schmersal PSC1-C-10 Series Installation Manual
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schmersal PSC1-C-10 Series Installation Manual

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  • Page 1 Installation manual PSC1 modules Series PSC1-C-10 PSC1-C-10-SDMx PSC1-E-3x...
  • Page 2 Information and specifications may be changed at any time. Please obtain information on the latest version at: www.schmersal.net. K. A. Schmersal GmbH & Co. KG Möddinghofe 30 42279 Wuppertal HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx...
  • Page 3 Installation manual Revision history Version-No. Date Comment V 1.0 Feb 2 , 2017 Release - V 2.0 May 2 , 2018 Editorial changes V 2.1 Oct 31 , 2018 Terminal designation CPU-ENC/ENC adapted, DC value specified for 2x Proxy 2, X22 without function with PSC1-E-(1)33-..., CANopen added, Reference to protective circuit for contactors, etc.,...

  • Page 4: Table Of Contents

    Installation manual Contents IMPORTANT NOTES ..................... 8 DEFINITIONS ......................8 Reference documents ..........................9 Abbreviations used ..........................10 SAFETY INSTRUCTIONS ..................11 Intended use ............................11 Usage in regions with UL/CSA requirement ..................12 General safety instructions ........................13 Operating and service ........................... 14 Transport/storage ..........................
  • Page 5 Installation manual Safety-related characteristic data and circuitry for the outputs ............73 4.3.1 Characteristics of the output elements ................. 73 4.3.2 Diagnostics in the shutdown circuit ..................75 4.3.2.1 Diagnostic functions ......................75 4.3.2.2 Overview of DC in relation to selected diagnostic functions ..........76 4.3.3 Permissible capacitive and inductive load on safe outputs ..........
  • Page 6 Installation manual RESPONSE TIMES OF THE PSC1 ..............133 Response times in standard operation ....................134 Response times for FAST_CHANNEL ....................135 Response times for overspeed distance monitoring ................135 Response times when using the PSC1-E-3x ..................137 COMMISSIONING ....................139 Procedure ............................
  • Page 7 Installation manual APPENDIX ...................... 184 13.1 Appendix A – categorisation of the switch types ................184 13.2 CE – declaration of conformity ......................189 HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 7 of 189 Version: 50F...

  • Page 8: Important Notes

    Installation manual 1 Important notes Definition of the individual target groups Designers of safe drive systems: Engineers and technicians Mounting, electrical installation, maintenance and device replacement Industrial electricians and service engineers Commissioning, operation and configuration: Technicians and engineers 2 Definitions The term PSC1 is used as the generic term for all derivatives of the PSC1 product line.

  • Page 9: Reference Documents

    Installation manual 2.1 Reference documents Description Reference Configuration of the PSC1 module with Programming manual SafePLC2 the "SafePLC2" programming system Validation report on the parameter Safety-related test with acceptance configuration implemented and the PLC report program Acceptance for general safety-related Certificate on the type test for safety applications control according to Machinery...

  • Page 10: Abbreviations Used

    Installation manual 2.2 Abbreviations used Abbreviation Meaning Alternating Current Instruction List BGIA (IFA) Institute for Industrial Safety at the DGUV (German Statutory Accident Prevention Association) Here: SSI systems clock Central Processing Unit Direct Current Deutsches Institut für Normung Digital Output ECFS EtherCAT Fail Safe;...

  • Page 11: Safety Instructions

    TB(1) T bus connector (backplane bus) PELV Protective Extra Low Voltage Programmable Logic Controller SD bus (on request) Serial diagnostic bus for electronic Schmersal safety switches SDDC (in preparation) Safe Device-Device Communication SELV Safety Extra Low Voltage SMMC (on request)

  • Page 12: Usage In Regions With Ul/Csa Requirement

    Installation manual The devices in series PSC1-C-10 and PSC1-C-10-SDMx incl. the expansion modules PSC1-E-3x are safety components as per Annex IV EC Machinery directive 2006/42/EC. They have been developed, designed and manufactured according to the above- mentioned directive as well as the EU directive 2014/30/EU Cf.

  • Page 13: General Safety Instructions

    Installation manual 3.3 General safety instructions Safety instructions:  To prevent injury and damage, only qualified personnel are allowed to work on the device. Qualified personnel are personnel who have electrical engineering training and who are familiar with the applicable rules and standards of electrical engineering. The qualified person must become familiar with the operating instructions (cf.

  • Page 14: Operating And Service

    Installation manual WARNING: The usage of our devices contrary to the rules and conditions stated here can result in the injury or the death of persons, as well as damage to the devices and machines connected! This usage will also render void any claim under the warranty or any claim for claim damages against the manufacturer.

  • Page 15: Transport/Storage

    For safe speed and/or position acquisition, 1-encoder solutions and also 2-encoder solutions are supported. See "Encoder specifications" Expansion modules Central or decentral (in preparation) I/O expansion for the PSC1-C-10 series. A maximum of 2 expansion modules can be used. Integrated communication interface The communication interface provides bidirectional data transmission from and to a higher- level controller using a standard fieldbus or safe standard fieldbus.

  • Page 16: Module Overview

    Installation manual 3.6 Module overview Basic modules Expansion modules Designation PSC1-C- PSC1-C- PSC1-E-37-14DI- PSC1-C- PSC1-E-31-12DI- PSC1-E-33-12DI- 10-SDM1 10-SDM2 10(-FBx 10DIO 6DIO-4RO 4DO-2RO-RIO (-FBx (-FBx General data Max. number of expansion modules Safe digital inputs Safe digital I/O Safe digital outputs switching / pp switching Safe analogue inputs Relay outputs (1-channel)

  • Page 17: Device Characteristic Data

    Installation manual 3.7 Device characteristic data 3.7.1 Basic modules 3.7.1.1 PSC1-C-10 (-FBx /-MC) Type designation Device features Version of the module with following peripherals: digital inputs pulse outputs relay outputs (1-channel) pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED...
  • Page 18 Installation manual  Optional: Communication interface incl. memory card slot o Standard and safe fieldbus protocols for communication with a higher-level controller o Safe cross-communication for the exchange of data between several basic devices o Safe remote IO communication for the exchange of data with distributed IO systems o Serial diagnostic bus "SD bus"...

  • Page 19: Tech. Characteristic Data Psc1-C-10 (-Fbx /Mc)

    Installation manual 3.7.1.2 Tech. characteristic data PSC1-C-10 (-FBx /MC) Safety-related characteristic data PL according to EN ISO 13849 max. PL e PFH / architecture 12.6 * 10 / KAT 4 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max.
  • Page 20 Installation manual Environmental data Temperature 0°C … +50°C operation -25C° … +70C° storage, transport Degree of protection IP 20 Climatic class 3k3 according to DIN 60 721-3 Minimum, maximum relative 5% - 85% humidity (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Use of operating equipment 2000m...

  • Page 21: Psc1-C-10-Sdm1 (-Fbx /Mc)

    Installation manual 3.7.1.3 PSC1-C-10-SDM1 (-FBx /MC) Type designation Device features Version of the module with following peripherals: axis encoder interfaces digital inputs pulse outputs relay outputs (1-channel) pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED status LEDs for inputs...
  • Page 22 Installation manual  Switchable safe outputs pn, pp switching for safety-related functions  Complete speed and position-related safety functions for drive monitoring as per IEC 61800-5-2 integrated into firmware o Spatial functions for safe speed and range monitoring possible  Parameter administration for expansion modules in the basic device ...

  • Page 23: Tech. Characteristic Data Psc1-C-10-Sdm1 (-Fbx /Mc)

    Installation manual 3.7.1.4 Tech. characteristic data PSC1-C-10-SDM1 (-FBx /MC) Safety-related characteristic data PL according to EN ISO 13849 PL e PFH / architecture 12.6 * 10 / KAT 4 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max. service life General data Max.
  • Page 24 Installation manual PSC1-C-10-SDM1 (-FBx /MC)= 100x115x67,5 Weight PSC1-C-10-SDM1 = 310 g PSC1-C-10-SDM1 (-FBx = 410 g Attachment Can be snapped to DIN rail Number of T-bus connector Included in the items supplied PSC1-C-10-SDM1 PSC1-C-10-SDM1 (-FBx /MC) Min. connection cross-section / AWG 0.2 mm²...
  • Page 25 Installation manual 3.7.1.5 PSC1-C-10-SDM2 (-FBx /MC) Type designation Device features Version of the module with following peripherals: axes encoder interfaces digital inputs pulse outputs relay outputs (1-channel) pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED status LEDs for inputs...
  • Page 26 Installation manual  Switchable safe outputs pn, pp switching for safety-related functions  Parameter administration for expansion modules in the basic device  Comprehensive diagnostic functions integrated  Coded status indication via 7-segment display and status LEDs on front  Multi-function button (Quit, Start, Reset) can be operated from the front ...

  • Page 27: Psc1-C-10-Sdm2 (-Fbx /Mc)

    Installation manual 3.7.1.6 Tech. characteristic data PSC1-C-10-SDM2 (-FBx Safety-related characteristic data PL according to EN ISO 13849 PL e PFH / architecture 12.6 * 10 / KAT 4 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max. service life General data Max.
  • Page 28 Installation manual Weight PSC1-C-10-SDM2 = 390 g PSC1-C-10-SDM2 (-FBx /MC) = 490 g Attachment Can be snapped to DIN rail Number of T-bus connector Included in the items supplied PSC1-C-10-SDM2 PSC1-C-10-SDM2 (- /MC) Min. connection cross-section / AWG 0.2 mm² / 24 Max.

  • Page 29: Central Expansion Modules

    Installation manual 3.7.2 Central expansion modules 3.7.2.1 PSC1-E-31 and PSC1-E-33 Type designation Device features Version of the module with following peripherals: digital inputs 10/6 digital I/O pulse outputs signal outputs relay outputs (1-channel) (PSC1-E- 31/33) status LEDs for inputs status LEDs for signal outputs status LEDs for relay outputs (PSC1-E-31/33) 10/6...
  • Page 30 Installation manual Properties of the module:  12 safe inputs, OSSD support  10 safe I/O - can be configured as input or output o PSC1-E-33 with a total of 4 relay outputs (1- channel) and 6 I/O  Pulse outputs for cross-circuit detection on digital input signals ...

  • Page 31: Tech. Characteristic Data: Psc1-E-31 And Psc1-E-33

    Installation manual 3.7.2.2 Tech. characteristic data: PSC1-E-31 and PSC1-E-33 Safety-related characteristic data PL according to EN ISO 13849 PL e PFH / architecture 9,2 * 10 / KAT 4 + on PSC1-E-33 1-channel per relay 2 * 10 (KAT 1) 2-channel per relay 1 * 10 (KAT 4) SIL according to EN 61508...
  • Page 32 Installation manual Mechanical data Size PSC1-E-31 = 100x115x45 (HxDxW [mm]) PSC1-E-33 = 100x115x67,5 Weight PSC1-E-31 = 300 g PSC1-E-33 = 400 g Attachment Can be snapped to DIN rail Number of T-bus connector Included in the items supplied PSC1-E-31 PSC1-E-33 Min.

  • Page 33: Decentralised Expansion Modules (In Preparation)

    Installation manual 3.7.3 Decentralised expansion modules (in preparation) 3.7.3.1 PSC1-E-37 Type designation Device features Version of the module with following peripherals: digital inputs pulse outputs relay outputs (1-channel) pn or pp switching outputs signal outputs 7-segment display status LED status LEDs for signal outputs status LEDs for inputs status LEDs for relay outputs status LEDs for outputs...

  • Page 34: Tech. Characteristic Data: Psc1-E-37

    Installation manual 3.7.3.2 Tech. characteristic data: PSC1-E-37 Safety-related characteristic data PL according to EN ISO 13849 PL e PFH / architecture 12,6 * 10 / KAT 4 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max. service life General data Connection RJ45 (SDDC)
  • Page 35 Installation manual Environmental data Temperature 0°C … +50°C operation -25C° … +70C° storage, transport Degree of protection IP 20 Climatic class 3k3 according to DIN 60 721-3 5% - 85% Minimum, maximum relative humidity (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Use of operating equipment 2000m...

  • Page 36: Optional Universal Communication Interface

    Installation manual 3.7.4 Optional universal communication interface Version Device features -FB1 Decentral SDDC and SMMC interface (2x RJ 45) Communication interface for decentral slave and master modules Fieldbus interface (2x RJ 45) Standard and secure fieldbus Memory Card (microSD) Storage medium for safety-related user program -FB2 Decentral SDDC...

  • Page 37: Tech. Characteristic Data: Optional Universal Communication Interface

    Installation manual 3.7.4.1 Tech. characteristic data: Optional universal communication interface Safety-related characteristic data PL according to EN ISO 13849 n.a. PFH / architecture n.a. SIL according to EN 61508 n.a. Proof test interval n.a. General data Decentral communication interfaces 2x RJ 45* (SDDC in preparation) Fieldbus interfaces -FB1...

  • Page 38: Possible Combinations

    Installation manual 3.7.4.2 Possible combinations FBx module is built into the following devices and not available separately. Versions -FB1 -FB2 SDDC SMMC PSC1-C-10 PSC1-C-10-SDM1 PSC1-C-10-SDM2 PSC1-E-31 PSC1-E-33 PSC1-E-37 Options: (in preparation) / always with option -FB1/2 or integrated in the module PSC1-E-37 (on request) / always with option –FB1/2 3.7.4.3 Using the memory card Any industrial microSD card between 2...

  • Page 39: Encoder Specifications

    Installation manual 3.7.5 Encoder specifications Encoder Connection Diagnostics Value type SIN/COS; TTL X1; X2 Max. frequency 200 kHz Amplitude SIN/COS 1 Vss +/- 0,3 V Type of connection Sub-D 9-pin SSI absolute X1; X2 Clock frequency Master mode 150 kHz / slave mode max. 250 kHz Max.

  • Page 40: Marking

    - Relay NO (pilot duty): 24 V⎓ / 2 A; 120 V∿ / 2 A IND.CONT.EQ. IND.CONT.EQ. K.A. Schmersal GmbH & Co. KG, DE-42279 Wuppertal Möddinghofe 30 www.schmersal.com Read manual before installation! Type plate PSC1-C-10-SDM1 HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx...

  • Page 41: Items Supplied

    Installation manual 3.9.2 Items supplied Included in the items supplied:  PSC1 module: o Connectors for all signal terminals not including encoder connection Not included in the items supplied:  SafePLC2 software package (order designation: PSC1-A-91-SAFEPLC2) consisting of: o CD with configuration software o Licence dongle o Installation manual o Programming manual...

  • Page 42: Safety-Related Features

    Installation manual 4 Safety-related features 4.1 General layout, safety-related architecture and characteristic data The internal layout of the PSC1 series comprises two separate channels with mutual result comparison. High-quality diagnostics are undertaken in each of the two channels for fault detection.
  • Page 43 Installation manual Characteristic data: Max. achievable safety class  SIL 3 as per EN61508  Category 4 as per EN945-1  Performance Level e as per EN ISO 13849- System structure 2-channel with diagnostics (1002) according to EN 61508 Architecture category 4 according to EN ISO 13849 Design of the operating mode "High demand"...

  • Page 44: Safety-Related Characteristic Data And Circuitry For Sensors Connected

    Installation manual 4.2 Safety-related characteristic data and circuitry for sensors connected The PSC1 modules have completely separate signal processing paths for each safety input. In addition, measures for obtaining the highest possible DC values are implemented. 4.2.1 Digital sensors: The digital inputs are completely redundant. The details for the categorisation, the DC and the achievable PL or SIL are listed in the following.

  • Page 45: Dc Digital Sensors/Inputs

    Installation manual 4.2.1.2 DC digital sensors/inputs The PSC1 modules provide wide-ranging diagnostic functions for the input sub-system. These are designed as continuous, or optional (cross-circuit monitoring using pulse detection, cross comparison, 2-channel or multiple-channel sensor with/without time monitoring, startup test). Continuously active diagnostic functions: Cross comparison: The inputs on the PSC1 modules are in principle designed internally as dual-channel.
  • Page 46 Installation manual Start-up testing: Each time the safety module is switched on (=PSC1 module), the input element must be tested in the low signal status direction (= defined safe status), e.g. actuation of the emergency stop button or a door lock after system start. Operative / organisational tests: Beyond the diagnostic measures on the PSC1 modules stated above, cyclic testing can be undertaken in the application.
  • Page 47 Installation manual For the safety-related assessment of the overall system, it is therefore possible in principle to use the following diagnostics for the input sensors: Characteristic Tests that can be Definition of the Comment s of the input configured / operative measure element tests...
  • Page 48 Installation manual Safety instructions:  For a safety-related assessment of the sensor sub-system, the information from the manufacturer (MTTF , PFH figures etc.) is to be used.  The DC values stated in the table are to be used conservatively and compliance with the boundary conditions (see "Comments"...

  • Page 49: Classification Of The Safe Digital Inputs

    Installation manual 4.2.1.3 Classification of the safe digital inputs 4.2.1.3.1 Digital inputs I00 … 13 Digital inputs Performance Level Remark that can be achieved Suitable for all types of input elements, with / I00 … I03 without pulses, achievable PL dependent on PL e I08 …...
  • Page 50 Installation manual 4.2.1.3.2 Digital inputs I/O (IQIx) Digital inputs Achievable Remark Performance Level Without pulse, single-channel static signal -> Signal input Without pulse, dual-channel static signal At least one demand/day due to PL e application Fault detection only on demand Without pulse, dual-channel static signal PL d Less than one demand/day due to...

  • Page 51: Connection Examples, Digital Sensors/Safety Switch

    Installation manual 4.2.1.4 Connection examples, digital sensors/safety switch Attention! Identifiers for "Xxy" terminal blocks (e.g. X14) are not printed on the terminal blocks. They are used in Section 5.7 Terminal assignment to find the individual terminals more quickly, e.g. "I00". 4.2.1.4.1 Single-channel sensor, without cross-circuit testing Single-channel sensor, without cross-circuit testing The single-channel sensor is connected to the PSC1 without test pulses, and without cross-...
  • Page 52 Installation manual On the usage of a single-channel sensor with test pulses, one connection is connected to the test pulse output T0 or T1 of the PSC1. The pulse assignment must then also be carried out in SafePLC2. The usage of a single-channel sensor with test pulses detects: Short-circuit to the supply voltage DC 24 V Short-circuit to DC 0 V Cable break (interruption of power is safe state!)
  • Page 53 Installation manual 4.2.1.4.3 Dual-channel sensor without time monitoring and without cross-circuit testing Faults are detected as a minimum on demand. The DC is medium and can be changed to the high category by using cyclic tests (start tests, operative/organisational tests) depending on the test frequency.
  • Page 54 Installation manual  PL d or higher according to EN ISO 13849-1 is achieved on the usage of switching elements / sensors with positively opening contacts or positive actuation according to EN 60947-5-1. When using sensors with non positive break contacts, the "Universal Input Module" macro (group) must be used in SafePLC2.
  • Page 55 Installation manual 4.2.1.4.4 Dual-channel sensor with time monitoring and cross-circuit testing By using two independent test pulse signals on the homogeneous sensor, all cross-circuits and connections to DC 24 V and DC 0 V can be detected. PL d or higher according to EN ISO 13849-1 can be achieved on: The usage of sensors / switching elements with positive actuation.

  • Page 56: Overview Of Achievable Pl For Digital Safety Inputs

    Installation manual 4.2.1.5 Overview of achievable PL for digital safety inputs Type of Input Tests that can be Achieva Fault exclusion for Condition for input sensor / configured / ble PL input element element input operative tests accordi element ng to EN ISO 13849-1 Input element proven in...
  • Page 57 Installation manual Type of Input Tests that can be Achieva Fault exclusion for Condition for input sensor / configured / ble PL input element element input operative tests accordi element ng to EN ISO 13849-1 Short-circuit on the Connection in the switch input/signal wire cabinet or protected laying Stuck / positive opening...

  • Page 58: Sensors For Speed And/Or Position Acquisition

    Installation manual 4.2.2 Sensors for speed and/or position acquisition 4.2.2.1 General safety-related layout of sensor interface for position and/or speed Different safety levels can be achieved depending on the encoder type and encoder combination. The safety assessment for the related sub-system is as follows: Sensor Sensor Sensor...

  • Page 59: 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, a series of diagnostic measures are implemented in the PSC1 series depending on the encoder type selected and their combination. The measures are activated automatically with the selection of the encoder type. In principle, the diagnostic measures can be classified in relation to their nature and effectiveness as per the table below: Diagnostics for sensors for position and/or speed acquisition:...

  • Page 60: Encoder Types And Their Combinations, Diagnostic Characteristic Data

    Installation manual 4.2.2.3 Encoder types and their combinations, diagnostic characteristic data When using a PSC1-C-10-SDM2, two cases must be considered:  1 axis with 2 encoders (so-called extended axis) o SafePLC2: Axis counter = 1 o Combination in table: Encoder 1: Column X1/X2, encoder 2: Column X3/X4 o Designation on device: Encoder 1: X1, encoder 2: X2 ...
  • Page 61 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction positio Encoder on Encoder on Encoder on 1-channel 2-channel 2-channel interface Interface X 23 sub-system sub-system sub-system X1/2 X3/4 dynamic non- Input (on request) dynamic (standstill (I04…I07) monitoring) 1 x proximity Fault exclusion mech.
  • Page 62 Installation manual Incremental proximity n.a. 90-95% switch 2 x proximity Incremental n.a. 90-95% switch 90° Incremental SIN/COS n.a. HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 62 of 189 Version: 50F...
  • Page 63 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder on Encoder on Encoder on 1-channel 2-channel 2-channel interface interface X 23 sub-system sub- sub-system X1/2 X3/4 system non- dynamic dynamic (on request) (Input (standstill I04…I07) monitoring) Incremental n.a.
  • Page 64 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder on Encoder on Encoder on 1-channel 2-channel 2-channel interface interface X 23 sub-system sub- sub-system X1/2 X3/4 system non- dynamic dynamic (on request) (Input (standstill I04…I07) monitoring) SIN/COS n.a.
  • Page 65 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction positio Encoder on Encoder on Encoder on 1-channel 2-channel 2-channel interface interface X 23 sub-system sub- sub-system X1/2 X3/4 system non- dynamic dynamic (on request) (Input (standstill I04…I07) monitoring) 2 x proximity n.a.

  • Page 66: Specific Diagnostic Measures In Relation To The Encoder Type Used

    Installation manual 4.2.2.4 Specific diagnostic measures in relation to the encoder type used Encoder type Incremental SIN/COS Proximity switch 2 x count input Proximity switch 1 x count input Incremental SIN_COS Options: Only in the high-resolution mode in preparation HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 66 of 189 Version: 50F...

  • Page 67: Safety-Related Shutdown Thresholds, Encoder Systems For Position And Speed Acquisition

    Installation manual 4.2.2.5 Safety-related shutdown thresholds, encoder systems for position and speed acquisition As a basic measure, plausibility tests between the two measurement channels A and B for speed and position on the PSC1 module are undertaken with the actual values for position and speed and tested against configured thresholds.
  • Page 68 Installation manual Value Value Acceleration [rev/min/s] Resolution (values in rev/min/s) Graph of acceleration resolution, rotary Acceleration [mm/s ] and [m/s ² ² Resolution (values in mm/s and m/s²) Graph of acceleration resolution, linear HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 68 of 189 Version: 50F...
  • Page 69 Installation manual Safety instructions:  The error can be optimised by the suitable selection of the sensor resolution for the related application.  For applications with limited resolution and/or time variance in the sampled signal, the functionality of the monitoring functions used can be improved by the usage of a mean value filter.
  • Page 70 Installation manual  The filter time can be set to between 0 and 64 in steps of 8. The dimension is "msec". To determine the response time of the overall system, the filter times must be added to the response times stated for the PSC1 system (see section 11). Safety instructions: ...

  • Page 71: Safety-Related Assessment Of The Encoder Types And Their Combination

    Installation manual 4.2.2.6 Safety-related assessment of the encoder types and their combination Due to the monitoring functions implemented in the PSC1 series, in applications with encoder systems there are initially no special requirements on the internal layout of the encoder electronics, i.e.
  • Page 72 Installation manual  On the usage of compact encoders with a dual-channel internal layout, e.g. SSI + incremental/SinCos, the instructions from the manufacturer in relation to the safety- related properties of diagnostic measures, mechanical connection and measures for the supply of power are to be followed. The encoder's safety level must correspond as a minimum to the safety level required for the overall arrangement.

  • Page 73: Safety-Related Characteristic Data And Circuitry For The Outputs

    Installation manual 4.3 Safety-related characteristic data and circuitry for the outputs The PSC1 modules have safe outputs of a different type. In the circuitry the related characteristic as per the description below is to be taken into account. 4.3.1 Characteristics of the output elements Aktuator Single-channel output PSC1 and single-channel actuator without diagnostics Aktuator...
  • Page 74 Installation manual Aktuator Single-channel output PSC1 with internal dual-channel processing (IQQx) and dual-channel actuator with dual-channel diagnostics Aktuator Dual-channel output PSC1 and dual-channel actuator with diagnostics Aktuator Dual-channel output PSC1 and dual-channel actuator with dual-channel diagnostics HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 74 of 189 Version: 50F...

  • Page 75: Diagnostics In The Shutdown Circuit

    Installation manual 4.3.2 Diagnostics in the shutdown circuit The shutdown circuits have diagnostic functions with a fixed implementation and diagnostic functions that can be configured. Certain diagnostic functions also include the external part of the shutdown circuit. The various DC values are dependent on the usage of these diagnostic functions.

  • Page 76: Overview Of Dc In Relation To Selected Diagnostic Functions

    Installation manual 4.3.2.2 Overview of DC in relation to selected diagnostic functions Measure Comment Usage Monitoring of outputs by one 0-90% DC dependent on the Monitoring of channel without dynamic test switching frequency electromechanical, pneumatic or hydraulic On the usage of elements for actuators / outputs increasing the switching rating (external relays or...

  • Page 77: Permissible Capacitive And Inductive Load On Safe Outputs

    Installation manual 4.3.3 Permissible capacitive and inductive load on safe outputs The safe outputs on the PSC1 are of an OSSD character. I.e. the outputs are shut down cyclically to test the shutdown capability and the status read back. The test on the shutdown capability is undertaken based on the following criteria / functions: After the shutdown of the output, the output voltage is allowed to be max.

  • Page 78: Digital Outputs

    Installation manual 4.3.4 Digital outputs The modules  PSC1-C-10, PSC1-C-10-SDM1, PSC1-C-10-SDM2  PSC1-E-31-..., PSC1-E-33-..., PSC1-E-37-... each have identical outputs. The PSC1 series provides different types of outputs that can be connected together either separately or in groups. Output Architecture Remark according to EN ISO 13849-1 Combination...
  • Page 79 Installation manual Safety instructions:  For applications with frequent demand for the safety shutdown, testing should be at short intervals, e.g. at the start of the shift, 1 x per week. However, a test should be undertaken cyclically at least 1 x per year. ...

  • Page 80: Example Circuits, Basic Outputs

    Installation manual 4.3.4.1 Example circuits, basic outputs Attention! Identifiers for "Xxy" terminal blocks e.g. X21 are not printed on the terminal blocks. They are used in Section 5.7 Terminal assignment to find the individual terminals more quickly, e.g. "Q0_P". 4.3.4.1.1 Single-channel switching relay or semiconductor output without testing For interfacing to multiple phase applications or if higher current is required, external contactors can be used.
  • Page 81 Installation manual 4.3.4.1.2 Single-channel switching relay or semiconductor output with external device for increasing the switching rating and testing On the usage of an external device for increasing the switching rating, or downstream electromechanical, pneumatic or hydraulic components, a device for testing the complete chain and a signalling/warning device on the detection of a fault are required to achieve PL c or higher.
  • Page 82 Installation manual 4.3.4.1.3 Single-channel switching relay or semiconductor output with dual-channel external circuit with testing For safety applications from PL c according to EN ISO 13849-1 it is recommended or required to operate two external shutdown elements. In addition, a device for testing the complete chain and a signalling/warning device on the detection of a fault are required to achieve PL c or higher –...
  • Page 83 Installation manual Q0_P Q1_N Q2_P Q3_N Single-channel switching output Q0_P with dual-channel external circuit as combination of electromechanical element and hydraulic/pneumatic valve monitoring on two inputs Safety instructions:  Only recommended to a limited extent for safety applications! On this topic see also the information in EN ISO 13849-1 on usage and the fault exclusions necessary.
  • Page 84 Installation manual 4.3.4.1.4 Dual-channel switching relay output with external monitoring - collective feedback For safety applications from PL d according to EN ISO 13849-1, two relays are used in the PSC1-C-10-x module and two external contactors. Q4.1 Q4.2 Q5.1 Q5.2 Dual-channel switching relay output with external monitoring –...
  • Page 85 Installation manual 4.3.4.1.5 Dual-channel output with relay output and semiconductor output – external control circuit with monitoring For safety applications from PL d and higher according to EN ISO 13849-1. The external circuit is operated using two channels via one relay output and one semiconductor output. Each of the two external shutdown paths is monitored.
  • Page 86 Installation manual 4.3.4.1.7 Dual-channel output with semiconductor output and external control circuit in PL e For safety applications from PL d and higher according to EN ISO 13849-1. The external circuit is operated using two channels via semiconductor outputs. PL e is required for the external circuit for PL e according to EN ISO 13849-1.

  • Page 87: Digital Outputs I/O (Iqqx)

    Installation manual 4.3.5 Digital outputs I/O (IQQx) The expansion modules PSC1-E-31-… and PSC1-E-33-… have configurable safe digital I/O (see section 3.6 Module overview). Configured as an output, this connection acts as a safe digital pp switching output (IQQx). 4.3.5.1 Classification of the I/O (IQQx) on usage as an output Classification Achievable PL Remark...

  • Page 88: Example Circuits For Safe Digital Outputs I/O (Iqqx)

    Installation manual 4.3.5.2 Example circuits for safe digital outputs I/O (IQQx) Attention! Identifiers for "Xxy" terminal blocks e.g. X12 are not printed on the terminal blocks. They are used in Section 5.7 Terminal assignment to find the individual terminals more quickly, e.g.
  • Page 89 Installation manual 4.3.5.2.2 Single-channel circuit with testing On the usage of a dual-channel output (IQQx) in conjunction with an external single-channel circuit with testing. In particular, positively driven auxiliary contacts are required for electromechanical devices, or valve position signal contacts are required for this purpose for hydraulic or pneumatic components.
  • Page 90 Installation manual 4.3.5.2.3 Circuit with safe shutdown circuit For safety applications from PL c and higher according to EN ISO 13849-1. The external circuit is operated directly using a dual-channel output. The achievable PL according to EN ISO 13849-1 is dependent on the usage of dynamic testing (see 4.3.2.1 DC) as well as the PL for the downstream device.
  • Page 91 Installation manual Safety instructions:  For the safety-related assessment of the output sub-system, on the usage of external elements in the shutdown circuit, e.g. for increasing the switching rating, the information from the manufacturer (MTTF , PFH figures, B10d value etc.) is to be used.
  • Page 92 Installation manual 4.3.5.2.5 Redundant dual-channel output Suitable for PL d or higher according to EN ISO 13849-1. Usage of two outputs IQQx in conjunction with a dual-channel external circuit. 4.3.5.2.5.1 Dual-channel circuit in same group IQQ00 IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07...
  • Page 93 Installation manual 4.3.5.2.5.2 Dual-channel circuit in different groups IQQ00 IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07 IQQ08 IQQ09 Redundant dual-channel outputs in different groups in conjunction with dual-channel shutdown circuit Safety instructions:  For the safety-related assessment of the output sub-system, on the usage of external elements in the shutdown circuit, e.g.

  • Page 94: Overview Of Achievable Pl For Digital Safety Outputs

    Installation manual 4.3.5.3 Overview of achievable PL for digital safety outputs Output Actuator / Category MTTF Achie Boundary condition Fault PSC1 external accordin actuat vable exclusion shutdown g to EN circuit accor 13849-1 ding to EN 13849- Single- Single-channel Cat. B Medium Contactor and channel...
  • Page 95 Installation manual Output Actuator / Category MTTF Achiev Boundary condition Fault PSC1 external accordin actuat able exclusion shutdown g to EN circuit accord 13849-1 ing to EN ISO 13849- Dual-channel Dual-channel Cat. 3 Monitori Medium Contactor and Short-circuit without Contactor, valve, ng in or high downstream actuators...

  • Page 96: Connection And Installation

    Installation manual 5 Connection and installation 5.1 General installation instructions It is imperative you follow the safety instructions during installation! Degree of protection IP20 Lay all signal wires for connection to the digital inputs and contact monitoring separately. In all circumstances separate voltages of 230 VAC from low-voltage wires, if these voltages are used in relation to the application.

  • Page 97: Installation And Mounting Psc1 Module

    Installation manual  All contactors in the area of the converter must be equipped with an appropriate suppressor circuit.  All contactors or comparable switching amplifiers must be equipped with appropriate protective circuitry (e.g. free-wheeling diodes).  Suitable measures for protection against overvoltages are to be taken. 5.2 Installation and mounting PSC1 module The module is only installed in switch cabinets that meet degree of protection IP54 as a minimum.

  • Page 98: Arrangement Examples

    Installation manual 5.3.1 Arrangement examples 5.3.1.1 PSC1-C-10-SDM1 + PSC1-E-31-…. + PSC1-E-33-…. PSC1-C-10- PSC1-E-31-…. PSC1-E-33-…. SDM1 5.3.1.2 PSC1-C-10-SDM2 + PSC1-E-33-…. PSC1-C-10-SDM2 PSC1-E-33-…. HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 98 of 189 Version: 50F...

  • Page 99: Mounting The Modules

    Installation manual 5.4 Mounting the modules The modules are mounted on standard C rails using a snap-action catch 5.4.1 Mounting on C rail The devices are fitted to the rail from above at an angle and snapped downward. They are removed using a screwdriver that is inserted in the slot on the catch protruding from the bottom of the device and then moved upward.

  • Page 100: Mounting On Backplane Bus

    Installation manual 5.4.2 Mounting on backplane bus After mounting the backplane bus, the devices can be mounted. For this purpose the module is fitted to the connector at an angle from above and snapped to the C rail Fit module at an angle from above Snap down onto the C rail HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 100 of 189...

  • Page 101: Installation And Configuration Of Master  Master (Smmc) And Master  Slave (Sddc)

    Installation manual The backplane connection can be retrofitted. In this way the system configuration can be expanded with additional modules. Snap backplane bus element to C rail and insert in the mating piece by pushing to the side 5.5 Installation and configuration of master  master (SMMC) and master ...

  • Page 102: Schematic Diagram Of The Network Topology

    Installation manual 5.5.1 Schematic diagram of the network topology SMMC SDDC CAN (central) SDDC? SDDC ETH (decentral) Communication of a PSC1 compact with  Central expansion modules via SDDC CAN backplane bus  SMMC via Ethernet Communication of a PSC1 modular with ...

  • Page 103: Installation Of I/O Expansion

    Installation manual 5.6 Installation of I/O expansion Note: Max. two PSC1-E-3x modules can be operated using a basic device. 5.6.1.1 Physical address configuration for the slave modules (central / decentral) The bus address must be set on the PSC1-E-3x modules with the aid of the address switch. The address is set on the rear panel depending on the slot (mounting position) of the module.

  • Page 104: Terminal Assignment

    Installation manual 5.7 Terminal assignment Attention! Identifiers for "Xxy" terminal blocks e.g. X11 are not printed on the terminal blocks. They are used in this Section to find the individual terminals more quickly, e.g. "A1.1" in the diagrams and the terminal assignment. HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 104 of 189 Version: 50F...

  • Page 105: Terminal Assignment Psc1-C-10 (-Fbx/-Mc)

    Installation manual 5.7.1 Terminal assignment PSC1-C-10 (-FBx/-MC) Option FB1/FB2 Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs 3 – A2.1 Device power supply 0 VDC 4 –...
  • Page 106 Installation manual 1 – A1.3 Power supply SD-Bus +24 V DC 2 – A2.3 Power supply SD-Bus 0 V DC Option 3 – SD SD-Bus connection FB1/FB2 Connect to FE or PE of the control 4 – FE Functional earth cabinet (use short cables) HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 106 of 189...

  • Page 107: Terminal Assignment Psc1-C-10-Sdm1 (-Fbx/-Mc)

    Installation manual 5.7.2 Terminal assignment PSC1-C-10-SDM1 (-FBx/-MC) Option FB1/FB2 Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs 3 – A2.1 Device power supply 0 VDC 4 –...
  • Page 108 Installation manual 1 – A1.3 Power supply SD-Bus +24 V DC 2 – A2.3 Power supply SD-Bus 0 V DC Option 3 – SD SD-Bus connection FB1/FB2 Connect to FE or PE of the control 4 – FE Functional earth cabinet (use short cables) HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 108 of 189...

  • Page 109: Terminal Assignment Psc1-C-10-Sdm2 (-Fbx/-Mc)

    Installation manual 5.7.3 Terminal assignment PSC1-C-10-SDM2 (-FBx/-MC) Option FB1/FB2 Terminal assignment Unit Termina Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs 3 – A2.1 Device power supply 0 VDC 4 –...
  • Page 110 Installation manual Terminal assignment Unit Termina Description Note 1 – UE1+ Encoder power supply DC (X2) 1 – UE1- Encoder power supply 0V DC (X2) 3 – NC No function 4 – NC No function 1 – NC No function 2 –...

  • Page 111: Terminal Assignment Psc1-E-31

    Installation manual 5.7.4 Terminal assignment PSC1-E-31 Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 V DC Attention: see: "External 24 VDC 2 – A1.2 Device power supply +24 V DC power supply" 3 – A2.1 Device power supply 0V DC 4 –...

  • Page 112: Terminal Assignment Psc1-E-33

    Installation manual 5.7.5 Terminal assignment PSC1-E-33 EXT-REL Note: The read-back contacts 0.11/12, 1.11/12, 2.11/12, 3.11/12 of the internal relays Q0, Q1, Q2, Q3 must be monitored for feedback loop monitoring (EMU) in addition to the read-back contacts of the connected contactors or other switching amplifiers. Terminal assignment Unit Terminal...
  • Page 113 Installation manual Terminal assignment Unit Terminal Description Note 1 – NC No function 2 – NC 3 – T0 Pulse outputs 4 – T1 1 – I 00 2 – I 01 3 – I 02 4 – I 03 1 –...

  • Page 114: Terminal Assignment Psc1-E-37 In Preparation

    Installation manual 5.7.6 Terminal assignment PSC1-E-37 in preparation Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs 3 – A2.1 Device power supply 0 VDC 4 – A2.2 1 –...

  • Page 115: Terminal Assignment Psc1-C-10(-Sdmx)-Fbx

    Installation manual 5.7.7 Terminal assignment PSC1-C-10(-SDMx)-FBx Please refer to the installation manual for PSC1 fieldbuses for the terminal assignments of the fieldbus or SDDC/SMMC interfaces of the various communication modules. HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 115 of 189 Version: 50F...

  • Page 116: External 24 Vdc Power Supply

    Installation manual 5.8 External 24 VDC power supply The PSC1 module requires a power supply of 24 VDC (on this topic see SELV or PELV, EN50178). During the planning and installation of the power supply unit to be used, attention is to be paid to the following boundary conditions: It is imperative the minimum and maximum tolerance on the supply voltage is observed.
  • Page 117 Installation manual Remark: The GND_ENC connection is not connected internally to GND! CPU-ENC GND- GND- Encoder Encoder PSC1-C-10-SDM2 PSC1-E-31 HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 117 of 189 Version: 50F...

  • Page 118: Connection Of The External Encoder Supply

    Installation manual 5.9 Connection of the external encoder supply 5.9.1 Incremental, HTL (on request), SIN/COS, SSI UE2- UE1- UE1+ UE2+ PSC1 Spannungs- überwachung der externen Geber- versorgungs- spannungen Options: Only PSC1-C-10-SDM2 The PSC1 module supports encoder voltages of 5V, 8V, 10 V, 12V, 20V and 24V that are monitored internally as per the configuration selected.
  • Page 119 Installation manual Monitoring of the supply voltage as per the nominal voltage selected: Nominal voltage Minimum voltage Maximum voltage 5 VDC 4.4 VDC 5.6 VDC 8 VDC 7 VDC 9 VDC 10 VDC 8 VDC 12 VDC 12 VDC 10 VDC 14 VDC 20 VDC 16 VDC...

  • Page 120: Connection Of The Digital Inputs

    Installation manual 5.10 Connection of the digital inputs  The PSC1 has 14 (PSC1-C-10(-SDMX)(-FBx) and PSC1-E-37) or 12 (PSC1-E-31/33) safe digital inputs. These are suitable for the connection of single or dual-channel signals with and without test pulses, or without cross-circuit testing. ...

  • Page 121: Connection Of Position And Speed Sensors

    Installation manual 5.11 Connection of position and speed sensors 5.11.1 General instructions Depending on the module type, the PSC1 module (PSC1-C-10-SDMx) has external encoder interfaces for the connection of the usual industrial incremental and absolute encoders. The encoder interfaces can be configured for incremental, SIN/COS, absolute SSI encoders or for proximity switches.
  • Page 122 Installation manual Attention: The encoder connections are not allowed to be connected or disconnected in operation. Electrical components on the encoder may be irreparably damaged. Disconnect from the electrical supply the encoders connected and the PSC1 module before connecting or disconnecting the encoder connections. For externally supplied encoders, pay attention to shutting down the external supply voltage (e.g.

  • Page 123: Encoder Interface Assignment

    Installation manual 5.11.2 Encoder interface assignment X1/X2 Options: only PSC1-C-10-SDM2 HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 123 of 189 Version: 50F...

  • Page 124: 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 for the supply voltage 24 V DC Pin 3 n.c. Pin 4 CLK- Sub-D- Pin 5 DATA+ Absolut- Stecker Encoder (9 polig) (Master-Betrieb) PSC1...

  • Page 125: 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- Sub-D- Pin 5 DATA+ Absolut- Stecker Encoder (9 polig) (Slave-Betrieb) PSC1 PSC1 Pin 6 DATA- n.c. Pin 7 CLK+ Pin 8 Pin 9...

  • Page 126: Connection Of An Incremental Encoder With Ttl Signal Level

    Installation manual 5.11.3.3 Connection of an incremental encoder with TTL signal level n.c. Pin 1 Pin 2 Ground Pin 3 n.c. Pin 4 Sub-D- Pin 5 Inkremental Stecker Encoder (9 polig) PSC1 Pin 6 n.c. Pin 7 Pin 8 Pin 9 Versorgungsspannung Pins 1, 3 and 7 remain open and are reserved for later expansions.

  • Page 127: 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 for the supply voltage 24 V DC Pin 3 n.c. Pin 4 COS- Sub-D- Pin 5 SIN+ SIN/COS Stecker Geber (9 polig) PSC1 Pin 6 SIN- n.c.

  • Page 128: Connection Of Proximity Switch Psc1-C-10-Sdm1/2

    Installation manual 5.11.3.5 Connection of proximity switch PSC1-C-10-SDM1/2 Connection is via the connector X23 to the digital inputs I04 … I07. The exact pin assignment is dependent on which encoder type is used and is given in the connection diagram in the programming software user interface. Note: On the usage of HTL encoder, it is to be noted that the tracks A+ and B+ or A- and B- must be combined correspondingly.

  • Page 129: Configuration Of The Measurement Sections

    Installation manual 5.12 Configuration of the measurement sections 5.12.1 General description of the encoder configuration The most important input variables for the module's monitoring functions are safe position, speed and acceleration. These are generated from the sensor systems connected using two channels.
  • Page 130 Installation manual SSI format parameter configuration: ClkN Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Index Daten Index Status K Daten O Status Status information Status Status Status Status ..Error Maske Mask Mask Mask Mask 0 = dont´t care ..

  • Page 131: Incremental Encoder

    Installation manual 5.12.2.2 Incremental encoder Physical layer: RS-422 compatible Measured signal A/B: Track with 90 degree phase difference Maximum input pulse frequency: 200 kHz or 500 kHz Options: Standard incremental HighRes incremental (on request); Diagnostics: Diagnostics Parameter Fault threshold Supply voltage monitoring Fixed values See section 5.9.1 5 V, 8 V, 10 V, 12 V, 20 V,...

  • Page 132: Extended Monitoring With 2 Proximity Switches

    Installation manual 5.12.2.5 Extended monitoring with 2 proximity switches The expanded monitoring detects the following faults: a) Failure of the supply voltage b) Failure of the output signal in the driver direction c) Proximity switch functional failure for high signal d) Signal path interruption e) Mechanical maladjustment of proximity switch / excessively large proximity switching distance...

  • Page 133: Response Times Of The Psc1

    Installation manual Logic processing: The following evaluation is to be undertaken in both channels: Signal A Signal B Result False High True High True High High True 6 Response times of the PSC1 The response time is an important safety-related property and must be taken into account for each application / safety function.

  • Page 134: Response Times In Standard Operation

    Installation manual 6.1 Response times in standard operation The basis for the calculation of response times is the cycle time of the PSC1. system. During operation this is T_cycle = 8 ms. The response times stated correspond to the related maximum propagation time within the PSC1 module for the specific application.

  • Page 135: Response Times For Fast_Channel

    Installation manual 6.2 Response times for FAST_CHANNEL FAST_CHANNEL refers to a property of the PSC1 to react faster to speed requirements than is possible on processing the safety program in the normal cycle (= 8 ms). The sampling time of the FAST_CHANNEL is 2 ms + 2 ms for signalling on bus. The following response times can be stated: ...
  • Page 136 Installation manual Resp Resp Fault Behaviour of the drive with / without overspeed distance For the V and s curves there are the following relationships without overspeed distance: Parameter Acceleration method Remark Value from PSC1 response time data Delay in external shutdown chain Resp + delay in external shutdown chain from relay / contactor, brake...

  • Page 137: Response Times When Using The Psc1-E-3X

    Installation manual For the V and s curves with overspeed distance the following applies: Parameter Acceleration method Remark Value from PSC1 response time data Delay in external shutdown chain Resp + delay in external shutdown chain from relay / contactor, brake manufacturer data etc.
  • Page 138 Installation manual Determination of the total response time TOTAL Example 1: Input on expansion module, activation of SLS and processing in PLC, output on basic module = 18 ms + 8 ms + 0 ms = 26 ms; TOTAL IN_31 OUT_Base Example 2: Input on basic module, activation of SLS and processing in PLC, output on expansion module...

  • Page 139: Commissioning

    Installation manual 7 Commissioning 7.1 Procedure Commissioning is only allowed to be undertaken by qualified personnel! Please follow the safety instructions during commissioning! 7.2 Sequences for switching on Each time after restarting the module, if there are no errors, the following phases are run through and displayed on the seven-segment display on the front: 7-segment Mode...

  • Page 140: Reset Behaviour

    Installation manual 7.3 Reset behaviour The reset function differentiates between a startup function after the return of the power supply = general reset and a status/alarm reset = "internal reset". The latter is triggered via the front button or an input configured accordingly = start/reset element with activated "alarm reset or logic reset"...

  • Page 141: Reset Types And Triggering Element

    Installation manual 7.3.1 Reset types and triggering element Reset type Triggering element Remark General reset Return of supply of power / device startup Reset function after completely switching off and on the device Internal reset The internal reset is triggered using Reset the Reset button button...

  • Page 142: Reset Timing

    Installation manual 7.3.2 Reset timing An "Internal Reset" is triggered with the falling edge of the reset input. Reset_In Reset_Status 7.3.3 Reset function Function unit General Internal Function Reset Reset Fatal error Reset error Alarm Reset alarm Monitoring functions Resetting a triggered monitoring function Flip-flop Status = Reset Timer...
  • Page 143 Installation manual V_Ist > SOS_V_Max V_Ist SOS_Result Reset_In Process value (speed) => no change to the output status on reset in the alarm state Max. 3 sec Max. 3 sec Max. 3 sec Q =I1 AND I2 Q =I1 AND I2 Q =I1 AND I2 IN_Result Reset_In...

  • Page 144: Example Reset Function With Protection Against Incorrect Usage

    Installation manual 7.3.3.1 Example reset function with protection against incorrect usage Function:  On a machine, the hazard area is to be protected in normal operation by a guard and in the setting up mode by an enable button in conjunction with standstill monitoring and safely limited speed.
  • Page 145 Installation manual Application-related measure: Using an operator in the PLC program, the activation of the outputs while bypassing the alarm state for this time is prevented. Example 1:  The enable function for the outputs (AND function) is also linked to a "reset timer". This operator prevents the activation of the outputs for t >...
  • Page 146 Installation manual Example 2:  The enable function for the outputs (AND function) is also linked to FF. This operator prevents the activation of the outputs after a reset if there is a fault present in the input circuit. The outputs are only enabled after an error-free input signal has been applied once.

  • Page 147: Led Indication

    Installation manual 7.4 LED indication Colour Mode Description System OK, configuration Green "Flashing" validated System OK, configuration not yet Yellow "Flashing" validated "Flashing" Alarm "Continuous" Fatal error System OK, configuration not Yellow - red "Flashing" validated, SMMC configured but no bus user System OK, configuration Green - red "Flashing"...

  • Page 148: Parameter Configuration

    Installation manual 7.5 Parameter configuration The parameters are configured using the program SafePLC2. To be able to send the data to the module, a programming adapter is required; the user must install the driver for this adapter prior to use. For a description of the parameter configuration, see Programming manual.

  • Page 149: Safety-Related Check

    Installation manual 8 Safety-related check To safeguard the safety functions implemented, the parameters and operators must be checked and documented by the user after completion of commissioning and parameter configuration. Support for this task is provided by the parameter configuration software SafePLC2 (see Programming manual).

  • Page 150: Maintenance

    Installation manual 9 Maintenance 9.1 Modification / dealing with changes to the device Servicing work is only allowed to be undertaken by qualified personnel. It is not necessary to undertake regular servicing work. Repair Devices are always to be replaced completely. It is only possible to repair a device in the factory.

  • Page 151: Technical Data

    Installation manual 10 Technical data 10.1 Ambient conditions Degree of protection IP 20 Ambient temperature 0 °C* ... 50 °C Climatic class 3k3 according to DIN 60 721 Service life 20 years in 50 °C environment (Tm, time to mission)) 10.2 Safety-related characteristic data ...

  • Page 152: Switch Types

    Installation manual 11 Switch types Switch symbol Truth table Function block Function Truth table behaves like an Öffner normally open contact, only the symbol is a normally closed contact Ausgang eSwitch_1o Normally open contact, like type Schließer Ausgang sSwitch_1s AND operation both inputs Öffner 1 Öffner 2 Ausgang...
  • Page 153 Installation manual Switch symbol Truth table Function Monitoring for NO = inactive and NC = active Öffner Schließer Ausgang eSwitch_1s1o Time monitoring Like 5, however with time monitoring of state changes. Öffner On signal change on one of the NC, complementary signal must Schließer follow within time t=3 s.
  • Page 154 Installation manual Switch symbol Truth table Function Time monitoring Like 7, however with time monitoring of state changes. Öffner 1 On signal change on NO (attention common wire!) or NC, Öffner 2 complementary signal must follow within time t=3 s. If not change to fault and O=0 Schließer Ausgang...
  • Page 155 Installation manual Time monitoring Like 8, however with time NC1 NC2 NC monitoring of state changes. Öffner 1 On signal change on one of the NC inputs the other inputs must Öffner 2 follow within time t=3 s. If not change to fault and O=0 Öffner 3 Ausgang...
  • Page 156 Installation manual Switch symbol Truth table Function Two-hand Monitoring for NO1*NO2 = control inactive and NC1*NC2 = active Öffner 1 + time monitoring of this state. I.e. if there is a signal change on an NO from 1->0 or NC from 0- >1 then the other signals (i.e.
  • Page 157 Installation manual Selector switch Unambiguous operator for the permissible switch positions Öffner Schließer Ausgang eMode_1s1o S3 O Selector switch Unambiguous operator for the permissible switch positions Schalter 1 Schalter 2 Schalter 3 Ausgang 1 eMode_3switch HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 157 of 189 Version: 50F...

  • Page 158: Notes For Designing, Programming, Validating And Testing Safety-Related Applications

    Installation manual 12 Notes for designing, programming, validating and testing safety- related applications The following notes describe the procedures for designing, programming, validating and testing safety-related applications The notes are intended to assist the user in arranging, clearly understanding and applying all steps from the risk assessment to the system test.
  • Page 159 Installation manual Risk assessment according to EN ISO 13849-1 S – severity of injury S1 = slight, reversible injury S2 = serious, irreversible injury F – frequency and/or exposure to hazard F1= seldom, not cyclic F2 = frequent to continuous and/or exposure time is long, cyclic operation P –...

  • Page 160: Technical Documentation Required

    Installation manual The risks to be considered are also given in the applicable directives and standards and are to be considered specifically by the manufacturer based on the manufacturer's specific knowledge of the machine. For machines placed on the market in the EU, the risks to be considered as a minimum are specified in the EU Machinery directive 2006/42/EC or in the latest version of this directive.

  • Page 161: Steps Required For Designing, Realisation And Testing

    Installation manual 12.3 Steps required for designing, realisation and testing The realisation of parts of systems with a safety-related function requires particular care during planning, realisation and testing. Guidelines on these issues are also given in the applicable standards (cf. EN ISO 13849-2 or EN ISO 61508). The effort here depends on the complexity of the task for parts of the system with a safety-related function.

  • Page 162: 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 Check on all passive and active validation of all measures to be taken such as safety measures for their correct passive and active covers, barriers, max.

  • Page 163: Specification Of The Safety Requirements (Breakdown)

    Installation manual 12.3.2 Specification of the safety requirements (breakdown) The safety requirements are to be analysed in detail based on the standards to be applied, e.g. product standards. Source: General specifications, extract BGIA Report 2/2008 on EN ISO 13849-1 HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 163 of 189 Version: 50F...
  • Page 164 Installation manual Example for an automatic handling system: Functional description: The automatic handling system is used to pick up varying height lorry cabs automatically. After pick-up the height of the cab is safely acquired so that the cab cannot be lowered below a certain height in the working area.
  • Page 165 Installation manual Example for a hazard analysis: HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 165 of 189 Version: 50F...

  • Page 166: Specification Of The Functional Safety System

    Installation manual 12.3.3 Specification of the functional safety system Derived from the general hazard and risk analysis for the machine, the active protection functions are to be identified and specified. Active protection functions are, e.g. safely limited speed in certain system states, monitored stop and standstill functions, range monitoring, processing of monitoring devices such as light grids, safety mats etc.

  • Page 167: Example - Specification Of The Safety Functions In Tabular Form

    Installation manual 12.3.3.3 Example – specification of the safety functions in tabular form Seq. Safety function Ref. Measured Implementation in Required Input/ Response/ value /sensor software Parameter activation output Limitation of the max. 1 x WCS Monitoring using tested 550mm/s Continuous Operation speed of movement,...

  • Page 168: Software Specification

    Installation manual 12.3.4 Software specification The software specification relates to the prior specification of the safety functions. It can also be replaced by a correspondingly prepared specification of the safety functions if this contains all specifications (see example in 12.3.3.3). However, it is recommended to prepare an extracted list.
  • Page 169 Installation manual Example software specification Safety function Measured New solution Input/activation Response/output . no. value /sensor Monitoring V_rope in Digital Monitoring using tested function SLS Continuous Operating stop relation to V_required incremental + SAC with comparison of speed Monitoring of the encoder, ranges / analogue value range = SF 1.3.1...

  • Page 170: Hardware Specification

    Installation manual 12.3.5 Hardware specification In the hardware specification, the complete system layout and in particular the components used here are to be described with their specific characteristic data. The hardware specification is used as the basis for determining the safety level achieved based on the architecture and the characteristic data of all devices involved in a safety function.

  • Page 171: Examples For Hardware Specification

    Installation manual 12.3.5.2 Examples for hardware specification Safety function Safely limited speed SF 2.2 Safely monitored limited speed with door open Type Designation Function Designation Characteristic data Comment Archite MTTF B10d Source Source cture [1/h] [years] Sensor Sensor 1 Door locking – monitoring A 3.1 10000 Data...

  • Page 172: Consideration Of Systematic Failures

    Installation manual 12.3.5.3 Consideration of systematic failures In addition, systematic failures are also to be considered in the hardware specification. Example of measures against systematic failures: Loss of power during operation. If there is a hazard here, a power loss must be considered like an operating state.
  • Page 173 Installation manual Examples for fault exclusions and measures assigned:  Positive locking connection on mech. shaft connections  Dimensioning based on adequate theoretical principles related to fracture of components in the safety chain  Positive guidance in conjunction with positive separation on sticking of switching contacts ...

  • Page 174: Hardware And Software Design

    Installation manual 12.3.6 Hardware and software design The specifications from the hardware and software specification are implemented in the actual system design. The specifications for the components to be used and their circuitry from the hardware specification are to be met as are the specifications for the fault exclusions. Both are to be safeguarded using suitable means and are to be documented.
  • Page 175 Installation manual As an example, a calculation according to EN ISO 13849-1 is shown: Safety function: Safely limited speed with open access door Schematic layout: Sensor Eink. Teilsyst. Zweik. Teilsyst. Spur A Mech.+ Sendeopt. Spur B Umrichter Sensor Aktuator Aktuator Safety-related schematic layout: Schütz Geschw.
  • Page 176 Installation manual Calculation according to EN ISO 13849-1: Channel A – shutdown via mains contactor: Component MTTFd [years] Door locking B10d = 100000 = 99% Switch NOP = 30/working days = 9270/year (309 working days/year) B10d MTTFd = = 108 Jahre 0,1 ∗...
  • Page 177 Installation manual HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 177 of 189 Version: 50F...

  • Page 178: Verification Of Software (Program) And Parameters

    Installation manual Resulting PL for both channels: Symmetrisation of both channels: MTTFd = [MTTFd_A + MTTFd_B − ] = 21,5 Jahre MTTFd_A MTTFd_B DCSwitch DCSinCos DCPES DCSchütz DCSTO DC average value MTTFd_Türz MTTFd_SinCos MTTFd_PES MTTFd_Schütz MTTFd_STO DCavg = MTTFd_Türz MTTFd_SinCos MTTFd_PES MTTFd_Netzsch DCavg = 0,9776 ~ 98%...
  • Page 179 Installation manual Example: Safety function:  Limitation of the max. travel speed of the running gear (FW) to 1.1 VMax  Monitoring of the maximum speed for < 1.1 VMax  "FW Max Speed OK", as long as FW Max Speed < 550 mm/s (bridged by "Lock error") ...
  • Page 180 Installation manual Safety function:  Engage drive and brake shutdown if emergency stop is actuated or one of the monitoring functions SS1, ECS or SSX is activated and these are not bridged by "gap present".  The running gear is switched off via two "SS1 FW" outputs. ...

  • Page 181: Validating Fup Against Il And Parameters Using Validation Report

    Installation manual 12.3.8.2 Validating FUP against IL and parameters using validation report The programming in the FUP is to be compared with the IL listing in the validation report. Example IL listing in the validation report Validation report PLC program Index Command Operand Validated...
  • Page 182 Installation manual After checking the program, the parameters are to be checked against the parameters in the specifications by comparing. Example SLS: Validation report Safely Limited Speed (SLS) Index Parameter Value Validated SLS - 1 Selected axis: Speed threshold: SLS - 2 Selected axis: Speed threshold: SLS - 3...

  • Page 183: Performance Of System Tests / Fit Test (Fault Injection Test)

    Installation manual General parameters correctly configured Parameters sensor 1 correct Parameters sensor 2 correct 12.3.9 Performance of system tests / FIT test (Fault Injection Test) For the FIT test the manufacturer must prepare a complete list of functions to be tested. This list includes the safety functions defined as well as fault tests for checking the correct response of the SRP/CS to these faults.
  • Page 184 Installation manual 13 Appendix 13.1 Appendix A – categorisation of the switch types General note: The individual switches for the following input elements can be assigned as required to the digital inputs I0 to I13. Enable switch Switch type Remark PL categorisation SIL categorisation according to EN ISO...
  • Page 185 Installation manual 2 normally open Door monitoring for PL e SIL 3 contact + 2 normally increased requirement closed contact 2 normally open Monitored door monitoring PL e SIL 3 contact + 2 normally closed contact time monitored 3 normally closed Door monitoring for PL e SIL 3...
  • Page 186 Installation manual Two-handed operation Switch type Remark Category SIL categorisation categorisation 2 change-over Two-hand button for Type III C PL e SIL3 contacts increased requirement 2 normally open Monitored two-hand button Type III A PL c SIL1 contacts Note: On these input elements there is a fixed pulse assignment that the user cannot change! Light curtain Switch type Remark...
  • Page 187 Installation manual 1 normally open Sensor input for increased PL e SIL 3 contact + 1 normally requirement closed contact 1 normally open Monitored sensor input PL e SIL 3 contact + 1 normally closed contact time monitored HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 187 of 189 Version: 50F...
  • Page 188 Installation manual Start / Reset Switch type Remark Category SIL categorisation categorisation 1 normally open Simple alarm reset (edge contact evaluation) 1 normally open Simple logic reset PL d SIL 2 contact 1 normally open Simple start monitoring contact (special function) Note: The alarm reset input can be operated with a continuous voltage of 24 V and is edge controlled.
  • Page 189 Installation manual 13.2 CE – declaration of conformity EC declaration of conformity for safety components in the context of the EC directive HB-37350-810-01-50F-EN PSC1-C-10 Installation manual V2.1.docx Page 189 of 189 Version: 50F...

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