Page 1 Operating Instructions English Language Translation Document-No. 5.07020.04 Part No. 422418 Status 07.02.2011 ® b maXX Systems b maXX safe PLC BMC-M-SAF-02 Read the Operating Instructions before beginning 5.07020.04...
Page 2 © Baumüller Nürnberg GmbH Ostendstr. 80 - 90 90482 Nürnberg Germany Tel. +49 9 11 54 32 - 0 Fax: +49 9 11 54 32 - 1 30 E-Mail: mail@baumueller.de Internet: www.baumueller.de...
Page 3: Table Of Contents
Table of Contents Document history ............Preface .
Page 4 Inhaltsverzeichnis Properties of the safety PLC ..........37 Properties of the power supply module .
Page 5 Inhaltsverzeichnis 12 System validation ............12.1 Function test .
Page 6 Inhaltsverzeichnis Index ..............117 Operating Instructions b maXX safe PLC BMC-M-SAF-02 Document No.: 5.07020.04 Baumüller Nürnberg GmbH...
Page 7: Document History
OCUMENT HISTORY Revision State Modifications level 5.07020.01 18.10.2007 Initial document 5.07020.02 31.03.2009 Revision and CFI module extension 5.07020.03 25.08.2009 Editorially checked contents 5.07020.04 07.02.2011 New declaration of conformity Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 of 118...
Page 8 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 9: Preface
REFACE Information on the Operation Manual This Operation Manual provides important information on handling the device. Compli- ance with all safety instructions operation instructions specified is a prerequisite for work safety. Furthermore, it is also necessary to comply with the local accident prevention legislation and general safety regulations applying to the device’s field of application.
Page 10: Legend
Legend Legend Warning notices Warning notices are indicated by symbols in this Operation Manual. The notices are in- troduced by signal words which express the extent of the hazard. Comply with the notices under all circumstances and act with caution in order to avoid accidents, personal injury and property damage.
Page 11: Limitation Of Liability
Preface Limitation of liability All statements and instructions in this Operation Manual have been compiled in compli- ance with the applicable standards and legislation while taking the current level of tech- nology and our long-term experience and findings into account. The manufacturer assumes no liability for damages resulting from: m failure to observe the Operation Manual m application for purposes other than those intended...
Page 12: Further Applicable Documents
Further applicable documents NOTICE! The content-related statements, texts, diagrams, images and other illustrations are copyright protected and subject to industrial property rights. Any improper use is lia- ble to prosecution. ® b maXX is a registered trademark of Baumüller Nürnberg GmbH ®...
Page 13: Customer Service
Preface clarified with the factor on a case-by-case basis. The warranty will be rendered null and void if the devices are operated differently than described here. 2.10 Customer service Our customer service is available for technical support. Information on the contact person responsible can be found at any time via telephone, fax, E-mail or over the internet.
Page 14 2.12 Certification IEC 62061 Appendix E Functional safety of security- related electric, electronic and programmable electronic sys- tems Fulfilment of increased stability requirements in accordance with Appendix E Additional standards Area of application EN 61131-2 General device requirements and tests for control systems EN 50178 Equipping of high voltage equip- ment with electronic utilities...
Page 15: Use Of This Handbook
SE OF THIS HANDBOOK This safety handbook contains information on the intended use of the Baumüller b maXX safe PLC. Knowledge of regulations and proper technical implementation of the safety instructions in this handbook by qualified personnel are prerequisites for the safe installation, commis- sioning and safety during the operation and maintenance of the Baumüller b maXX safe PLC.
Page 16 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 17: Safety
AFETY This section provides an overview of all important safety aspects for the optimum protec- tion of the personnel as well as for safe and trouble-free operation. Contents of the Operation Manual All persons assigned to work on or with the device must have read and understood that Operation Manual before beginning work with the device.
Page 18: Intended Use
Intended use Intended use This device is exclusively designed and constructed for the intended purpose of use de- scribed here. The b maXX safe PLC uses for operation an attached power supply (BMC-M-PSB-02). Furthermore, the safety control can be expanded by the addition of various system com- ponents.
Page 19: Operator Responsibility
Safety Operator responsibility The device is implemented in an industrial zone. The operator of the device is thus sub- ject to the legal work safety obligations. In addition to the work safety instructions in this Operation Manual, the safety, accident prevention and environmental protection regulations applicable to the area of application of this device must also be complied with.
Page 20: Personnel Training
Personnel training Personnel training WARNING! Risk of injury if operated by insufficiently qualified persons! Improper handling can lead to severe personal injury and property damage. Therefore: m Only allow certain activities to be conducted by persons specified in the respective chapters of this Operation Manual.
Page 21: Personnel Protective Equipment
Safety Personnel protective equipment Wearing the appropriate personal protective equipment when working is required in order to minimize hazards to the health. m Always wear the respective protective equipment required for the respective task when working. m Observe signs on personal safety in the work area! Protective work clothes denotes tight-fitting work clothing with low tear resistance, tight sleeves and no pro- truding parts.
Page 22: Special Dangers
Special dangers Special dangers The residual risks arising as a result of the hazard analysis will be specified in the follow- ing section. Observe the safety instructions described here and the warning notices in the following chapters in order to reduce health hazards and avoid dangerous situations. Electric current DANGER! Live-threatening danger from electric current!
Page 23: Firefighting
Safety Moving parts WARNING! Risk of energy from moving parts! Rotating and/or linear moving parts can cause severe injuries. Therefore: m Do not interfere with moving parts during operation. m Do not open covers during operation. m The mechanical residual energy depends on the application. Powered parts will also keep rotating/moving for a certain time after the power supply has been shut off.
Page 24: Electric Safety
4.10 Electric safety 4.10 Electric safety The safety control is designed for contamination level 2 in accordance with EN 50178. This means that only non-conductive contamination may appear during operating time. Short-term conductivity from condensation is only permissible if the control is not in oper- ation.
Page 25: Conduct In The Event Of Danger And Accidents
Safety 4.12 Conduct in the event of danger and accidents m Always be prepared for accidents or fire! Preventative mea- sures m Keep first aid equipment (first aid kits, blankets, etc.) and fire extinguishers readily available. m Instruct personnel in accident reporting, first aid and rescue equipment. m Put the device out of operation immediately with the EMERGENCY STOP.
Page 26: Signage
4.13 Signage 4.13 Signage The following symbols and notification signs are found in the work area. They relate to the immediate environment in which they are placed. WARNING! Live-threatening danger from electric current! In the course of time, stickers and symbols on the device can become dirty or other- wise illegible.
Page 27: Functional Safety
UNCTIONAL AFETY This chapter describes parameters in relation to functional safety. First of all, in accor- dance with IEC 61508, safety means that a system is free of unwarranted risks. Function- al safety is the part of the overall safety, which ensures that a safety system’s response to its input conditions is free of errors.
Page 28 Safety-related parameters for 20 years of operation No proof test is necessary during the expected life cycle of the device of up to 20 years. CAUTION! If the user calculates his safety application with 20 years for the specified values, the safety control will have to be decommissioned and sent back to the manufacturer within not more than 20 years.
Page 29: Packaging And Shipping
ACKAGING AND SHIPPING Before shipping, we package every Baumüller device in such a manner that damaging occurring during transport is very unlikely. Shipping Modules are packaged at the factory according to the order. h Avoid heavy shaking and concussions when shipping. h Avoid static discharges to the electronic components of the module.
Page 30: Disposing Of The Packaging
Disposing of the packaging h Open the packaging of the device. h Check the items included in the delivery against the bill of delivery. The items included in the delivery are: m b maXX safe PLC, m this Operation Manual including certificate of conformity / manufacturer's declaration h if any shipping damages can be found or any items are missing from the delivery, file a complaint to the Baumüller representative assigned to you.
Page 31: Description Of The B Maxx Safe Plc Module
ESCRIPTION OF THE B MA SAFE MODULE This chapter describes the b maXX safe PLC module and the type code applied to the module. General The b maXX safe PLC is an SPC for the implementation of central, hybrid and decentral automation technology.
Page 32: Safety Programming
General ® The 3964R protocol is a registered trademark of Siemens AG. System compo- The scope of operation of the b maXX safe PLC can be expanded by the use of system nents components. Examples of available system components include: m CANopen master m EtherCAT master m Ethernet activation...
Page 33 Description of the b maXX safe PLC module Supported Data Types Supported Comment DWORD SAFEWORD SAFEINT SAFETIME SAFEBYTE Supported Functions and Function Blocks at Basic Level Supported Functions and Supported Comment FBs-Basic Level Type Conversion functions SAFEWORD_TO_SAFEBOOLS SAFEBOOLS_TO_SAFEWORD SAFEBOOL_TO_BOOL SAFEBYTE_TO_BYTE SAFEDWORD_TO_DWORD SAFEINT_TO_INT SAFETIME_TO_TIME...
Page 34 General Supported Functions and Supported Comment FBs-Extended Level GT, GE, EQ, LE, LT, NE GE, GT, EQ, LE, LT, NE Type conversion functions SAFEWORD_TO_SAFEBOOLS SAFEBOOLS_TO_SAFEWORD CTUD Bistable FBs SR, RS Edge detection F_TRIG, R_TRIG Overview of the safety function blocks Function Blocks Supported Comment SF_Equivalent...
Page 35: Configuration Of The Bmc-M-Saf-02
Description of the b maXX safe PLC module Configuration of the BMC-M-SAF-02 A = Jack (for additional BAUMULLER BAUMULLER BAUMULLER system components SAF-02 on the side) B = Plug (for power supply or CF card, if present; on the side)
Page 36: Interfaces
Interfaces BAUMULLER BAUMULLER BAUMULLER BAUMULLER SAF-02 PSB-02 Figure 2: b maXX safe PLC (BMC-M-SAF-02) with power supply Dual channel safety PLC Interfaces 123456678 123456678 BAUMULLER SAF-02 RS232 RS485 Figure 3: Connection diagram b maXX safe PLC taking the dual-channel safety PLC as an example Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04...
Page 37: Properties Of The Standard Plc
Description of the b maXX safe PLC module Properties of the standard PLC m 32-Bit RISC CPU 667 MHz m Program memory (Flash, 16-bit length) for saving the boot project 15 MB m Program memory (SDRAM, 32-bit length) 14 MB for executable program code n max.
Page 38: Properties Of The Power Supply Module
See the Operation Manual on the power supply for the b maXX controller/safe PLC Properties of the memory card module A = Jack (for PLC; on the side) BAUMULLER B = Plug (for the power supply; on the side) C = Unlocking handle (white, bottom)
Page 39: Danger Zones
Description of the b maXX safe PLC module Danger zones The following illustration provides an overview of the danger zones present on the mod- ule. BAUMULLER BAUMULLER BAUMULLER BAUMULLER SAF-02 CFI-01 Figure 5: Danger zones of the BMC-M-SAF-02 with memory card...
Page 40 Marking of the control - type code NOTICE! All modules in hardware version “-1x-” are not compatible with modules in hardware version “-0x-”, since the knife-edge contacts between the power supply, PLC and po- tential field bus modules have been changed. Only modules in version “-1x-” can be connected for that reason.
Page 41: Planning Of A Safety-Oriented Control System
LANNING OF A SAFETY ORIENTED CONTROL SYSTEM The entire process of defining the safety system is carried out in the planning phase. In addition to risk assessment, the planning contains the detailed definition of all system components, the definition of the system parameters and the detailed installation and wir- ing of the components.
Page 42 Risk assessment CAUTION! It is absolutely necessary to conduct the risk assessment during the planning phase and before conducting retrofitting work. The risk assessment should be conducted according to the procedure described in the following. Figure 6: Risk assessment procedure in accordance with DIN EN ISO 12100-1 and EN ISO 14121 Delineation of the system: Determination of the system’s boundaries and the intended use Hazard analysis:...
Page 43: Installation And Wiring Plan
Planning of a safety-oriented control system The determination of the required safety class (SIL, performance level) is carried out in the scope of risk assessment. The course of action in accordance with DIN EN ISO 13849-1 and IEC 62061 is described in the Application Handbook. Installation and wiring plan An installation and wiring plan for the entire safety system is to be compiled in the plan- ning phase.
Page 44 Course of the planning phase The system can be expanded to the right with the direct connection of I/O modules such as digital input and output modules, analog input and output modules, thermal elements such as PT100, counter modules, feed terminals as well as with digital input and output terminals.
Page 45: Assembly And Installation
SSEMBLY AND INSTALLATION This chapter describes the mechanical assembly and electrical installation of the b maXX safe PLC. The assembly and installation process consists of the following steps: 1 Assemble the module. 2 Connect the module to the power supply. General safety regulations CAUTION! ZC.2–...
Page 46: Requirements On The Personnel Conducting The Work
Be aware of all areas of the b maXX System which could pose a danger to you during the assembly process. The following illustration provides an overview of the danger zones present on the mod- ule. BAUMULLER BAUMULLER BAUMULLER BAUMULLER...
Page 47: Preparation For Assembly
Assembly and installation Preparation for assembly You can prepare for the assembly by using the project planning documents for your plant. You can determine the installation location and the dimensions for the mounting holes for ZInstallation space – the 35mm C-rails based on the installation space needed (see from page 47 onward).
Page 48: Assembly Instructions
Assembly instructions BMC-M-SAF-02 65 mm Minimum clearence 57 mm 30 mm 123456678 123456678 123456678 BAUMULLER BAUMULLER BAUMULLER BAUMULLER SAF-02 SAF-01 Depth: 91 mm CFI-01 76 mm Minimum clearence 84 mm 30 mm BMC-M-SAF-02 with memory card module Figure 8: Installation space b maXX System NOTICE! The specified spacings are minimum spacings.
Page 49 Check the type code on the type plate ("E" in ZFigure 1– on page 35 for BMC-M-SAF-02) to make sure that you have the correct module ready A = Jack (for additional BAUMULLER BAUMULLER BAUMULLER system components SAF-02 on the side) B = Plug (for power supply or CF card, if present;...
Page 50 1 Shut off the power to the power supply if necessary and make sure that it does not turn back on accidentally during the assembly work. Disconnect any already attached ca- bles or lines from the connections 2 Open the electrical cabinet 3 Plug the b maXX safe PLC into the power supply BAUMULLER BAUMULLER BAUMULLER BAUMULLER SAF-02...
Page 51 Assembly and installation BAUMULLER BAUMULLER BAUMULLER SAF-02 PSB-02 BAUMULLER PSB-01-0000 S_Nr.123456789 Figure 11: b maXX safe PLC with power supply 5 Use a small screwdriver to pull the orange handle on the right part of the power supply forward so that you can grip the handle easily...
Page 52 Assembly instructions 6 Set the module block onto the 35 mm C-rail and hold it firmly. 7 Pull the orange handle on the right part of the power supply further forward and press the module block backward at the same time. 8 Release the orange handle.
Page 53: Installation
Installation Wire the b maXX safe PLC module during the installation process. 9.6.1 Connection diagram 123456678 123456678 BAUMULLER SAF-02 RS232 RS485 Figure 13: Connection diagram of the b maXX safe PLC taking the dual-channel safety PLC as an example 9.6.2...
Page 54: Safety-Related Connection Technology
Installation In order to be able to fulfil the EN 60 204-1 standard (electrical equipment of machines), you will have to use the cables it recommends. The connection plugs must not be able to fall out - otherwise, the danger of short circuits, external voltage, etc. will arise. h Make sure that the connection cable is routed in a EMC-compatible manner.
Page 55: Installation Procedure
Assembly and installation 9.6.5 Installation procedure h Make sure that the power to the b maXX System has been switched off. h Make sure that the external power supply has been shut off and is secured from being switched back on. h Connect the 9-way SUB-D jack X1 to the front plate of the left part of the b maXX safe ZRequirements on PLC with the PROPROG programming cable (for more on this, see...
Page 56 Installation Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 57: Programming, Configuration And Parameterization With Prosafety
ROGRAMMING CONFIGURATION AND PARAMETERIZATION WITH AFETY NOTICE! Since the user administration is not initialized after the installation of ProSafety, the installation of ProSafety should be limited to authorized persons by company policy. Detailed instructions on programming the safety control can be found in the Application Handbook for the b maXX safe PLC or in ProSafety’s online help system Operation Manual b maXX safe PLC BMC-M-SAF-02...
Page 58 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 59: Commissioning
OMMISSIONING This chapter describes the process of starting up the assembled and installed (see ZAssembly and installation – from page 45 onward) b maXX safe PLC module for the ini- tial operation. The process of commissioning ensures that the b maXX safe PLC module functions properly.
Page 60: Description Of The Operation Modes, Run/Stop Switch
11.1 Description of the operation modes, RUN/STOP switch CAUTION! Adjusting the safe cycle time is only permissible if the reaction times established in the planning phase are complied with. In this case, computational evidence will have to be provided. ZTroubleshooting and rectification – Please take note of from page 83 onward for rectifying errors during the commissioning process.
Page 61: Combined Operation Of The Safety Plc
Commissioning may be potentially reached after the download or certain slaves may not be reached any longer (display in diagnostic markers). NOTICE! If a bus configuration on the standard PLC is present and a safety project including configuration files is present on the safety PLC, the safe communication will run in RUN status as well as the STOP status of the safety PLC.
Page 62: General Safety Regulations
11.2 General safety regulations NOTICE! The safe communication will only run if a bus configuration is present on the standard PLC, a safety project including configuration files is present on the safety PLC and the standard PLC is in RUN status. The status of the safety PLC ("RUN" or "STOP"), on the other hand, is of no concern.
Page 63: Requirements On The Personnel Conducting The Work
Commissioning 11.3 Requirements on the personnel conducting the work The commissioning work may only be conducted by professionally trained personnel, in particular persnnel which understands the safety regulations and can follow them. 11.4 Description/inspection of the safety and monitoring equipment Before commissioning the b maXX safe PLC module, you will have to make sure that the +24 V supply is properly connected to the power supply for the b maXX controller/safe PLC and that the +24 V supply matches the specifications.
Page 64: Description And Inspection Of The Operation And Display Elements
11.7 Description and inspection of the operation and display elements Once the fourth address is confirmed, the address will be overtaken and will enter into effect after the next restarting. The entry is aborted if you stop pushing button S1 on channel 2 of the PLC and button S1 on the power supply.
Page 65: Switching On And Initialization The Bmc-M-Saf-02
Commissioning 11.7.1.1 Switching on and initialization the BMC-M-SAF-02 m After being switched on, a basis initialization of the b maXX safe PLC is carried out which is necessary for the further initialization. H9 (blue) will turn on once this basis ini- tialization is complete.
Page 66: Operation Of The Bmc-M-Saf-02
11.7 Description and inspection of the operation and display elements m Project present, status “STOP”: → only LED H6 (red) lights up. m Project present, status “INIT”, the control is in cold start or warm start phase: → only LED H5 (green) lights up. m Project present, status “RUN”: →...
Page 67: Rotary Switch S1 Of Bmc-M-Saf-02
Commissioning 11.7.2 Rotary switch S1 of BMC-M-SAF-02 Rotary switch S1 of BMC-M-SAF-02 is intended for future developments and is not in use at this time. 11.7.3 S2 switch/button for changing operating statuses of the BMC-M-SAF-02 The b maXX safe PLC module has the S2 switch/button to change the operation statuses ZFigure 1–...
Page 68: Display On Channel 2 With The Bmc-M-Saf-02
11.7 Description and inspection of the operation and display elements 11.7.4 Display on channel 2 with the BMC-M-SAF-02 The 7-segment display has the following functions: Status Function ZSetting the station number – Normal operation Station number display. See from page 63 onward. One number of the four-digit station number is displayed per second.
Page 69: Commissioning Procedure
Commissioning LEDs Meaning H1 H2 H3 H4 ⊗ Control in RUN Control in STOP ⊗ Error in the control has occurred Control status OK ⊗ BLINKING: Inserted CF card detected during start-up or safety code entry is running ⊗ BLINKING: Copy code entry is running ⊗...
Page 70: Testing The Functioning Of The Bmc-M-Saf-02 (Standard Plc)
11.9 Startup and operation options with inserted memory card 11.8.2 Testing the functioning of the BMC-M-SAF-02 (standard PLC) m Two statuses can occur when the b maXX systems is switched on: n No boot project (= no user project on the standard PLC) present: The LED H2 (red) will light up briefly and then the LEDs H5 (green) and H6 (red) will light up steadily.
Page 71 Commissioning CAUTION! The programming of serial machines with a memory card is the responsibility of the machine manufacturer. In the process, special organizational measures will be nec- essary, which are also the responsibility of the machine manufacturer. If a memory card is inserted during the system startup, the data from the card will initially be compared to the data of the internal memory.
Page 72 11.9 Startup and operation options with inserted memory card CATION! Memory cards of the b maXX safe PLC-Systems may only contain the data of a b maXX safe PLC system and may not be used simultaneously for systems of other applications or for storing data not related to the application.
Page 73: Starting Behavior With Inserted Memory Card
Commissioning 11.9.2 Starting behavior with inserted memory card Is CF card available? Is a s afety project present on the C F card? Is the The control runs up project check sum to the “RUN” status. identical? Waiting for an entry yellow LED H3 blinks Press the button short Press the button long (>...
Page 74: Data Transfer From The Card To The Control
11.9 Startup and operation options with inserted memory card m Insert the memory card into the first slot of the CFI-01 CF module (see ZFigure 4– page 38). m Set the S2 switch/button on the b maXX safe PLC to "RUN" (switch down). m Switch on the +24 V DC of the electrical supply.
Page 75: Data Transfer From The Control To The Card
Commissioning The entry process can be repeated once if an incorrect code has been entered. The re- peat entry is activated by briefly pushing the S1 button on the CF module and the S1 but- ton on channel 2 of the PLC simultaneously. If the second code entry is also incorrect, it will not be possible to enter the code again.
Page 76 11.9 Startup and operation options with inserted memory card The code for triggering the entire project transfer including the configuration files of the standard PLC and safety PLC on the CF module is “01”. No further codes are assigned at this time. Code entry: 1 The 7-segment display on channel 2 of the PLC indicates the value of rotary switch S2 of the CF module in blinking numbers.
Page 77: Description And Inspection Of The Operating And Display Elements
Commissioning NOTICE! The standard PLC and the safety PLC will continue to run in the entire processing process, meaning that the online communication will also be running. NOTICE! Once the project has been copied to the memory card during only the residual time of the control, the procedure can take considerably longer than in running up or when the control is in “STOP”...
Page 78: Programming, Configuration And Parameterization With Prosafety
11.10 Programming, configuration and parameterization with ProSafety 11.10Programming, configuration and parameterization with ProSafety See >Application Handbook b maXX safe PLC<. Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 79: System Validation
YSTEM VALIDATION All safety functions as well as the trouble-free functioning of the installed and pro- grammed system must be tested with the initial operation. The testing of the system must be documented. WARNING! Danger during commissioning! The control system may only be put into commission after being tested successfully by a technical expert Therefore: m Conduct a complete function test.
Page 80 12.1 Function test The following course of action is recommended when conducting the function tests: 1 Separate all actuators and drives from the output terminals electrically. 2 Test the logic circuit by forcing variables in the ProSafety safe programming interface (see chapter “FORCING AND OVERWRITING“...
Page 81: Operation
PERATION DANGER! It is not permitted to make any changes to the system configuration during the oper- ation of the safety control. Therefore: m Before expanding the system and removing individual system components and making changes in the wiring, the control must as a rule be disconnected from the power source and put into safe condition by technical trained personnel.
Page 82 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 83: Troubleshooting And Rectification
ROUBLESHOOTING AND RECTIFICATION This chapter describes the error indications of the b maXX safe PLC module. We will de- scribe the meaning of each error indication and what you should do as a reaction. 14.1 Safety regulations ZSafety – Observe the applicable safety regulations, see from page 17 onward.
Page 84: Detecting Errors In The Periphery
14.3 Error diagnosis m The file system for the administration of application programs and program code is pro- tected from being changed by CRC values. Any changes detected will cause the sys- tem to go into safe status. Detecting errors with BMC-M-SAF-02 The standard PLC signals errors by means of the H4 LED (red) and H8(red).
Page 85 Troubleshooting and rectification CAUTION! I/O terminals which are used in a safety oriented manner must have suitable approv- al. Safe I/O terminals must have an own diagnostic procedure. Diagnostic results can be transmitted to the safety control via the bus protocol. The extent of the diagnostic options depends on the I/O terminals used.
Page 86: Reaction Im The Event Of An Error, Diagnostic Messages
14.4 Reaction im the event of an error, diagnostic messages THis LED will not be relevant to you if you want to use the b maXX safe PLC and further modules without the I/O bus. Yes: Check the contacts between the b maXX safe PLC and power supply for bent pins.
Page 87: Exchanging Devices
Troubleshooting and rectification 14.6 Exchanging devices If a defect in the safety system is detected, the safety control will have to be taken out of operation immediately. If a memory card with a complete copy of the application and con- figuration data for the affected safety control is available, the safety control can be re- placed with a new safety control without having to use the safe programming interface.
Page 88: Error Messages On Channel 2 Of The Bmc-M-Saf-02
14.7 Error messages on channel 2 of the BMC-M-SAF-02 CAUTION! It is necessary to label defective components to indicate that they are defective. It is absolutely necessary to prevent defective components from being reused by taking measures in the scope of quality management on the user’s side (see also the chap- ZRepairs –...
Page 89: Maintenance
AINTENANCE ZAppendix D - If you are complying with the mandatory environmental conditions, see Technical data– page 115), then the b maXX safe PLC is maintenance-free. If you detect or suspect a defect in the b maXX safe PLC module, contact Baumüller Nürnberg GmbH. CAUTION! Take organizational measures to make sure that the interval for the repeat testing of ZSafety-related parameters for 10...
Page 90 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 91: Repairs
EPAIRS You cannot repair a defective b maXX safe PLC module. Please contact Baumüller Nürn- berg GmbH for a replacement. CAUTION! Defective components may only be repaired by the manufacturer. Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 of 118...
Page 92 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 93: Disassembly, Storage
ISASSEMBLY STORAGE This chapter describes how to decommission the b maXX safe PLC module and store it. 17.1 Safety regulations h Observe ZSafety – from page 17 onward. CAUTION! Damage through electrical destruction. The component assembly can be destroyed by electricity if it is removed when the power is turned on.
Page 94: Requirements On The Personnel Carrying Out The Work
17.2 Requirements on the personnel carrying out the work 17.2 Requirements on the personnel carrying out the work The personnel you assign to carry out the disassembly must have the knowledge and training necessary to perform this work properly. The personnel should be selected so that it will be able to understand and use the safety instructions attached to the device and its components as well as the connections.
Page 95 Disassembly, storage BAUMULLER BAUMULLER BAUMULLER SAF-02 PSB-02 BAUMULLER PSB-01-0000 S_Nr.123456789 Figure 19: b maXX safe PLC with power supply, taking the dual-channel safety PLC as an example 7 Pull the orange handle on the right part of the power supply forward (with a screwdriv- er, for instance), so that you can get a good grip on it.
Page 96: Storage Conditions
17.4 Storage conditions 8 Pull (by hand) the orange handle on the right part of the power supply further forward and then pull the module block forward, thus removing it from the 35 mm C-rail. The module block comprises the power supply, the b maXX safe PLC and, if applica- ble, additional system components for the b maXX safe PLC.
Page 97: Disposal
ISPOSAL This chapter describes the proper and safe disposal of the b maXX safe PLC module. For the most part, it can be classified as electronic scrap. m Prerequisite: The disassembly process has already been carried out, see ZDisassembly, storage – from page 93 onward.
Page 98: Recycling Collection Center/Offices
18.4 Recycling collection center/offices 18.4 Recycling collection center/offices Make sure that the disposal is carried out in compliance with your company’s disposal guidelines as well as those of the competent recycling collection centers and offices. In the event of uncertainty, contact the industrial inspectorate responsible for your company or the environmental agency.
Page 99: Appendixa - Abbreviations
A - A PPENDIX BBREVIATIONS Controller Area Network Central Processing Unit Diagnostic Coverage DRAM Dynamic RAM Electromagnetic compatibility European standard Electrostatic sensitive device EXT, ext External Input/Output I/O bus Bus between b maXX safe PLC and the modules right of the PLC and/or power supply Light-emitting diode MTTF...
Page 100 Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 101: Appendix B - Accessories
B - A PPENDIX CCESSORIES This appendix lists all accessory items which are available from Baumüller Nürnberg GmbH for the b maXX safe PLC module. If you have enquiries or suggestions on the accessory items, the Baumüller product man- agement will be glad to assist you. List of all accessory items B.1.1 Programming cable (serial RS232) Conduction type: K-SS-01-xx (9-way sub-D, 9-way sub-D):...
Page 102 List of all accessory items Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 103: Appendixc - Checklists
C - C PPENDIX HECKLISTS The use of checklists serves documentation purposes and guides in the implementation of a safety system. The checklists reproduced in Appendix C - Checklists serve to prevent errors and must be processed carefully for every project. It is also required to make cop- ies of the printed checklists.
Page 104 Planning checklist Seria Fulfilled l no. Requirement Remarks Does the wiring of the safety components meet the requirements of the previously determined safety classification? (Example: Dual-channel wiring of an emergency stop for SIL 2 application) Do the components meet the environmen- tal conditions prevailing in the application? Does the system fulfil the required type of protection?
Page 105: Installation Checklist
Checklists Installation checklist Seria Requirement Fulfilled Remarks l no. Yes No Installation Has it been ensured that there are no short circuits from the wiring of the input and out- put terminals? Has it been ensured that the safety switch devices have not been bypassed as a result of wiring errors? Has a wiring inspection in accordance with...
Page 106: Commissioning And Validation Checklist
Commissioning and validation checklist Commissioning and validation checklist Seria Requirement Fulfilled Remarks l no. Yes No Commissioning Has it been ensured that all safe communi- cation participants of a system have a unique safe device address? This also applies to participants belonging to different safety controls, if the controls are connected to one another via gateways (such as ether- net).
Page 107: Modification And Retrofitting Check List
Checklists Modification and retrofitting check list Seria Requirement Fulfilled Remarks l no. Yes No Modification and retrofitting Is the modification/retrofitting of the system compatible? Do all of the checklist’s require- ments on the planning, installation and com- missioning/validating continue to be fulfilled? Are the calculated reaction times still com- plied with after the modification/retrofitting?
Page 108 Modification and retrofitting check list Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 109: Appendix D - Technical Data
D - T PPENDIX ECHNICAL DATA This appendix contains the technical data for the b maXX safe PLC module from Baumüller Nürnberg GmbH. Connection values D.1.1 BMC-M-SAF-02 Processor Clock frequency Channel 1: 667 MHz Channel 2: 400 MHz Power supply +5 V DC internal Power consumption typ.
Page 110: Operational Conditions
Operational conditions Operational conditions D.2.1 Climatic properties Environmental conditions 0°C ... 55°C 95% relative humidity, no condensation Storage conditions -25°C ... 85°C 95% relative humidity, no condensation Transport conditions -25°C ... 85°C 95% relative humidity, no condensation WARNING! The operating conditions specified in the table above may not be exceeded at any time.
Page 111: Pin Configuration Of Sub-D Socket For Rs232 Interface
Technical data D.2.3 EMC properties EMC resistance / emission in accordance with EN 61000-6-2 / EN 61000-6-4 Pin configuration of sub-D socket for RS232 interface Pin no. Configuration Not allocated TxD (transmit data) RxD (receive data) Connected to pin 6 GND (signal ground) Connected to pin 4 CTS (clear to send)
Page 112: Memory Cards For Cf Cards (Bmc-M-Cfi-01)
Memory cards for CF cards (BMC-M-CFI-01) NOTICE! The signal grounds of the RS232 and RS485 interfaces are connected to one anoth- CAUTION! Danger from electrical short circuit. An electrical short circuit can damage the device. Therefore: m The +5 V on pin 2 of the X2 sub-D socket of the b maXX safe PLC module are only intended for the supply of external Baumüller RS485/RS232 converters and may not be bypassed or connector to one another in a ring.
Page 113: Appendix E - Declaration Of Conformity
E - D PPENDIX ECLARATION OF ONFORMITY In this section we provide general information about EC directives, the CE symbol and the Declaration of Conformity. What is an EC directive? EC directives specify requirements. The directives are written by the relevant bodies with- in the EU (which used to be called the EC, and the EEC before that, hence the now illog- ical term EC directive), and are implemented by all the member countries of the EU in national law.
Page 114: Definition Of The Term Declaration Of Conformity
Definition of the term Declaration of Conformity The electrical safety and function of the control system will be checked with the harmo- nized standard EN 61131-2. With specified application of this Baumüller equipment in your machinery, you can act on the assumption that the equipment satisfies the requirements of 2006/42/EC (machinery directive).
Page 115 Declaration of Conformity Declaration of EC conformity Doc.-Nr: 5.10069 Date: 01 Feb. 2011 according to machinery directive 2006/42/EC We the manufacturer: Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nürnberg, GERMANY declare that our product Name: Programmable Safety Controller b maXX safe PLC Type: BMC-M-SAF-02/BMC-M-CFI-01/BMC-M-PSB-02 Date of manufacture:...
Page 116 Declaration of Conformity Operation Manual b maXX safe PLC BMC-M-SAF-02 Document no.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 117 Index Numerics 2004/108/EC HMI Interface 2006/42/EC Connection 2006/95/EC Installation plan Assembly instructions Installation space Intended use Interfaces Baumüller BMC-M-SAF-02 13, 35 Communication Limitation of liability Display elements Low Voltage Directive LED display Machinery directive CE symbol Mean Time To Failure (MTTFd) Checklists Mechanical properties Conformity...
Page 118 Stichwortverzeichnis Standard PLC Properties STOP 66, 69 Storage Switch/button Switch/Button S2 Switch/button S2 Switching on System components Technical Data Technology functions Terms Definition Testing the functioning Type code Module Waranty conditions Wiring plan Operating Instructions b maXX safe PLC BMC-M-SAF-02 Document No.: 5.07020.04 Baumüller Nürnberg GmbH of 118...
Page 120 Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nuremberg Tel: +49(0)911-5432-0 Fax: +49(0)911-5432-130 www.baumueller.de All the information in these Operating Instructions is non-binding customer information; it is subject to ongoing further development and is updated on a continuous basis by our permanent change management system. Note that all the data/numbers/information that are quoted are current values at the time of printing. This information is not legally binding for dimensioning, calculation and costing.

Baumuller b maXX BMC-M-SAF-02 Operating Instructions Manual

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