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Pilz PMCprotego S1 Operating Manual
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Pilz PMCprotego S1 Operating Manual

Pilz PMCprotego S1 Operating Manual

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Operating Manual PMCprotego S1
Operating Manual PMCprotego S1
PMCprotego S1
Safety Card - Servo amplifiers
Operating Manual — No. 1001431-EN-06

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Summary of Contents for Pilz PMCprotego S1

  • Page 1 Operating Manual PMCprotego S1 Operating Manual PMCprotego S1 PMCprotego S1 Safety Card - Servo amplifiers Operating Manual — No. 1001431-EN-06...
  • Page 2 Preface This document is a translation of the original document. All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made for internal purposes. Suggestions and comments for improving this documentation will be gratefully received.

  • Page 3: Table Of Contents

    Contents Contents Contents Page Chapter 1 Introduction Validity of documentation 1.1.1 Retaining the documentation Overview of documentation Definition of symbols Chapter 2 Overview Unit structure 2.1.1 Unit features Front view Chapter 3 Safety Intended use 3.1.1 Permitted motor types 3.1.2 Permitted motor encoder types 3.1.3 Use of qualified personnel...
  • Page 4 Contents Chapter 5 Installation General requirements Dimensions Installing the safety card Chapter 6 Wiring General wiring guidelines Connector pin assignment Shielding Digital inputs Digital outputs 6.5.1 Supply voltage 6.5.2 Single-pole outputs 6.5.3 Dual-pole outputs Encoder 6.6.1 Supply voltage 6.6.2 Incremental encoder with TTL signal Chapter 7 Commissioning Safety guidelines Initial commissioning...
  • Page 5 Contents 9.2.1.1 MTTF >= 10 years 9.2.1.2 MTTF >= 57 years 9.2.2 Safe actuator with two encoders Chapter 10 Glossary...
  • Page 6 Contents...

  • Page 7: Chapter 1 Introduction

    Validity of documentation 1100 Validity of documentation 1- Einf Gltigkeit der Dokumentation This documentation is valid for the product PMCprotego S1. It is valid until new documentation is published. ][BA_Einfhrung_Einleitung This operating manual explains the function and operation, describes the installation and provides guidelines on how to connect the product PMCprotego S1.

  • Page 8: Overview Of Documentation

    Introduction Overview of documentation Overview of documentation 1200 Overview of documentation 1- Einf_Uebersicht_Doku 1 Introduction The introduction is designed to familiarise you with the contents, struc- ture and specific order of this manual. 2 Overview This chapter provides information on the product's most important fea- tures.

  • Page 9: Definition Of Symbols

    Introduction Definition of symbols Definition of symbols 1300 Definition of symbols 1- Einfhrung Zeichen Information that is particularly important is identified as follows: DANGER! This warning must be heeded! It warns of a hazardous situation that poses an immediate threat of serious injury and death and indicates preventive measures that can be taken.
  • Page 10 Introduction Definition of symbols...

  • Page 11: Chapter 2 Overview

    2100 Unit structure 2- Uebersicht_Merkmale The safety card PMCprotego S1 is an expansion of the servo amplifier PMCprotego D. It is used for safe motion monitoring, which is achieved in conjunction with the standard motor encoder and servo amplifier. In the event of an error, the servo amplifier's power element shuts down the power quickly and safely.
  • Page 12 Overview Unit structure LEDs for Supply voltage (POWER)  System status (RUN)  Download of configuration data (CONFIG)  Fault (FAULT) ...

  • Page 13: Front View

    Overview Front view Front view 2200 Front view 2- Uebersicht_Front_Voll POWER CONFIG FAULT 8176105 12 100001 Uebersicht_Front_Legende_Basis Key: 1: Screw for attachment to the servo amplifier  2: LEDs to display operating states  3: Inputs/outputs and supply voltage  4: Labelling strip with: ...
  • Page 14 Overview...
  • Page 15 Intended use 3100 Intended use 3- ][BA_Sicherheit_Bestimmung_FS The safety card PMCprotego S1 is an expansion of the servo amplifier PMCprotego D. It is designed for use in safety-related applications. Sicherheit_Bestimm_prot_S It meets the requirements for safety functions in accordance with EN 61800-5-2, with regard to safe motion monitoring.

  • Page 16: Intended Use

    Safety Intended use The safety card PMCprotego S1 from Version 1.0 may only be used in conjunction with the following servo amplifiers: PMCprotego D.01 from Version 1.1  PMCprotego D.03 from Version 1.1  PMCprotego D.06 from Version 1.1 ...

  • Page 17: Use Of Qualified Personnel

    Safety Intended use 3.1.3 Use of qualified personnel Use of qualified personnel 3- Sich Qualif. Personal The products may only be assembled, installed, programmed, commis- sioned, operated, maintained and decommissioned by competent per- sons. A competent person is someone who, because of their training, experi- ence and current professional activity, has the specialist knowledge re- quired to test, assess and operate the work equipment, devices, systems, plant and machinery in accordance with the general standards...

  • Page 18: Standards

    Safety Standards Standards 3200 Standards 3- Sicherheit_Normen_Sicherheitskarte Knowledge of and compliance with the relevant standards and direc- tives are a prerequisite for using the safety card. The following standards are relevant: EN 61326-3-1:2008: Electrical equipment for measurement, control  and laboratory use - EMC requirements EN 61800-3:2004: Adjustable speed electrical drives ...

  • Page 19: Chapter 4 Function Description

    The safety card is built into a servo amplifier PMCprotego D. This con- verts the servo amplifier into a safe servo amplifier. Funkt_Uebersicht_Antriebssystem A safe drive system from Pilz consists of the following: Servo amplifier (PMCprotego D)  Safety card PMCprotego S built into the servo amplifier ...
  • Page 20 Function Description Overview The safety card Activates safety functions  Monitors safe motion sequences  Signals the status of safety functions to the safety control system  In the event of an error, activates the safe pulse disabler which is in- ...

  • Page 21: Inputs And Outputs

    Function Description Inputs and outputs Inputs and outputs 4200 Inputs and outputs 4.2.1 Inputs Inputs 4- Funkt_Eingaenge_Sich The single-pole digital inputs are used to activate the safety functions. SS1 Activate: Safe stop 1  SS2 Activate: Safe stop 2  SOS Activate: Safe operational stop ...
  • Page 22 Function Description Inputs and outputs  SOS Acknowledge – 1: Motor is within the permitted limit values for standstill. – 0: Standstill monitoring is inactive or motor is outside the standstill range  SDI Acknowledge – 1: Drive is moving in the permitted direction. –...

  • Page 23: Dual-Pole Outputs

    Function Description Inputs and outputs Signals at the output “0” signal (0 V) at the output:  – Output is high impedance – No current to the load – Safety function not activated “1” signal (+24 V) at the output: ...

  • Page 24: Output Test

    Function Description Inputs and outputs 4.2.2.3 Output test Output test 4- Funkt_Ausgaenge_Test The outputs are tested regularly: Outputs that are switched on are checked via regular off tests.  – Test pulses for outputs that are switched on: see technical details –...
  • Page 25 Function Description Inputs and outputs Characteristic: Output capacitance C dependent on load current I C [µF] I [A]...
  • Page 26 Function Description Safety functions Safety functions 4300 Safety functions 4- Funkt_Sicherheitsfunktion_Allg Safety functions maintain a safe condition on a plant or prevent hazard- ous conditions arising on a plant. The safety functions for electrical drives are defined in EN 61800-5-2. The safety card implements the following safety functions: Safe stop 1 (SS1) ...
  • Page 27 Function Description Safety functions 4.3.1 Safe torque off - STO Safe torque off - STO 4- Sicherheitsfunktion_STO_Ueber_S1 The safety function "Safe Torque Off" (STO) removes the power to the motor. It is implemented via the servo amplifier's shutdown path and the safety card's safe outputs.

  • Page 28: Safety Functions

    Function Description Safety functions Reaction: The drive is switched to torque-free  "STO Acknowledge" output: “1” Signal  Sicherheitsfunktion_haengende_Lasten If any external forces influence the motor axis (e.g. suspended loads), additional measures (e.g. a safety holding brake) are required in order to eliminate hazards.
  • Page 29 Function Description Safety functions Features of the safety function: The motor becomes torque-free and no longer generates any hazard-  ous movements. The safety function "safe stop 1" corresponds to a category 1 stop  (controlled braking) in accordance with EN 60204-1. Sicherheitsfunktion_Sxx_Ueberwach The safety card monitors the following functions: Braking ramp...
  • Page 30 Function Description Safety functions The safety function is activated via 1/0 pulse edge at the input "SS1 Activate"  1/0 pulse edge at the input "SS1 SIL3/Reset"  Internal error  Signal status of the inputs "SS1 Activate" and "SS1 SIL3/Reset" The STO delay time starts when one of the two inputs "SS1 Activate"...
  • Page 31 Function Description Safety functions Reaction Controlled braking of the drive, with the configured braking ramp.  When the STO delay time has elapsed, the safety card activates the  safety function "safe torque off" (STO). The motor becomes torque- free. "STO Acknowledge"...

  • Page 32: Safe Stop 2 - Ss2

    Function Description Safety functions Timing diagram: STO is started during the STO delay time Braking ramp Tolerance window Braking ramp Limit value Standstill detection STO delay time SS1 Activate SS1 SIL3/Reset Ready STO Acknowledge Fig. 4-3: Safety function SS1 : Activation of safety function SS1 ...

  • Page 33: The Safety Card Monitors The Following Functions: Braking Ramp

    Function Description Safety functions The safety card monitors the following functions: Braking ramp  Sicherheitsfunktion_SS1_SS2_Ueberwach_Bremsrampe In the Configurator, the braking ramp is specified and monitoring is activated. The braking period depends on the speed of the motor when braking is started. The braking ramp can be monitored via a maximum position error specified in the Configurator.
  • Page 34 Function Description Safety functions Input Input Safety Card Safety Card Controller Servo Amplifier Servo Amplifier Drive-activated braking ramp Controller-activated braking ramp Sicherheitsfunktion_SS2_Reaktion Reaction: Controlled braking of the drive, with the configured braking ramp.  The drive remains in a controlled standstill and is monitored for "safe ...

  • Page 35: Safe Operating Stop - Sos

    Function Description Safety functions Timing diagram Braking ramp s, v Tolerance window Standstill position s (t) Tolerance window Braking ramp v (t) Limit value Standstill detection SOS delay time SS1 Activate SS1 SIL3/Reset SS2 Activate Ready STO Acknowledge SOS Acknowledge Fig.

  • Page 36: Specified In The Configurator

    Function Description Safety functions Features of the safety function: The drive's control functions are maintained in the standstill position.  Power to the motor is not shut down.  Sicherheitsfunktion_Sxx_Ueberwach The safety card monitors the following functions: Standstill position  Sicherheitsfunktion_SS2_SOS_Ueberwach_Stillstand_Pos –...
  • Page 37 Function Description Safety functions Timing diagram s, v Tolerance window Standstill position s (t) v (t) Limit value Standstill detection SOS delay time SS1 Activate SS1 SIL3/Reset SOS Activate Ready STO Acknowledge SOS Acknowledge Fig. 4-5: Safety function SOS t1: Activation of safety function SOS ...

  • Page 38: Safely Limited Speed - Sls

    Function Description Safety functions 4.3.5 Safely limited speed - SLS Safely limited speed - SLS 4- Sicherheitsfunktion_SLS_Ueber The safety function "safely limited speed" (SLS) monitors the drive to check that it stays within a defined speed limit. Sicherheitsfunktion_Sxx_Voraussetzung_S1 Prerequisites for normal operation: Input "SS1 Activate"...
  • Page 39 Function Description Safety functions Reaction: If the tolerance range is exceeded, the safety function SS1 (E-STOP  braking ramp) is activated. The following diagrams illustrate the sequences, with and without the tolerance range activated. Sicherheitsfunktion_SLS_S1_oT_Diagramm Timing diagram without tolerance range activated Speed limit value + Speed...
  • Page 40 Function Description Safety functions Sicherheitsfunktion_SLS_S1_mT_Diagramm Timing diagram with tolerance range activated Tolerance amount Speed limit value + Speed limit value - Tolerance amount SLS delay time SS1 Activate SS1 SIL3/Reset SLS Activate Ready STO Acknowledge SRA Acknowledge Fig. 4-7: Safety function SLS with tolerance range activated Tolerance amount as % of the speed limit value ...

  • Page 41: Safe Speed Range - Ssr

    Function Description Safety functions STO Acknowledge: Output for feedback from safety function STO  SRA Acknowledge: Output for monitoring the limit value on the motor  4.3.6 Safe speed range - SSR Safe speed range - SSR 4- Sicherheitsfunktion_SSR_Ueber The safety function "safe speed range" (SSR) monitors the drive's cur- rent speed to ensure it stays within a maximum and minimum permitted limit value.
  • Page 42 Function Description Safety functions Activate the tolerance range: The tolerance range becomes active the first time the speed limit val-  ue is exceeded (see flowchart). Reaction: If the tolerance range is exceeded, the safety function SS1 (E-STOP  braking ramp) is activated. The following diagrams illustrate the sequences, with and without the tolerance range activated.
  • Page 43 Function Description Safety functions SSR Activate: Input for safety function SLS  Ready: Output for operating status of the safety card  STO Acknowledge: Output for feedback from safety function STO  SRA Acknowledge: Output for monitoring the limit value on the motor ...

  • Page 44: Safe Direction - Sdi

    Function Description Safety functions : Tolerance period  SS1 Activate: Input for safety function SS1  Sicherheitsfunktion_Legende_SSR_S1 SS1 SIL3/Reset: Input for SIL3 and reset  SSR Activate: Input for safety function SLS  Ready: Output for operating status of the safety card ...
  • Page 45 Function Description Safety functions Timing diagram s (t) Tolerance window SDI delay time SS1 Activate SS1 SIL3/Reset SDi Neg Activate SDi Pos Activate Ready STO Acknowledge SDI Acknowledge Fig. 4-10: Safety function SDI : Activation of safety function SDI  : Once the SDI delay time has elapsed, the direction of rotation is ...
  • Page 46 Function Description Safety functions If an SDI delay time t has been configured, it will start when the new direction of rotation monitoring is activated. In A, the SDI delay time is shown = 0. The SDI delay time can be used to optimise the time taken to switch ...
  • Page 47 Function Description Safety functions Tolerance window SDI delay time SS1 Activate SS1 SIL3/Reset SDI Neg Activate SDI Pos Activate Ready STO Acknowledge SDI Acknowledge Fig. 4-12: Changing the direction of rotation with SDI delay time : Activation of safety function SDI in negative direction of rotation ...

  • Page 48: Safe Brake Control - Sbc

    Function Description Safety functions 4.3.8 Safe brake control - SBC Safe brake control - SBC 4- Sicherheitsfunktion_SBC_Ueber The safety function "safe brake control" (SBC) is used to control external brakes. Features of the safety function: After executing safety functions STO and SS1, an additional mechan- ...

  • Page 49: Safe Brake Test - Sbt

    Function Description Safety functions Timing diagram v, I B v(t) I B (t) SS1 Activate SS1 SIL3/Reset Ready STO Acknowledge SBC+/SBC- Fig. 4-13: Safety function SBC : Activation of safety function STO and SBC  : End of safety function SBC ...
  • Page 50 Function Description Safety functions The safety card monitors the following functions: During the brake test, the safety function SOS performs position mon-  Sicherheitsfunktion_SBT_Ueberwach itoring. The brake test must be carried out cyclically within a defined test pe-  riod, after 8 hours at the latest. The test period and tolerance time can be set in the Configurator.
  • Page 51 Function Description Safety functions Timing diagram v, I M v(t) I M (t) SBT delay time Monitoring period Delay time Delay time Ventilation Energisation SS1 Activate SS1 SIL3/Reset Ready SBT Activate SBT Acknowledge STO Acknowledge SOS Acknowledge SBC+/SBC- Fig. 4-14: Safety function SBT : Activation of safety function SBT, start of SBT delay time ...
  • Page 52 Function Description Safety functions SOS Acknowledge: Output for feedback from safety function SOS  SBC+: Brake control output  4-34...

  • Page 53: Operating Mode Of The Servo Amplifier

    Function Description Operating mode of the servo amplifier Operating mode of the servo amplifier 4400 Operating mode of the servo amplifier 4- Funkt_Uebergaenge_Zustaende Activation of safety functions SS1 and SS2 has repercussions on the servo amplifier's operating mode: SS1 when OPMODE = 0 ... 8 The drive-activated safety function "safe stop 1"...
  • Page 54 Function Description Operating mode of the servo amplifier SS2 when OPMODE = 0 ... 8 With the drive-activated safety function "safe stop 2" (SS2), the  movement is ultimately continued. The status of the safety card (SS2 activated) is transmitted to the ser- ...
  • Page 55 Function Description Operating mode of the servo amplifier INFORMATION Further information on the command can be found in the servo amplifier's online help, on the "Motion Control" CD (file ascii_dd5-protego.chm). Please also refer to the operating instructions for the servo amplifier. 4-37...

  • Page 56: Reaction Times

    Function Description Reaction times Reaction times 4500 Reaction times 4- Funkt_Reaktionszeiten The reaction times refer exclusively to the inputs and outputs on a servo amplifier with safety card when: The signal at the inputs changes  The limit value is exceeded ...
  • Page 57 Function Description Reaction times PMCprotego Sx PMCprotego Dx Input Controller Output Pulse disabler Power element CYCLE PULSE t (ms) Error reaction time = 2 ms Response time = 4 ms 4-39...

  • Page 58: Configuration

    Function Description Configuration Configuration 4600 Configuration 4- Funkt_Konfiguration The safety functions to be carried out by the safety card are defined in the safety card's configurator: Configuration of the safety functions  Setting of limit values, braking ramps for the safety functions, moni- ...

  • Page 59: Chapter 5 Installation

    Installation General requirements 5 5 000 Installation Installation 5- 5.1 General requirements 5100 General requirements 5- Montage_Allg Please also refer to the operating manual for the servo amplifier. CAUTION! Damage due to electrostatic discharge! Electrostatic discharge can damage components. Ensure dis- charge before touching the safety card, e.g.

  • Page 60: Dimensions

    Installation Dimensions Dimensions 5200 Dimensions 5- Montage 103 (4.06") 18,5 87,5 (3.45") (0.73") Fig. 5-1: Dimensions stated in mm (")

  • Page 61: Installing The Safety Card

    Installation Installing the safety card Installing the safety card 5300 Installing the safety card 5- Montage_S1 The expansion card is installed in slot 3 of the servo amplifier. When in- stalling, please note the guidelines given under "Installation" in the op- erating manual for the servo amplifier.
  • Page 62 Installation...

  • Page 63: Chapter 6 Wiring

    Wiring General wiring guidelines 6 6 000 Wiring Wiring 6- 6.1 General wiring guidelines 6100 General wiring guidelines 6- Verdr_Allgemein_S1_S2 Inputs Appropriate wiring must be used to exclude short circuits between  the inputs or to a supply line! Signal lines must be shielded. ...

  • Page 64: Connector Pin Assignment

    Wiring Connector pin assignment Connector pin assignment 6200 Connector pin assignment 6- Verdr_X30_Belegung_S1 Name Description SS1 Activate Activate safety function SS1 SS2 Activate Activate safety function SS2 SOS Activate Activate safety function SOS SLS Activate Activate safety function SLS STO Acknowledge Status: STO activated SOS Acknowledge Status: SOS activated...

  • Page 65: Shielding

    Wiring Shielding Shielding 6300 Shielding 6- Verdr_Schirmung_S1 For immunity reasons, the signal lines for the digital inputs, outputs and encoder must be shielded: All shielded cables are to be attached at both ends to the shield ter-  minals provided or should be connected to the connector housing. Use cables with a braided shield, with a minimum coverage of 80 %.

  • Page 66: Digital Inputs

    Wiring Digital inputs Digital inputs 6400 Digital inputs 6- Verdr_DI_Belegung_S1 Connector pin assignment Connector X30 Designation Description SS1 Activate Activate safety function SS1 SS2 Activate Activate safety function SS2 SOS Activate Activate safety function SOS SLS Activate Activate safety function SLS SSR Activate Activate safety function SSR SDI Neg Activate...

  • Page 67: Digital Outputs

    Wiring Digital outputs Digital outputs 6500 Digital outputs 6.5.1 Supply voltage Supply voltage 6- Verdr_DO_Versorgung The digital outputs need a 24 VDC supply. When selecting the power supply, please refer to the requirements  stated under “Technical Details”. The power supply must be able to bridge a power outage of 20 ms. ...

  • Page 68: Single-Pole Outputs

    Wiring Digital outputs *) XGND: PMCprotego D.01 … D.24:  X4A, Pin 2 PMCprotego D.48/D.72:  X4, Pin 3 6.5.2 Single-pole outputs Single-pole outputs 6- Verdr_DO_Belegung_S1 Connector pin assignment Connector X30 Name Description STO Acknowledge Status: STO activated SOS Acknowledge Status: SOS activated SDI Acknowledge Status: SDI activated...

  • Page 69: Dual-Pole Outputs

    Wiring Digital outputs Connection Output circuit Digital output 24 VDC Servo Amplifier Referenced to earth: 0V Supply STO SIL3 STO2-ENABLE XGND Verdr_XGND_protego *) XGND: PMCprotego D.01 … D.24:  X4A, Pin 2 PMCprotego D.48/D.72:  X4, Pin 3 Verdr_STO2-ENABLE_protego **) STO2-ENABLE: PMCprotego D.01 …...
  • Page 70 Wiring Digital outputs Connection External mechanical brake Digital output Shielded cable Max. cable length: 30 m SBC+ Brake's supply voltage: 24 VDC, SBC- tolerance 0 … 15% 21, 22 *) Please note the following: Link X30, Pin 21 or 22 to XGND on Servo Amplifier the servo amplifier XGND...

  • Page 71: Encoder

    Wiring Encoder Encoder 6600 Encoder 6.6.1 Supply voltage Supply voltage 6- Verdr_Versorgung_Warnung WARNING! Electric shock! Safe electrical isolation must be ensured for the external power supply that generates the supply voltage. Failure to do so could result in electric shock. The power supplies must comply with EN 60950-1, 05/2006, EN 61558-2-6, 11/1997.

  • Page 72: Incremental Encoder With Ttl Signal

    Wiring Encoder 6.6.2 Incremental encoder with TTL signal Incremental encoder with TTL signal 6- Verdr_X31_Inkrementalgeber If the cable length is > 50 m, please speak to our Customer Support. Connector pin assignment Connector X31 Name Description Channel A Channel B Reference pulse Z Supply voltage n.c.

  • Page 73: Chapter 7 Commissioning

    Commissioning Safety guidelines 7 7 000 Commissioning Commissioning 7- 7.1 Safety guidelines 7100 Safety guidelines 7- Inbetrieb_Sicherheit When commissioning/recommissioning, please note the following: Secure the site in accordance with the regulations (barrier, warning  signs etc.). The system may only be commissioned/recommissioned by qualified personnel.

  • Page 74: Initial Commissioning

    Commissioning Initial commissioning Initial commissioning 7200 Initial commissioning 7- Inbetrieb_Erstinbetrieb_1_S1 1. Preparing for commissioning The safety card has been properly configured in the Configurator.  Please ensure that you only configure the safety functions that are actually wired up to the safety card inputs. INFORMATION When configuring the safety card, please refer to the Configura- tor's online help.
  • Page 75 Commissioning Initial commissioning 4. Switch on the supply voltages Switch on all the supply voltages for the servo amplifier and safety  card. You will know when the servo amplifier and safety card are ready for operation by the display elements on the individual components. The display elements on the safety card are described in this manual, un- der "Operation".
  • Page 76 Commissioning Initial commissioning SS1 Activate SS1 SIL3/Reset STO Acknowledge Ready LED "CONFIG" LED "RUN" CONFIG STARTUP SS1 Activate: Input for safety function SS1  SS1 SIL3/Reset: Input for SIL3 and reset  STO Acknowledge: Output for feedback from safety function STO ...

  • Page 77: Recommissioning

    Commissioning Recommissioning Recommissioning 7300 Recommissioning 7.3.1 Recommissioning at a restart Recommissioning at a restart 7- Inbetrieb_Neustart The timing diagram below illustrates the signal sequence of the servo amplifier and safety card at a restart. The safety card has already been configured (see "Initial commissioning") Inbetrieb_Neustart_S1 Servo Amplifier...

  • Page 78: Recommissioning After Error

    Commissioning Recommissioning Key: Servo amplifiers  – 24 V: Supply voltage – BTB/RTO: Relay contact for operational readiness, servo amplifier – L1, L2, L3: Mains voltage – X8: Intermediate circuit – STO-ENABLE: Start interlock – HW-/SW-Enable: Hardware and software enable –...

  • Page 79: Ss1 Sil3/Reset

    Commissioning Recommissioning 2. Switch input "SS1 Activate" or "SS1 SIL3/Reset" to 24 V. The safety card switches to a "STARTUP" condition. The device and  the safe pulse disabler are tested. The "RUN" LED flashes. The safety card switches to a "RUN" condition. The "RUN" LED is lit ...

  • Page 80: Swap Safety Card

     Please note down the serial number of the new safety card. We recommend that you swap the whole unit (servo amplifier with  safety card). Please contact Pilz. Montage_EMV ESD CAUTION! Damage due to electrostatic discharge! Electrostatic discharge can damage components. Ensure against discharge before touching the product, e.g.

  • Page 81: Download Configuration From Configurator

    Commissioning Recommissioning Configurator Configurator Configurator RS 232 RS 232 Ethernet Ethernet Fig. 7-1: Download configuration Key: Downloading a configuration from the Configurator directly to safety card 1 Downloading a configuration via an SD card, which is written by the PC Inserting an SD card into the read device of the servo amplifier for safe- ty card 1 Downloading a configuration to the safety card from an SD card in the...

  • Page 82: Download Configuration To Sd Card

    Commissioning Recommissioning Procedure:  Select in the safety card's Con- Online Mode -> Download Project figurator. Allgemein_Hinweis_Online_Hilfe INFORMATION Further information is available in the safety card Configurator's online help. 7.3.3.2 Download configuration to SD card Download configuration to SD card 7- Inbetrieb_Konf_uebertragen_Tool_SD_Karte You can download the configuration data to the safety card via an SD card.

  • Page 83: Download Configuration From Sd Card To

    Commissioning Recommissioning INFORMATION Further information is available in the safety card Configurator's online help. 7.3.3.3 Download configuration from SD card to safety card Download configuration from SD card to safety card 7- Inbetrieb_Konf_uebertragen_Tool_SD_Karte_Hinweis Before carrying out the steps described in this section, please note the following safety guidelines: CAUTION! Make absolutely sure that the SD card with the safety card con-...
  • Page 84 Commissioning Recommissioning Procedure: 1. Switch off the 24 V supply to the servo amplifier. 2. Insert the SD card into the read device in the servo amplifier. 3. Keep both operator keys on the servo amplifier pres- sed down. 4. Switch on the 24 V supply to the servo amplifier. 5.

  • Page 85: Safety Checks

    Commissioning Safety checks Safety checks 7400 Safety checks 7- Inbetrieb_Pruefungen The machine manufacturer must check and verify the functionality of the employed safety functions. The safety functions may only be checked by qualified personnel.  The safety function must be checked After initial commissioning ...
  • Page 86 Commissioning 7-14...
  • Page 87 Operation 8 8 000 Operation Operation 8- Betrieb_Allg Prerequisites for normal operation are: Commissioning is complete  The safety card contains the configuration data  The safety functions have been tested  The "RUN" LED is lit  During operation Any pulse edge change at the safety card's safe inputs is monitored ...

  • Page 88: Chapter 8 Operation

    Operation Operating states Operating states 8100 Operating states 8- Betrieb_Zustaende The safety card is always in clearly defined operating states. Download configuration NORMAL CONFIG OPERATION Demand Reset upon Configurator Error Error POWER ON Safety Safety function function activated deactivated Limit values Error SS1 Activate Internal error...
  • Page 89 Operation Operating states SS1 is activated  – After violation of the limit values – After an error – After a demand upon safety function SS1 Transition to STO: After activation of SS1 (drive is brought to a stand-  still with a defined braking ramp) There is no power to the motor after execution of safety function STO ...

  • Page 90: Testing The Safe Pulse Disabler

    Operation Testing the safe pulse disabler Testing the safe pulse disabler 8200 Testing the safe pulse disabler 8- Sicherheit_Impulssperre_S1 The safety card meets the requirements of EN IEC 61508 up to SIL 3 and EN ISO 13849-1 up to PL e. To achieve category SIL 3 or PL e, the operator must ensure that the function of the safe pulse disabler is tested periodically, after 8 hours at the latest, by triggering safety functions SS1 or STO:...

  • Page 91: Display Elements

    Operation Display elements Display elements 8300 Display elements 8- Betrieb_LED The expansion card has LEDs to display the status of the operating states. Meaning Name Colour Status POWER - - - Supply voltage is not present Green Supply voltage is present - - - System not ready...

  • Page 92: Messages

    Operation Messages Messages 8400 Messages 8- Betrieb_Fehlermeldungen Any errors on the safety card are indicated on the servo amplifier display with message "F31". The following options are available for detailed diagnostics and fault de- tection: LEDs on the front of the safety card provide information on operating ...

  • Page 93: Chapter 9 Technical Details

    Technical Details 9 9 000 Technical Details Technical Details 9- 9.1 Technical Details 9100 Technical Details 9- Technische Daten_S1 Technical details PMCprotego S1 Application range Failsafe Electrical data Supply voltage U 24.0 V Voltage tolerance -15 %/+20 % Inputs Number...
  • Page 94 Technical Details Technical Details Encoder input SSI encoder Voltage range 10 ... 30 VDC, 4.75 ... 5.25 VDC Output signal (clock) Differential signal (RS 422) Max. number of bits on the counter input 12 - 25 Bit Transmission rate 1,000.0 kHz Coding of the input signal Binary, Grey Signal at the data input...

  • Page 95: Safety Characteristic Data

    SI_Kennzahlen_protego S1_ein_Geber_MTTF_10_Bild Subsystem Safe actuator PMCprotego D PMCprotego S1 Motor encoder with MTTF ³ 10 years SI_Kennzahlen_alle_Sicherheitsfunkt_protego S The safety-related characteristic data is valid for all safety functions. Si_Kennzahlen_Erläuterung_1 All the units used within a safety function must be considered when cal- culating the safety characteristic data.
  • Page 96 SI_Kennzahlen_protego S_ein_Geber_MTTF_57_Bild Subsystem Safe actuator PMCprotego D PMCprotego S1 Motor encoder with MTTF ³ 57 years SI_Kennzahlen_alle_Sicherheitsfunkt_protego S The safety-related characteristic data is valid for all safety functions. Si_Kennzahlen_Erläuterung_1 All the units used within a safety function must be considered when cal- culating the safety characteristic data.
  • Page 97 Technical Details Safety characteristic data Subsystem Subsystem Sensor Safe actuator PMCprotego D Sensor 1 PMCprotego S1 Diversity Motor encoder with cross- comparison Sensor 2 External encoder SI_Kennzahlen_alle_Sicherheitsfunkt_protego S The safety-related characteristic data is valid for all safety functions. Si_Kennzahlen_Erläuterung_1 All the units used within a safety function must be considered when cal-...
  • Page 98 Technical Details...
  • Page 99 Glossary 10000 Glossary Glossary Safety function in acccordance with EN 61800-5-2, supplies a safe output SBC - Safe brake control signal to drive an external brake. SBC is the abbreviation for safe brake control. Safety function which tests an external holding brake and the motor brake. SBT - Safe brake test SBT is the abbreviation for safe brake test.