terminals without encoder connection Not included in the scope of delivery: • SafePLC configuration software CD with ➢ Installation manual ➢ Programming manual ➢...
Page 55: Safety Related Characteristics
4 Safety related characteristics 4.1 General design, safety related architecture and characteristic data The inner structure of SMX series consist of two separate channels with reciprocal comparison of results. High quality diagnoses for fault detection are made in each of the two channels.
Page 56 Installation manual Characteristic data: • Max. obtainable safety class SIL 3 acc. to IEC 61508 • Category 4 acc. to EN ISO 13849-1 • Performance-Level e acc. to EN ISO 13849-1 System structure System structure 2-channel with diagnose /1002) acc. to EN 61508 Architecture category 4 acc.
Page 57: Safety Related Characteristic Data And Wiring For The Connected Sensors
Installation manual 4.2 Safety related characteristic data and wiring for the connected sensors The SMX modules have completely separated signal processing paths for each safety input. This applies for both the digital and the analog inputs. Furthermore, measures for achieving the highest possible DC-values have been implemented.
Page 58: Dc Digital Sensors/Inputs
Installation manual 4.2.1.2 DC digital sensors/inputs The SMX modules ensure far reaching diagnostics functions for the input element. These are carried out permanently, or optionally (cross-shorting monitoring by means of pulse identifier, cross-comparison, 2- or multi-channel sensor with/without time-out, start-up test). Permanently active diagnostics functions: Cross-comparison: SMX module inputs are in general internally designed with two channels.
Page 59 Installation manual Start test: Each time the safety module (=SMX module) is switched on, the input element must be tested in direction of the Low signal status (defined Safe State), e.g. by actuating the Emergency Stop button or a door lock after the system has been started. Operational / organizational tests: Apart from the previously mentioned diagnostic measures for the SMX modules, cyclic testing can be performed within the application.
Page 60 Installation manual The following diagnoses for input sensors can generally be used for the safety related assessment of the entire system: Input element Parameterized / Definition of measure Note characteristic operational tests Single-channel Cyclic test pulse by dynamic A sufficiently high >60 change of input signals test rate must be...
Page 61: Classification Of Digital Inputs
Installation manual Safety note: • The manufacturer's data (MTTFD, FIT-numbers, etc.) must be used for a safety related assessment of the partial system "Sensors". • The DC-values listed in the table must be used conservatively and compliance with the boundary conditions (see table under „Remarks“) must be ensured. •...
Page 62 Installation manual 4.2.1.3.2 Digital inputs I/O’s (IQIx) Digital inputs Achievable Comment performance level Without pulse, single channel static signal -> auxiliary input Without pulse, dual channel static signal At least one request/day required by PL e application Fault detection only upon request Without pulse, dual channel static signal PL d Less than one request/day required by...
Page 63: Exemplary Connections Of Digital Sensors
Installation manual 4.2.1.4 Exemplary connections of digital sensors 4.2.1.4.1 Single-channel sensor, without cross-shorting test Fig.: Single-channel sensor, without cross-shorting test The single-channel sensor is connected to the SMX without clocking or without cross-shorting test. This design is not recommended for safety applications. Pl b acc. to EN ISO 13849-1 can maximally be reached.
Page 64 Installation manual When using a single-channel sensor with clocking, the power supply of the switching element is attached to the clock exit T1 or T2. The clock must subsequently be assigned to the SMX. The use of a single-channel sensor with clock detects: short-circuit to supply voltage DC 24 V short-circuit to DC 0 V cable interruption (current interruption is safe state!)
Page 65 Installation manual 4.2.1.4.3 Dual-channel sensor without timeout with cross-shorting test Faults are at least detected when requested. The DC is medium and by using cyclic tests (start test, operational/organizational tests) can be changed up to high level. depending on the test frequency.
Page 66 Installation manual Safety note: • Pl d or higher in accordance with EN ISO 13849-1 is achieved by using switching elements / sensors with positively opening contacts or positive actuation acc. to EN 60947-5-1 • Using devices for which the fault exclusion double fault for the intended safety level can be specified for the switching elements, is permitted.
Page 67 Installation manual 4.2.1.4.4 Dual-channel sensor with time-out and cross-shorting test Cross-shorting as well as connections to DC 24 V and DC 0 V can be detected by using two independent clock signals on the homogeneous sensor. Pl d or higher acc. to EN ISO 13849-1 can be achieved when: - Use of sensors/switching elements with forced actuation.
Page 68: Overview Of Achievable Pi For Digital Safety Inputs
Installation manual 4.2.1.5 Overview of achievable PI for digital safety inputs Parameterized / Typ des Input Achieva Fault exclusion Condition for input operational tests Sensors / ble PI for input element Eingangs acc. to element element EN ISO 13849-1 Operation proven input element I01..I14 All faults at the...
Page 69 Installation manual Typ des Input Parameterized / Achieva Fault exclusion Condition for input operational tests Sensors ble PI for input element acc. to element Eingang EN ISO selemen 13849-1 Short-circuit at Connection in control cabinet input/signal line or protected routing Getting caught / positively MTTF...
Page 70: Sensors For Speed And/Or Position Detection
4.2.2.1 General safety related structure of the sensor interface for position and/or speed The base modules of the SMX series can be optionally equipped with one (SMX11/12), or two encoder interfaces (SMX11-2/12-2) per axis. Depending on encoder type and combination, different safety levels can be reached. The...
Page 71: General Diagnostic Measures For Encoder Interface
Installation manual 4.2.2.2 General diagnostic measures for encoder interface For fault detection in the sensor system the SMX series has a number of diagnostic measures implemented, depending on the chosen encoder type or its combination. These are automatically activated when choosing the encoder type.
Page 72: Encoder Types And Their Combination, Diagnostic Data
Installation manual 4.2.2.3 Encoder types and their combination, diagnostic data 2-channel 2-channel partial Safe Safe Safe 1-channel partial system Encoder A Encoder B absolute Fault exclusion speed direction partial system non- Position system dynamic dynamic (standstill monitoring) Fault exclusion mech. shaft breakage, 1 x Proxi 1 x Proxi positive encoder shaft connection...
Page 73 Installation manual 2-channel Safe 2-channel partial Safe Safe absolute 1-channel partial system Encoder A Encoder B speed direction Fault exclusion Position partial system non- system dynamic dynamic (standstill monitoring) Resolver n.a. 95-99% n.a. 90-95% Fault exclusion mech. shaft breakage, SIN/COS positive encoder shaft connection 90-95% required...
Page 74: Specific Diagnostic Measures With Regard To The Encoder Type Used
Installation manual 4.2.2.4 Specific diagnostic measures with regard to the encoder type used Encoder type Incremental SIN/COS Proxi 2 x counting input Proxi 2 x counting input Incremental Resolver SIN_COS Only in High-Resolution Mode HB-37350-810-01-51F-EN SMX Installation manual.docx Page 74 of 234 Version: 50F...
Page 75: Safety Relevant Cut-Off Thresholds Encoder Systems For Position And Speed Detection
Installation manual 4.2.2.5 Safety relevant cut-off thresholds encoder systems for position and speed detection Plausibility tests with the current position and speed values are performed between both measuring channels A and B of the SMX module as a basic measure, which are then checked against parameterizable thresholds.
Page 76 Installation manual Value Wert Acceleration [rev/min/s] Resolution Graph acceleration, rotary (Values in rev/min/s) Graph acceleration, linear (Values in mm/s and m/s²) Safety note: • The fault can be optimized by choosing a suitable sensor resolution for the corresponding application. • For applications with limited resolution and/or time variance of the sensing signal, the functional performance of the monitoring function used can be improved by using an average filter.
Page 77 Installation manual • The filter time can be variably set between 0 and 64 in steps of 8. The dimension is "msec". In order to determine the response time of the overall system, the filter times must be added to the specified response times of the SMX systems (see chapter 11). Safety note: •...
Page 78: Safety Related Assessment Of Encoder Types Or There Combination
Installation manual 4.2.2.6 Safety related assessment of encoder types or there combination Due to the monitoring functions implemented in the SMX-series, no special demands are initially made on the internal design of the encoder electronics in applications with encoder systems, i.e. standard encoders can normally be used.
Page 79 Installation manual The SMX module generally detects the following faults in the external encoder system: • Short-circuits between safety relevant signal lines • Interruptions in safety relevant signal lines • Stuck at 0 or 1 on one or all safety relevant signal lines Each encoder type has further specific diagnoses for fault detection in the external encoder system assigned.
Page 80: Analog Sensors
Installation manual 4.2.3 Analog sensors The basic modules SMX10A, SMX10AR, SMX12A, SMX12-2A verfügen have two analog inputs with two input channels each. Only 2-channel sensors can generally be connected to this interface. The internal signal processing takes place separately in the two channels with cross-comparison of the results.
Page 81: Exemplary Connection Of Analog Sensors
Installation manual Safety note: • The manufacturer's data (MTTF , FIT-numbers, etc.) must be used for a safety related assessment of the partial system "Sensors". • The DC-values listed in the table must be used conservatively and compliance with the boundary conditions (see table under „Remarks“) must be ensured.
Page 82: Safety Related Characteristic Data And Wiring Of The Outputs
Installation manual Safety related characteristic data and wiring of the outputs SMX modules all have safe outputs of various types. For wiring, the corresponding characteristic as specified in the following description, must be accounted for. 4.3.1 Characteristic of the output elements Actuator Aktuator Single-channel output SMX and single-channel actuator without diagnostics...
Page 83: Diagnoses In The Cut-Off Circuit
Installation manual Actuator Aktuator Single-channel output SMX with internal dual-channel processing (IQQx) and dual-channel actuator with dual-channel diagnose Actuator Aktuator Dual-channel output SMX and dual-channel actuator with single-channel diagnose Actuator Aktuator Dual-channel output SMX and dual-channel actuator with dual-channel diagnose 4.3.2 Diagnoses in the cut-off circuit The cut-off circuit is equipped with durably implemented and parametrizable diagnostics functions.
Page 84: Overview Dc With Respect To The Chosen Diagnostics Functions
Installation manual Parametrizable diagnostics functions: Readback of the actuator status via auxiliary contacts, position indicators, etc.: The current status of the actuator is detected by correspondingly suitable auxiliary contacts or position indicators and compared with the nominal status. Any deviation is thereby clearly recognized.
Page 85: Permissible Capacitive And Inductive Load At Safe Outputs
Installation manual 4.3.3 Permissible capacitive and inductive load at safe outputs The safe outputs of the SMX exhibit an OSSD character. That is, the outputs are cyclically switched off for the test of the switching off ability and the status is read back. The examination of the switching off ability takes place according to the following criteria/functions: After switching the output off, the output voltage may max.
Page 86: Digital Outputs
Installation manual 4.3.4 Digital outputs The modules • SMX10/10A/10R/10AR(/2), SMX11(/2), SMX11-2(/2), SMX12/12ª(/2), SMX12-2/12-2A(/2) • SMX31/31R/31R-4(/2), SMX32-0(R)/2/D, SMX32-1(R)/2/D all have basic outputs of identical design. 4.3.4.1 Characteristic data of the basic outputs The SMX-Serie provides a total of 8 outputs, which can be interconnected individually or in groups.
Page 87 Installation manual Safety note: • For applications with frequent safety shut-down requests these tests should be performed more frequently, e.g. at the beginning of the shift, 1 x per week. However, a test should at least be carried out cyclically 1 x year. The test function for the outputs is performed for groupes and individual controls.
Page 88: Wiring Examples Basic Outputs
24V, as this does not permit the specifications of the EN 81-20/-50 resp. EN 81-1/-2. With an infringement, the guarantee expires and BBH does not pay compensation. 4.3.4.2 Wiring examples basic outputs Single-channel switching relay or semi-conductor output without test 4.3.4.2.1...
Page 89 Installation manual Safety note: • Not recommended for safety applications! In this context see also the notes in EN ISO 13849-1 concerning the application and the required fault exclusions. 4.3.4.2.2 Single-channel switching relay or semi-conductor output with external switching amplifier and testing When using external switching amplifiers or downstream electro-mechanical, pneumatic or hydraulic components, the setup for testing the complete chain and a message/warning feature for detected faults is required in order to achieve PI c or higher.
Page 90 Installation manual 4.3.4.2.3 Single-channel switching relay or semi-conductor output with dual-channel external circuit with testing For safety applications from PL C after EN ISO 13849-1 it is recommended, or demanded to access two external switching off elements. For reaching error of PL c or higher, a device for testing the complete chain and a notification/warning device is further required when an error is recognized - for this see notes under 0.
Page 91 Installation manual Q1_PP Q2_PN Q3_PP Q4_PN Fig.: Single-channel switching output Q1_PP with dual-channel external circuit as combination of electro-mechanical element and hydraulic/pneumatic valve and monitoring at two inputs Safety note: • Only conditionally recommended for safety applications! In this context see also the notes in EN ISO 13849-1 concerning the application and the required fault exclusions.
Page 92 Installation manual 4.3.4.2.4 Two-channel switching relay output with external monitoring - group feedback For safety related applications from Pl d acc. to EN ISO 13849-1 two relays on the SMX1xx module and two external power contactors are used. Q5.1 Q5.2 Q6.1 Q6.2 Two-channel switching relay output with external monitoring –...
Page 93 Installation manual 4.3.4.2.5 Dual-channel output with relay output and semi-conductor output – external control circuit with monitoring For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via a relay and a semi-conductor output. Each of the two external cutout paths is monitored.
Page 94 Installation manual 4.3.4.2.7 Dual-channel output with semi-conductor output and external control circuit in PI e For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via the semi-conductor outputs. For PL e acc. to EN ISO 13849-1 PI e is demanded for the external circuit Q1_PP Pl e...
Page 95: Digital Outputs I/O's (Iqqx)
Installation manual 4.3.5 Digital outputs I/O’s (IQQx) The expansion of modules of the SMX31/31R/31R-4(/2) and SMX32-1(R)/2/D have configurable safe digital I/Os (see chapter 3 module overview). This connection acts as safe digital pp- switching output parameterized as output. 4.3.5.1 Classification of the I/O‘s (IQQx) when used as output Classification Achievable Pl Comment...
Page 96: Wiring Examples For Safe Digital Outputs I/O's I/O's (Iqqx)
Installation manual 4.3.5.2 Wiring examples for safe digital outputs I/O's I/O’s (IQQx) 4.3.5.2.1 Wiring single-channel without testing When using a two-channel output (IQQx) in connection with a single-channel external wiring without external examination it must be taken into account that and adherence of one or several external contacts of the SMX1x module is not recognized.
Page 97 Installation manual 4.3.5.2.2 Wiring single-channel with testing When using a two-channel output (IQQx) in connection with a single-channel external wiring with testing. Positively guided auxiliary contacts are especially needed for electro-mechanical devices and message contacts for the valve position are required for hydraulic or pneumatic components. Furthermore, a message/warning device for indicating a failure is required.
Page 98 Installation manual 4.3.5.2.3 Wiring with safe cut-off circuit For safety applications from PI c and higher acc. to EN ISO 13849-1. The external circuit is controlled directly via a two-channel output. The achievable PL acc. to EN ISO 13849-1 depends on the use of dynamic testing (see 4.3.2.1 DC) and the PL of the downstream device.
Page 99 Installation manual 4.3.5.2.5 Redundant two-channel output Suitable for PI d and higher acc. to EN ISO 13849-1. Use of two outputs IQQx in connection with a dual-channel external wiring. 4.3.5.2.5.1 Wiring dual-channel in the same group IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07...
Page 100 Installation manual 4.3.5.2.5.2 Wiring dual-channel in different groups IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07 IQQ08 IQQ09 IQQ10 Fig.: Redundant two-channel outputs in different groups in connection with two-channel switching-off circuit Safety note: • For a safety related assessment of the partial system output the data issued by the respective manufacturer (MTTF , FIT-numbers, B10d-value, etc.) must be used when using external elements, e.g.
Page 101: Overview Of Achievable Pi For Digital Safety Outputs
Installation manual 4.3.5.3 Overview of achievable PI for digital safety outputs Output SMX Actuator / Categor MTTF Achieva Boundary Fault external shut- y acc. to Actuat ble PI conditions exclusion down circuit EN13849 acc. to EN ISO 13849-1 Single-channel Single-channel Cat.
Page 102 Installation manual Output SMX Actuator / Categor MTTF Achieva Boundary Fault external shut- y acc. to Actuat ble PI conditions exclusion down circuit EN13849 acc. to 13849-1 Dual-channel Dual-channel Cat. 3 Monitoring Medium Contactor and Short circuit without Contactor, valve, in both or High downstream...
Page 103: Connection And Installation
Installation manual 5 Connection and installation 5.1 General notes on installation Strictly follow the safety regulations when installing! Degree of protection IP20 Route all signal lines for the interfacing of digital inputs and contact monitoring separately. You should in any case disconnect 230VAC (120VAC cULus) voltages from low voltage power lines, if these voltages are used in connection with the application.
Page 104 Installation manual • All contactors in the environment of the power converter must be equipped with appropriate suppressor circuits. • Suitable measures to protect against overvoltages must be applied. Verwendete Symbole gemäß UL 61010-1xxx Used symbols acc. to UL 61010-1 xxx Symbol 14 •...
Page 105: Installation And Assembly Of The Smx Module
SMX12-2/12-2A) on one top hat rail in connection with the backplane bus system is also possible. These modules can be combined with a communication extension. In this case the backplane bus system needs to be configured by BBH when placing the order and delivered in accordance with the application in question.
Page 106: Arrangement Examples
Installation manual Using the backplane bus connector TB2: The backplane bus connector TB2 is used for combining several base modules with expansion modules. A detailed description can be found under point 5.3.1. 5.3.1 Arrangement examples 5.3.1.1 SMX11 + SMX11 + SMX11 + SMX5x SMX11 SMX11 SMX11...
Page 107: Assembling The Modules
Installation manual 5.4 Assembling the modules The modules are mounted on C-standard rails by means of snap-on latches. 5.4.1 Assembly on C-rail The devices are inserted into the rail under an oblique angle and then snapped on downwards. For disassembling use a screwdriver, insert it into the slot of the downwards pointing latch and then move it up.
Page 108: Assembly On Backplane Bus
Installation manual 5.4.2 Assembly on backplane bus After assembling the backplane bus the device can be installed. For this purpose insert the module from above into the plug connection under a oblique angle and snap it onto the C-rail. Insert the module from above under an oblique angle. Snap-on downwards on to the C-rail.
Page 109: Installation Und Konfiguration Von Master <-> Master (Smmc) Und Master <-> Slave (Sddc)
Installation manual The backplane plug connection can later be extended. The system configuration can thus be extended by additional modules. Snap the backplane bus element into the C-rail and insert it into the counter-piece by sliding it sideways. 5.5 Installation und Konfiguration von Master <–> Master (SMMC) und Master <->...
Page 110: Network Topology
Installation manual 5.5.1 Network topology SMMC SDDC CAN (Zentral) SDDC ETH (Dezentral) Communication of a SMX compact with • central expansion modules via SDDC CAN rear wall bu • SMMC via Ethernet Communication of a SMX modular with • central expansion modules via SDDC CAN rear wall bus •...
Page 111: Installation I/O-Extension
Installation manual 5.5.2 Installation I/O-extension Note: Max. 2 SMX3x modules can be operated with one basic unit. 3.1.1.1 Physical address configuration of the slave modules (central/decentral) On the SMX3x module the bus address must be set with the help of the address switch. This setting is made on the back of the module Note: •...
Page 112: Terminal Assignment
Installation manual 5.6 Terminal assignment 5.6.1 Terminal assignment SMX10 SMX10 SMX10/2 (SMXGen2 (/2): Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT...
Page 113 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - NC 1 - NC No function 2 - NC 2 - NC 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 – DO 0.2 4 - Y2 1 - DI1 1 - I01 2 - DI2...
Page 114: Terminal Assignment Smx10R
Installation manual 5.6.2 Terminal assignment SMX10R SMX10R SMX10R/2 (SMXGen2 (/2): EXT-REL EXT-REL Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 7.11 1 – K3/11 Read back contact Relais 3 2 – 7.12 2 – K3/12 3 – 8.11 3 –...
Page 115 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT 3 - A2.1 Voltage supply device 0 VDC 4 - GND_EXT 4 - A2.2...
Page 116: Terminal Assignment Smx10A
Installation manual 5.6.3 Terminal assignment SMX10A SMX10A SMX10A/2 (SMXGen2 (/2): ENC- ENC- ANALOG ANALOG Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT...
Page 117 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - NC 1 - NC No function 2 - NC 2 - NC 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 – DO 0.2 4 - Y2 1 - DI1 1 - I01 2 - DI2...
Page 118: Terminal Assignment Smx10Ar
Installation manual 5.6.4 Terminal assignment SMX10AR SMX10AR ENC- EXT-REL ANALOG Terminal assignment Unit Terminal Description Note 1 – K3/11 Read back contact Relais 3 2 – K3/12 3 – K4/11 Read back contact Relais 4 4 – K4/12 1 – K5/11 Read back contact Relais 5 2 –...
Page 119 Installation manual Terminal assignment Unit Terminal Description Note 1 - U24_EXT Voltage supply device +24 VDC 2 - U24_EXT 3 - GND_EXT Voltage supply device 0 VDC 4 - GND_EXT 1 - DI13 Safe digital inputs 2 - DI14 3 - P1 Clock outputs 4 - P2 1 –...
Page 120 Installation manual Terminal assignment Unit Terminal Description Note 1 - NC 2 - NC 1 - NC 2 - NC No function 1 - NC 2 - NC 1 - NC 2 - NC Analog 1 – AI 1.1+ 2 – AI 1.1- Safe analog input 3 –...
Page 121: Terminal Assignment Smx11
Installation manual 5.6.5 Terminal assignment SMX11 SMX11 SMX11/2 (SMXGen2 (/2): CPU-ENC CPU-ENC Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT 3 - A2.1...
Page 122 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – UE1+ 1 – U_ENC_1 Voltage supply encoder +24V DC X31 2 – UE1- 2 – GNC_ENC_1 Voltage supply encoder 0V DC X31 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 –...
Page 123: Terminal Assignment Smx11-2
Installation manual 5.6.6 Terminal assignment SMX11-2 SMX11-2 SMX11-2/2 (SMXGen2 (/2): CPU-ENC EXT-ENC CPU-ENC EXT-ENC Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT...
Page 124 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – UE1+ 1 – U_ENC_1 Voltage supply encoder +24V DC X31 2 – UE1- 2 – GNC_ENC_1 Voltage supply encoder 0V DC X31 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 –...
Page 125: Terminal Assignment Smx12
Installation manual 5.6.7 Terminal assignment SMX12 SMX12 SMX12/2 (SMXGen2 (/2): CPU-ENC CPU-ENC Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT 3 - A2.1...
Page 126 Installation manual Unit Terminal Description Note SMXGen2 (/2) 1 – UE1+ 1 – U_ENC_1 Voltage supply encoder +24V DC X31 2 – UE1- 2 – GNC_ENC_1 Voltage supply encoder 0V DC X31 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 –...
Page 127: Terminal Assignment Smx12A
Installation manual 5.6.8 Terminal assignment SMX12A SMX12A SMX12A/2 (SMXGen2 (/2): ENC- ENC- CPU-ENC CPU-ENC ANALOG ANALOG Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2)
Page 128 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – UE1+ 1 – U_ENC_1 Voltage supply encoder +24V DC X31 2 – UE1- 2 – GNC_ENC_1 Voltage supply encoder 0V DC X31 3 – DO 0.1 3 - Y1 Auxiliary outputs 4 –...
Page 129: Terminal Assignment Smx12-2
Installation manual 5.6.9 Terminal assignment SMX12-2 SMX12-2 CPU-ENC EXT-ENC EXT-ENC SMX12-2/2 (SMXGen2 (/2): CPU-ENC EXT-ENC EXT-ENC HB-37350-810-01-51F-EN SMX Installation manual.docx Page 129 of 234 Version: 50F...
Page 130 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT 3 - A2.1 Voltage supply device 0 VDC 4 - GND_EXT 4 - A2.2...
Page 131 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – U_ENC_3 1 – UE3+ Voltage supply encoder +24V DC X33 2 – GND_ENC_3 2 – UE3- Voltage supply encoder 0V DC X33 3 – U_REF_3 3 – UR3 Reference voltage encoder X33 4 –...
Page 132 Installation manual Terminal assignment Termi Unit Description Note SMXGen2 (/2) 1 – U_ENC_2 1 – UE2+ Voltage supply encoder VDC X32 2 – GND_ENC_2 2 – UE2- Voltage supply encoder GND X32 3 – NC 3 – NC No function 4 –...
Page 133: Terminal Assignment Smx12-2A
Installation manual 5.6.10 Terminal assignment SMX12-2A SMX12-2 ENC- CPU-ENC EXT-ENC EXT-ENC ANALOG SMX12-2/2 (SMXGen2 (/2): ENC- CPU-ENC EXT-ENC EXT-ENC ANALOG HB-37350-810-01-51F-EN SMX Installation manual.docx Page 133 of 234 Version: 50F...
Page 134 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - U24_EXT 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - GND_EXT 3 - A2.1 Voltage supply device 0 VDC 4 - GND_EXT 4 - A2.2...
Page 135 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – U_ENC_3 1 – UE3+ Voltage supply encoder +24V DC X33 2 – GND_ENC_3 2 – UE3- Voltage supply encoder 0V DC X33 3 – U_REF_3 3 – UR3 Reference voltage encoder X33 4 –...
Page 136 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – U_ENC_2 1 – UE2+ Voltage supply encoder +24V DC X32 2 – GND_ENC_2 2 – UE2- Voltage supply encoder 0V DC X32 3 – NC 3 – NC No function 4 –...
Page 137: Terminal Assignment Smx31
Installation manual 5.6.11 Terminal assignment SMX31 SMX31 SMX31/2 (SMXGen2 (/2): Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.3 Voltage supply device +24V DC outputs 2 - U24_EXT 2 - A1.4 3 - GND_EXT 3 - A2.3 Voltage supply device 0V DC 4 - GND_EXT 4 - A2.4...
Page 138 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - NC 1 - NC No function 2 - NC 2 - NC 3 - DO0.1 3 - Y1 Auxiliary outputs 4 - DO0.2 4 - Y2 1 - DI1 1 - I01 2 - DI2 2 - I02...
Page 139: Terminal Assignment Smx31R
Installation manual 5.6.12 Terminal assignment SMX31R SMX31R SMX31R/2 (SMXGen2 (/2): EXT-REL EXT-REL EXT-REL EXT-REL Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 1.11 1 – K1/11 Read back contact Relais 1 2 – 1.12 2 – K1/12 3 – 2.11 3 –...
Page 140 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 1.11 1 – K5/11 Read back contact Relais 5 2 – 1.12 2 – K5/12 3 – 2.11 3 – K6/11 Read back contact Relais 6 4 – 2.12 4 –...
Page 141 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - NC 1 - NC No function 2 - NC 2 - NC 3 - DO0.1 3 - Y1 Auxiliary outputs 4 - DO0.2 4 - Y2 1 - DI1 1 - I01 2 - DI2 2 - I02...
Page 142: Terminal Assignment Smx31R-4/2
Installation manual 5.6.13 Terminal assignment SMX31R-4/2 SMX31R-4/2 (SMXGen2 (/2): EXT-REL Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 1.11 1 – K5/11 Read back contact Relais 1 2 – 1.12 2 – K5/12 3 – 2.11 3 – K6/11 Read back contact Relais 2 4 –...
Page 143 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - U24_EXT 1 - A1.3 Voltage supply device +24V DC outputs 2 - U24_EXT 2 - A1.4 3 - GND_EXT 3 - A2.3 Voltage supply device 0V DC 4 - GND_EXT 4 - A2.4 1 –...
Page 144: Terminal Assignment Smx32-0/2/D
Installation manual 5.6.14 Terminal assignment SMX32-0/2/D SMX32-0/2/D (SMXGen2 (/2): Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - A1.1 Voltage supply device +24 VDC from SMXGen2 2 - A1.2 Voltage supply device +24 VDC Outputs (/2) 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13...
Page 145 Installation manual Terminal assignment Unit Terminal Description Note Release /2 1 - NC No function 2 - NC 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 1 - I05 2 - I06 Safe digital inputs 3 - I07...
Page 146: Terminal Assignment Smx32-0/2/D
Installation manual 5.6.15 Terminal assignment SMX32-0/2/D SMX32-0R/2/D (SMXGen2 (/2): EXT-REL Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 1.11 Read back contact Relais 1 2 – 1.12 3 – 2.11 Read back contact Relais 2 4 – 2.12 1 –...
Page 147 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs 2 - I14 3 - T1...
Page 148: Terminal Assignment Smx32-1/2/D
Installation manual 5.6.16 Terminal assignment SMX32-1/2/D SMX32-1/2/D (SMXGen2 (/2): Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 149 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - A1.3 Voltage supply device +24 VDC 2 - A1.4 Voltage supply device +24 VDC Outputs 3 - A2.3 Voltage supply device 0 VDC 4 - A2.4 1 - IQ01 Safe digital inputs, outputs pp-switching 2 - IQ02 3 - Y3...
Page 150: Terminal Assignment Smx32-1R/2/D
Installation manual 5.6.17 Terminal assignment SMX32-1R/2/D SMX32-1R/2/D (SMXGen2 (/2): EXT-REL Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 – 1.11 Read back contact Relais 1 2 – 1.12 3 – 2.11 Read back contact Relais 2 4 – 2.12 1 –...
Page 151 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs 2 - I14 3 - T1...
Page 152 Installation manual Terminal assignment Unit Terminal Description Note SMXGen2 (/2) 1 - NC No function 2 - NC 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 1 - I05 2 - I06 Safe digital inputs 3 - I07...
Page 153: Terminal Assignment Smx5X
Installation manual 5.6.18 Terminal assignment SMX5x Please take the terminals assignments of the individual communication modules from the corresponding installation manuals. 5.6.19 Terminal assignment SMX1x/4x Please take the terminals assignments of the individual communication modules from the corresponding installation manuals. HB-37350-810-01-51F-EN SMX Installation manual.docx Page 153 of 234 Version: 50F...
Page 154: External 24 Vdc - Voltage Supply
Installation manual 5.7 External 24 VDC – voltage supply The SMX module requires a 24 VDC power supply with PELV characteristic in accordance to EN50178. Please comply with the following boundary conditions when planning and installing the specified power supply unit: Strictly comply with the minimum and maximum supply voltage tolerance.
Page 155 Installation manual CPU-ENC EXT-ENC EXT-ENC GND- GND- GND- GND- Encoder Encoder Encoder Encoder SMX12-2 SMX31 HB-37350-810-01-51F-EN SMX Installation manual.docx Page 155 of 234 Version: 50F...
Page 156: Connection Of The External Encoder Supply
Installation manual 5.8 Connection of the external encoder supply 5.8.1 Incremental, HTL, SIN/COS, SSI L-_ENC1-2 L-_ENC2-2 L+_ENC1-2 L+_ENC2-2 L-_ENC2 L-_ENC1 L+_ENC1 L+_ENC2 Monitoring of Spannungs- external encoder überwachung supply voltages der externen Geber- versorgungs- spannungen 1) Only SMX 11-2(/2) and SMX 12-2(/2) 2) Only SMX 12(/2) and SMX 12-2(/2) 3) Only SMX 12-2(/2) The SMX module supports encoder voltages of 5V, 8V, 10 V, 12V and 24V, which are internally...
Page 157: Resolver
Installation manual 5.8.2 Resolver L-_ENC1-2 L-_ENC1-2 L+_ENC1-2 L+_ENC1-2 Reference Reference Referenz- Referenz- signal signal Signal- Signal- generation generation generierung generierung Only SMX 11-2(/2) and SMX 12-2(/2) Only SMX 12-2(/2) When using resolvers in Master-Mode an additional 24V DC power supply is required for generating the reference signal.
Page 158: Connection Of Digital Inputs
Installation manual 5.9 Connection of digital inputs The SMX comes with 14 (SMX10/11/12) or 12 (SMX31) safe digital inputs. These are suitable for connecting single or two-channel signals with and without cycling, or without cross-shorting test. The connected signals must have a "High"-level of DC 24 V (DC +15 V..+ DC +30 V) and a "Low"-level of (DC -3 V...
Page 159: Connection Of Analog Inputs
Installation manual 5.10 Connection of analog inputs With the executions with analog processing. max. 2 analog signals to be processed safely: The analog inputs can be connected as follows: Voltage -7VDC +10VDC Note: The modules can optionally be equipped with voltage and, or current inputs. Safety note: •...
Page 160: Connection Of Position And Speed Sensors
Installation manual 5.11 Connection of position and speed sensors 5.11.1 General notes Depending on module type the SMX module (SMX11/12) has external encoder interfaces for the connection of industrial incremental and absolute encoders. The encoder interfaces can be configured as incremental, SIN/COS, or as absolute SSI-encoders. It is also possible to connect 2 incremental signal generating sensors (e.g.
Page 161 Installation manual Attention: The sensor connections must neither be plugged on nor pulled off during operation. This could cause damage to electrical components of the encoder. Always de-energize connected encoders and the SMX module before plugging on or pulling off encoder connections. With externally supplied encoders, pay attention to switching off the external supply voltage (e.g.
Page 162: Assignment Of Encoder Interface
Installation manual 5.11.2 Assignment of encoder interface X31/X32 Sensor assignment Absolute encoder only SMX12(/2) X33/X34 Sensor assignment SSI – Absolute X 31/X 32 only SMX12-2(/2) NOTE: With the terminals X33/X34 of the modules SMX11-2(/2) and SMX12-2(/2), the connection is inverse to the presented and to X31/X32 with application of a incremental counting system. With encoders not connected inversely to X33/X34, the direction of rotation is thus indicated inversely.
Page 163: Connection Variants
Installation manual 5.11.3 Connection variants 5.11.3.1 Connection of an absolute encoder as master n.c. Pin 1 Ground Pin 2 GND of the supply voltage 24 V DC Pin 3 n.c. Pin 4 CLK- Sub-D plug Pin 5 Sub-D- DATA+ absolute (9 pin) Absolut- Stecker...
Page 164: Connection Of An Absolute Encoder As Slave
Installation manual 5.11.3.2 Connection of an absolute encoder as slave n.c. Pin 1 Pin 2 Ground Pin 3 n.c. Pin 4 CLK- Pin 5 Sub-D- DATA+ Sub-D plug absolute Absolut- Stecker (9 pin) SMX encoder Encoder (9 polig) (Slave-Betrieb) (Slave mode) Pin 6 DATA- n.c.
Page 165: Connecting An Incremental Encoder With Ttl-Signal Level
Installation manual 5.11.3.3 Connecting an incremental encoder with TTL-signal level n.c. Pin 1 Pin 2 Ground Pin 3 n.c. Pin 4 Incremental Sub-D plug Sub-D- Pin 5 Inkremental encoder (9 pin) SMX Stecker Encoder (9 polig) Pin 6 n.c. Pin 7 Pin 8 Pin 9 Versorgungsspannung...
Page 166: Connection Of A Sin/Cos Encoder
Installation manual 5.11.3.4 Connection of a SIN/COS encoder n.c. Pin 1 Pin 2 Ground GND of the supply voltage 24 V DC Pin 3 n.c. Pin 4 COS- Sub-D plug Sub-D- Pin 5 SIN+ SIN/COS SIN/COS Stecker (9 pin) SMX encoder Geber (9 polig)
Page 167: Connection Of A Resolver As Master
Installation manual 5.11.3.5 Connection of a resolver as master Reference Out + Pin 1 Reference Out - Pin 2 Reference In + Pin 3 Pin 4 COS - GND of the supply voltage 24 V DC Sub-D plug Sub-D- Pin 5 SIN + Resolver (9 pin) SMX...
Page 168: Connection Of A Resolver As Slave
Installation manual 5.11.3.6 Connection of a resolver as slave Pin 1 Monitor Reference Pin 2 Voltage GND Reference In + Pin 3 Pin 4 COS - Sub-D- Sub-D plug Pin 5 Resolver SIN + Stecker Resolver (9 pin) (Slave mode) (9 polig) (Slave-Betrieb) Pin 6...
Page 169: Connection Of Proximity Switch Smx1X(/2)
Installation manual 5.11.3.7 Connection of proximity switch SMX1x(/2) The connection is made via plug connector X23 on the digital inputs I05 …I08. The exact pin assignment depends on the encoder type and is shown in the connecting plan of the programming interface. Note: When using HTL-encoders please bear in mind that the tracks A+ and B+ or A- and B- must be combined accordingly.
Page 170: Connection Of Htl/Proximity Switch Smx11-2/Smx12-2 (/2)
Installation manual 5.11.3.8 Connection of HTL/proximity switch SMX11-2/SMX12-2 (/2) The connection is made via plug connectors X27 and X28, or X29 and X30 5.11.3.8.1 HTL-encoder with A+/A- or B+/B- signal Terminal strip Klemmleiste Inkremental Incremental encoder Terminal strip Encoder Klemmleiste Supply voltage Versorgungsspannung Klemmleiste...
Page 171 Installation manual 5.11.3.8.2 HTL-encoder with A+ or B+- signal Terminal strip Klemmleiste Inkremental Terminal Encoder Klemmleiste strip Supply voltage Versorgungsspannung Terminal Klemmleiste strip Ground Spannungsversorgung Power supply Geber Encoder SMX11-2(/2) Encoder 3 SMX12-2(/2) Encoder 4 HB-37350-810-01-51F-EN SMX Installation manual.docx Page 171 of 234 Version: 50F...
Page 172: Configuration Of Measuring Distances
Installation manual 5.12 Configuration of measuring distances 5.12.1 General description of encoder configuration The most important input variables for the monitoring functions of the module are safe position, speed and acceleration. These are obtained by dual-channel generation from the connected sensor system.
Page 173 Installation manual Parameterization of SSI-format: ClkN Number Clk Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Index Index Daten Data Index Status K Data K Daten O Status Status information Status Status Status Status ..Fault mask Error Maske Mask Mask...
Page 174: Incremental Encoder
Installation manual 5.12.2.2 Incremental encoder: Physical Layer: RS-422 compatible Measuring signal A/B. Track with 90 degree phase difference maximum frequency of input cycles 200 KHz or 500 kHz Diagnoses: Diagnose Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20 % +/-2 %(measuring 5 V, 8V, 10V, 12V, 20V, 24V tolerance) Monitoring of differential level...
Page 175: Proxi - Switch
Installation manual 5.12.2.5 Proxi - switch Signal level. 24V/0V Max. counting frequency. 10kHz Circuit logic de-bounced Diagnoses: Diagnose Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20 % +/-2 %(measuring tolerance) HB-37350-810-01-51F-EN SMX Installation manual.docx Page 175 of 234 Version: 50F...
Page 176: Extended Monitoring Proximity Switch / Proximity Switch
Installation manual 5.12.2.6 Extended monitoring proximity switch / proximity switch The extended monitoring uncovers the following faults: a) Supply voltage failure b) Failure of output signal in driver direction c) Malfunction of High signal proximity switch d) Interruption of signal path e) Mechanical de-adjustment of proximity switch / excessive switching distance of proximity switch For diagnostic purposes both status conditions of the counting signal are additionally recorded...
Page 177: Htl - Sensor
Installation manual HTL – Sensor 5.12.2.7 Signal level. 24V/0V Physical Layer: Push/Pull Measuring signal A/B track with 90° phase difference Max. counting pulse frequency: 200 kHz on X27/28 or X29/30 (only SMX11-2/12-2) Diagnoses: Diagnosis Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20 % +/-2 %(measuring 5 V, 8V, 10V, 12V, 20V,...
Page 178: Response Times Of The Smx
Installation manual 6 Response times of the SMX The response time is a very important safety related characteristic and must be strictly observed for each application / application related safety function. The following chapter lists the response times for individual functions, probably also in dependence on further parameters. If these data are insufficient for a specific application you should validate the actual time behaviour against the nominal behaviour by means of separate measurements.
Page 179 Installation manual Response Explanation Function time [ms] With a monitoring function that has already been activated via ENABLE, the module requires one cycle Response of an already activated to calculate the current speed value. During the next monitoring function including cycle after calculation of the monitoring function the PLC editing in case of position and information is further processed and output by the...
Page 180: Response Time For Fast_Channel
Installation manual 6.2 Response time for FAST_CHANNEL FAST_CHANNEL describes a characteristic of SMX to respond quicker to speed requirements than this would be possible with the execution of the safety programs in normal cycle (= 8 msec) The sampling time of FAST_CHANNEL is 2 msec. The following response times can be specified: •...
Page 181 Installation manual 0,60 Reakt Reakt Fehler 0,50 V w. overspeed V m. Overspeed Distance [m/s] Distanz [m/s] 0,40 V ohne Overspeed V w/o. overspeed 0,30 Distance [m/s] Distanz [m/s] 0,20 0,10 0,02 0,06 0,1 0,14 0,18 0,22 0,26 0,3 0,34 0,38 0,42 0,46 0,5 0,14 0,12 0,10...
Page 182: Reaction Times When Using Smx 31X/32X
Installation manual With overspeed distance the following connections result for the course of V and s. Parameters Calculation methods Comment Value for response time data SMX + Deceleration time in external shut-off Response deceleration time in external shut-down chain derived from relay/contactor chain and brake data, etc.
Page 183 Installation manual Determination of the total response time TOTAL Example 1: Input to extension module, activation of SLS and processing in PLC, output to basic module. = 18 ms + 8 ms + 0 ms = 24 ms; TOTAL IN_31 OUT_Base Example 2: Input to basic module, activation of SLS and processing in PLC, output to extension module.
Page 184: Start-Up
Installation manual 7 Start-up 7.1 Procedure Start-up must only be performed by qualified personnel! Strictly follow the safety regulations when commissioning! 7.2 Making sequences The following phases are passed through and displayed by the front side seven segment display after each new start and fault-free running of the module: 7 segment display Mode Description...
Page 185: Reset-Function
Installation manual 7.3 Reset-Function The reset-function is divided into a startup-function after a power cycle (power off / on) and a status-/alarm-reset = internal reset-function. The internal reset is called by pushing the “Reset”- button on the SMX front panel or by a input port, configured as “Reset-Element” with active “Alarmreset”.
Page 186: Reset-Timing
Installation manual 7.3.2 Reset-Timing The reset-input for a internal reset is time monitored in „RUN“-mode. A internal reset is called by a falling edge of the reset-input under the pre-condition of T<3sec between raising / falling edge. Max. 3 sec Max.
Page 187 Installation manual V_Ist > SOS_V_Max V_Ist SOS_Result Reset_In Max. 3 sec Max. 3 sec Process value (speed) => no change of the output status with reset in the alarm condition Max. 3 sec Max. 3 sec Max. 3 sec Q =I1 AND I2 Q =I1 AND I2 Q =I1 AND I2 IN_Result...
Page 188: Example Reset-Function With Safeguarding Against False Utilization
Installation manual 7.3.3.1 Example Reset-Function with safeguarding against false utilization Function: On a machine for normal operation mode, the hazardous area shell be protected by a mechanical guard system. If in setup mode, the safety level is kept by a release button in conjunction with standstill monitoring respevtive safe limited speed.
Page 189 Installation manual Applicative measure: By logic combination within the PLC-program the activation of the outputs by false utilization of the reset-function is prevented Example 1: The release function of the outputs (ID 88) is additionaly AND combined with a “Reset-Timer“. This timer prevents activation of the outputs for T> 3sec after a call of the reset-function.
Page 190 Installation manual Example 2: The release function of the outputs (ID 88) is additionaly AND combined with a FF. This FF-element prevents activation of the outputs after a reset with still applied failures on the inputs. Just after a first correct detection of the input signals –...
Page 191: Led Display
Installation manual 7.4 LED display Colour Mode Description System OK, configuration green "flashing" validated System OK, configuration yellow "flashing" not yet validated "flashing" Alarm "permanent" Fatal Fault System OK, configuration not yet validated, SMMC yellow - red "flashing" configured however participant is missing System OK, configuration green - red...
Page 192: Parameterization
Installation manual 7.5 Parameterization Parameterization takes place via the program SafePLC SMX. The transmission of these data to the module requires a programming adapter, the drivers of which must first be installed by the user. Parameterization is described in the programming manual. 7.6 Function test In order to guarantee safety of the module, the user must carry out a functional test of the safety functions at least once in a year.
Page 193: Safety Related Examination
Installation manual 8 Safety related examination In order to assure the reliability of the implemented safety functions the user must check and document the parameters and links after the start-up and parameterization has taken place. This is supported by the parameterization software SafePLC SMX (see programming manual). On the first page one can enter general system data.
Page 194: Maintenance
Installation manual 9 Maintenance 9.1 Modification / handling changes to the device Maintenance work must solely be carried out by qualified personnel. Regular maintenance work is not required. Repair The devices must always be replaced as whole units Repair work on the device can only be performed in the factory. Warranty By opening the module without permission the warranty will become null and void.
Page 195: Technical Data
Installation manual 10 Technical data 10.1 Environmental conditions IP 20 Class of protection 0°C* ... 50°C Ambient temperature 3k3 acc. to DIN 60 721 Climatic category Min-, Maximum relative 5% - 85% humidity (no condensation) Overvoltage category Degree of contamination Operating materials 2000m 90000h at 50°C ambient...
Page 196: Switch Types
Installation manual 11 Switch types Type Graphic symbols Truth table Logic function Function block Function LD E.1 Closing contact (S), Ö Normally Öffner ST IE.X only in display opening contact closed contact Ausgang Output eSwitch_1o Normally LD E.1 Normally open, as type 1 Öffner closed ST IE.X...
Page 197 Installation manual Type Graphic symbols Truth table Function LD E.1 Monitoring for S=inactive and Ö Normally AND NOT E.2 Ö=active closed Open contact Öffner ST IE.X contact Normally Schließer open contact Ausgang Output eSwitch_1s1o Ö LD E.1 Time monitoring Like 5, but with time monitoring Normally OR NOT E.2 MET1..MET4...
Page 198 Installation manual Type Graphic symbols Truth table Function LD E.1 Time monitoring Like 6, but with time monitoring S1 Ö Ö2 Normally OR E.2 MET1..MET4 of state changes. closed 1 Öffner 1 OR NOT E.3 In case of signal changes at S Normally ST META_EN.1 (Attention: Bus line) or Ö...
Page 199 Installation manual Type Graphic symbols Truth table Function LD NOT E.1 Two-hand Monitoring for S1*S2=inactive Ö Ö Normally OR E.2 operation and Ö1*Ö2=active + temporal Öffner 1 closed 1 OR NOT E.3 monitoring of this status. This OR E.4 means that in case of a signal ST MEZ_EN.1 change of an S from 1->0 or Ö...
Page 200 Installation manual Type Graphic symbols Truth table Function S1 S2 A LD E.1 Selector switch Clear linkage of permissible Normally AND NOT E.2 switch positions Öffner closed ST IE.X1 contact Normally Schließer LD NOT E.1 open AND E.2 contact ST IE.X2 Ausgang Output eMode_1s1o...
Page 201: Notes On Designing, Programming, Validating And Testing Safety Related Applications
Installation manual 12 Notes on designing, programming, validating and testing safety related applications The following notes describe the procedure for designing, programming, validating and testing safety related applications. The information should help the user to classify, to easily understand and to use all steps from risk assessment all the way to the system test.
Page 202 Installation manual Risk assessment as per EN ISO 13849-1 S – Severe physical injury S1 = minor, reversible injury Lower contribution S2 = severe, irreversible injury to reduce risks F – Frequency and/or duration of exposure to danger F1= rarely, not cyclic F2 = frequently up to permanent and/or long duration, cyclic operation P –...
Page 203: Required Technical Documents
Installation manual Further information concerning the risk assessment and the safe design of machines can be found in the standards EN 14121 Safety of machines - risk assessment EN 12100 Safety of machines - basic terms, general design guidelines Measures to be applied in order to reduce identified risks must at least be of the same level as the danger itself.
Page 204: Necessary Steps For Draft, Realization And Testing
Installation manual 12.3 Necessary steps for draft, realization and testing The realization of plant sections with safety related function requires special attention in planning, realization and testing. Also for this the standards (see ISO 13849-2 or EN ISO 61508) contain specific guidelines. The effort thereby is orientated on the complexity of the task for system components with safety related function.
Page 205: Phases Of The V-Model
Installation manual 12.3.1 Phases of the V-model Designation Description Design phase Validation phase Specification and Specification of all safety Testing of all passive and active validation of all measures to be applied, such safety measures for correct passive and active as covers, barriers, max.
Page 206: Specification Of Safety Requirements (Structural Schematic)
Installation manual 12.3.2 Specification of safety requirements (structural schematic) The safety requirements must be individually analysed on the basis of applicable standards, e.g. product standard. HB-37350-810-01-51F-EN SMX Installation manual.docx Page 206 of 234 Version: 50F...
Page 207 Installation manual HB-37350-810-01-51F-EN SMX Installation manual.docx Page 207 of 234 Version: 50F...
Page 208 Installation manual Source: General specification, excerpt from BGIA Report 2/2008 concerning EN ISO 13849-1 HB-37350-810-01-51F-EN SMX Installation manual.docx Page 208 of 234 Version: 50F...
Page 209 Installation manual Example for an automatic handling machine: Description of function: The automatic handling machine serves the purpose of automatically picking up truck cabins of different heights. After being picked up, the height of the cabin is correctly detected, so that within the working area the cabin cannot be lowered below a certain height.
Page 210 Installation manual Example for a risk analysis: Risk analysis HB-37350-810-01-51F-EN SMX Installation manual.docx Page 210 of 234 Version: 50F...
Page 211: Specification Of The Functional Safety System
Installation manual 12.3.3 Specification of the functional safety system Derived from the general danger and risk analysis for the machine, the active safety functions must be identified and specified. Active safety functions are, e.g. safely reduced speed under certain system conditions, monitored stop and standstill functions, area monitoring facilities, processing of monitoring facilities like light grid, switching mats, etc.
Page 212: Example - Specification Of Safety Functions In Form Of A Table
Installation manual Example – Specification of safety functions in form of a table 12.3.3.3 Safety function Measuring Implementation of Nominal Input/activation Response/ value /sensor software parameters output Limitation of max. travel 1 x WCS Monitoring by means of 550mm/s Input/activation Operation speed to limitation of absolute...
Page 213: Software Specification
Installation manual 12.3.4 Software specification The software specification refers to the previous specification of the safety functions. It can also be replaced by a correspondingly worked out specification of the safety functions, as far as this contains all specifications (see example under 12.3.3.3). However, it is recommended to prepare an extracted list.
Page 214 Installation manual Example of software specification Safety function Measuring Solution new Input/ Response/ value /sensor activation output Monitoring V_Rope to Digital Monitoring by means of tested Permanently Operation stop V_Nominal incremental function SLS + SAC with comparison Monitoring of differences encoder, of speed ranges /analog value SF 1.3.1...
Page 215: Hardware Specification
Installation manual 12.3.5 Hardware specification The hardware specification should describe the entire system design and, in particular, the components used with their specific characteristic data. The hardware specification serves as basis for the determination of the achieved safety level based on the architecture and the characteristic data of all devices involved in a safety function.
Page 216: Beispiel Für Vorgabe Hw
Installation manual 12.3.5.2 Beispiel für Vorgabe HW Safety function Safely reduced speed Safely monitored limited speed with door open Type Designation Function Design Characteristic data Note Archite MTTF B10d Source Source cture [1/h] [Years] Door lock – Monitoring of the Sensor Sensor 1 A 3.1...
Page 217: Consideration Of Systematic Failures
Installation manual 12.3.5.3 Consideration of systematic failures Within the hardware specification one must also consider systematic failures. Examples for measures against systematic failures: Power drop during operation. If this causes a danger, a power drop must be considered a operating status. The SRP/CD must be able to cope with this condition, so that a safe state is maintained.
Page 218: Hard And Software Design
Installation manual 12.3.6 Hard and Software design The performance targets from the hardware and software specification are implemented in the actual system design. The performance targets for the components to be used and their wiring from the hardware specification must also be met, the same applies for the performance targets for fault exclusions.
Page 219 Installation manual A calculation acc. to EN ISO 13849-1 shall serve as an example: Safety function: Safely reduced speed with access door open Structural diagram: Sensor Single channel partial system Dual-channel partial system Eink. Teilsyst. Zweik. Teilsyst. Track A Spur A Mech.
Page 220 Installation manual Calculation acc. to EN ISO 13849-1: Channel A – shut-down via mains contactor: Component MTTFD [years] Door closer B10d = 100000 DCSwitch = 99% Nop = 30/AT = 9270/ year (309 AT/ year) B10d MTTFD = = �� 0,1 ∗...
Page 221 Installation manual Channel B – shut-down via STO/inverter: Component MTTFD [years] Door closer B10d = 100000 DCSwitch = 99% Nop = 30/AT = 9270/year (309 AT/year) B10d MTTFD = = �� 0,1 ∗ Nop SIN/COS- MTTFD_SinCos = 30 years DCEncoder = 99% encoder PFH = 1,4 * 10...
Page 222: Verification Software(Program) And Parameters
Installation manual Note: The PI can also be determined with the program tool "Sistema" from BGIA. 12.3.8 Verification software(program) and parameters Verification takes place in two steps: 1. Checking the FUP with respect to the specified functionality. 2. Checking the FUP against the AWL-listing of the validation report, or the default parameters against the one listed in the validation report.
Page 223 Installation manual Safety function: Carriage shut down Shut down of travel system and deactivation of brakes Shut down on carriage Emergency stop Gap available Release brake Release brake The carriage is switched off via two outputs (IQQ1.5 ID 257 and 1.6 ID 261). The brakes are released via two outputs (IQQ1.3 ID 253 and 1.4 ID 249).
Page 224: Validation Of Fup Against Awl And Parameters By Means Of Validation Report
Installation manual 12.3.8.2 Validation of FUP against AWL and parameters by means of validation report. The programming that took place in the FUP must be compared with the AWL-listing of the validation report. Example AWL-listing in validation report Validation report OLC-program Name: <leer>...
Page 225 Installation manual Example encoder configuration: Validation report Axis configuration / sensor interface Axis 1 General parameters Measuring distance: Type: Rotational Position processing: Activ Maximum speed: 2000 Incremental shut-down: 10000 Shut-down speed: Sensors Type: SSI-standard SSI-standard Format: Binary Binary Direction of rotation: Ascending Ascending Supply voltage:...
Page 226: Performance Of The System Test / Fit (Fault Injection Test)
Installation manual 12.3.9 Performance of the system test / FIT (fault injection test) For the FIT the manufacturer must prepare a complete list of the functions to be tested. This list includes the defined safety functions as well as the fault test for checking the right response of the SRP/CS to this fault Example test list: Setup...
Page 227: Appendix
Installation manual Appendix Appendix A – Classification of switch types General note: The individual switches of the following input elements can be assigned to the digital inputs DI1 to DI8 as desired. Enable switch Switch type Comment Classification PI acc. Classification SIL acc.
Page 228 Installation manual Two-hand button Switch type Comment Classification Classification SIL category 2 two-way switch Two-hand button higher Type III C PL e SIL3 requirements 2 normally open Two-hand button Type III A PL e SIL1 monitored Note: With these in Port elements a fixed pulse assignment takes place, which cannot be influenced by the user! Light curtain Switch type...
Page 229 Installation manual Start / reset element Switch type Comment Classification Classification SIL category 1 normally open Alarm reset standard (evaluation of edge) 1 normally open Logic reset standard PL d SIL 2 1 normally open Start monitoring standard (optional function) Note: The alarm reset input can be operated with 24V continuous voltage and is edge triggered.
Page 230: Appendix B - Ce-Declaration
2006/42/EG Maschines Appendix The safety component Manufacture: BBH Products GmbH, Weiden Type: SMX Compact series and expansion modules has been developed, designed and manufactured in compliance with the above mentioned directive as well as the EC-directive • EC-EMC directive 2014/30/EU dated 26. February 2014...
Page 231 Installation manual The following harmonized standards were applied: • EN 61800-5-2:2007 Electrical power drive systems with adjustable number of revolutions - Part 5-2: Requirement of security - functional security • EN ISO 13849-1:2008 + AC:2009 Safety of machines, safety related parts of controls Part 1: General design principles •...
Page 232 The safety, installation and operating instructions described in the product manual must be followed. Dipl.-Ing. (FH) Gerhard Bauer is responsible for the product manual. Weiden, 26.07.2010 ........... Gerhard Bauer General Manager BBH Products GmbH HB-37350-810-01-51F-EN SMX Installation manual.docx Page 232 of 234 Version: 50F...
Page 233 • Maschines 2006/42/EG Appendix IV The safety component Manufacture: BBH Products GmbH, Weiden Type: SMXGen2 series and expansion modules has been developed, designed and manufactured in compliance with the above mentioned directive as well as the EC-directive • EC-EMC directive 2014/30/EU dated 26. February 2014...
Page 234 The safety, installation and operating instructions described in the product manual must be followed. Dipl.-Ing. (FH) Gerhard Bauer is responsible for the product manual. Weiden, 24.3.2017 ........... Gerhard Bauer General Manager BBH Products GmbH HB-37350-810-01-51F-EN SMX Installation manual.docx Page 234 of 234 Version: 50F...

BBH SMX Series Installation Manual

1 Important Notes

2 Safety Regulations

3 Device Types

4 Safety Related Characteristics

5 Connection and Installation

6 Response Times of the Smx

7 Start-Up

8 Safety Related Examination

9 Maintenance

10 Technical Data

11 Switch Types

12 Notes on Designing, Programming, Validating and Testing Safety Related Applications

Appendix

Appendix A - Classification of Switch Types

Appendix B - CE-Declaration

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