schmersal PSCBR-C-10 Series Installation Manual

Hide thumbs

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

page of 204

/ 204
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

Installation manual

Installation Manual

For

PSCBR modules

Series PSCBR-C-10

Page 1 of204

Table of Contents

Need help?

Do you have a question about the PSCBR-C-10 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for schmersal PSCBR-C-10 Series

Page 1 Installation manual Installation Manual PSCBR modules Series PSCBR-C-10 Page 1 of204...
Page 2 Information and specifications can be changed at any time. Please keep yourself informed about the current version under www.schmersal.com.br Devices of the ACE Schmersal Eletroeletrônica Industrial Ltda. Rodovia Boituva - Porto Feliz, Km 12 Jd. Esplanada CEP 18550-000...
Page 3: Table Of Contents
Installation manual Contents IMPORTANT NOTES ..................... 6 Definitions ............................6 Co-valid documents ..........................7 Abbreviations used ..........................7 SAFETY REGULATIONS ..................9 Intended use ............................9 See appendix "EC Declaration of Conformity" ..................... 9 Use in regions with UL/CSA requirements ..................9 General safety regulations ........................
Page 4 Installation manual Installation of backplane bus system ....................75 5.3.1 Arrangement examples ......................76 5.3.1.1 PSCBR-C-10-SDM1 + PSCBR-C-10-SDM1 + PSCBR-C-10-SDM1 + PSCBR-F ... 76 5.3.1.2 PSCBR-C-10-SDM2 + PSCBR-C-10-SDM1 + PSCBR-F ..........76 Assembling the modules ........................77 5.4.1 Assembly on C-rail........................ 77 5.4.2 Assembly on backplane bus ....................
Page 5 Installation manual 7.3.3.1 Example Reset-Function with safeguarding against false utilization ......117 LED display ............................. 120 Parameterization ..........................121 Function test ..........................121 Validation ............................121 SAFETY RELATED EXAMINATION ..............121 MAINTENANCE ....................123 Modification / handling changes to the device ................123 Exchanging a module ........................
Page 6: Important Notes
Installation manual 1 Important notes Definition of individual target groups Project engineers for safe drive systems: Engineers and technicians Assembly, electric installation, maintenance and replacement of devices: Maintenance electricians and service technicians Commissioning, operation and configuration: Technicians and engineers 1.1 Definitions The designation PSCBR is used as generic term for all derivatives from the PSCBR product range.
Page 7: Co-Valid Documents
Installation manual 1.2 Co-valid documents Description Reference Configuration of the PSCBR module SafePLC programming manual for stand-alone applications without (System CD) field-bus interfacing with the program "SafePLC" Validation report for implemented Safety inspection with acceptance parameterization and PLC-program protocol Acceptance test for general safety Certificate for type approval test for fail- related applications safe control system acc.
Page 8 Installation manual Abbreviation Meaning Central Processing Unit Direct voltage DI1..DI14 Digital Input Deutsches Institut für Normung (German Institute for Standardization) Digital Output Emergency Monitoring Unit Electromagnetic compatibility Emergency Limit Control European Standard HISIDE Output with 24VDC nominal level switching to plus IP20 Degree of protection for housing International Organisation for Standardisation...
Page 9: Safety Regulations
Installation manual 2 Safety regulations 2.1 Intended use Devices of the PSCBR-C-10/11/12 series are programmable fail-safe control system intended for the establishment of emergency shut-down features and functions. The devices are intended for use in EMERGENCY STOP facilities, as safety component as defined by the EC machine directive 2006/42/EC, as PES for risk reduction as defined by EN 61508, in safety circuits acc.
Page 10: General Safety Regulations
Installation manual 2.3 General safety regulations Safety note:  In order to avoid damage to persons and property only qualified personnel is entitled to work on the device. The term qualified personnel refers to persons who have successfully completed electrotechnical training and are fully familiar with the applicable rules and standards of electrical engineering.
Page 11: Operation And Service
This will also cause the loss of all warranty and compensation claims against Schmersal. 2.4 Operation and service The module must always be de-energized before installation and removal, or before disconnecting signal lines.
Page 12: Characteristic Data Of Device
Installation manual Digital I/O extension for PSCBR-C-10/11/12 series. The extension module has 12 safe inputs, 10 safe I/O for optional configuration as input or output and 2 signal outputs. Communication modules Extension module for the transfer of diagnostic and status data to an imposed control by means of standard field bus.
Page 13 Installation manual Technical characteristic data Safety related characteristic data Pl acc. to EN 13849 Pl e -9 / PFH / architecture 3,0 * 10 architecture class 4 SIL acc. to EN 61508 SIL 3 Proof test interval 20 years = max. utilization period General data Max.
Page 14: Pscbr-C-10-Sdm1
Installation manual 3.1.1.2 PSCBR-C-10-SDM1 Type designation Device design Design of module with the following periphery: sensor interface digital inputs, alternatively 4 counting inputs pulse outputs relay outputs LOSIDE HISIDE signal outputs diagnostic and configuration interface function button 7-segment display status LED status LEDs for inputs status LEDs for pulse outputs status LEDs for relay outputs...
Page 15 Installation manual Technical characteristic data Safety related characteristic data Pl acc. to EN 13849 Pl e -9 / PFH / architecture 2,2 * 10 architecture class 4 SIL acc. to EN 61508 SIL 3 Proof test interval 20 years = max. utilization period General data Max.
Page 16: Pscbr-C-10-Sdm2
Installation manual 3.1.1.3 PSCBR-C-10-SDM2 Type designation Device design Design of module with the following periphery: sensor interfaces digital inputs, alternatively 4 counting inputs pulse outputs relay outputs LOSIDE HISIDE signal outputs diagnostic and configuration interface function button 7-segment display status LED status LEDs for inputs status LEDs for pulse outputs status LEDs for relay outputs...
Page 17 Installation manual Technical characteristic data Safety related characteristic data Pl acc. to EN 13849 Pl e -9 / PFH / architecture 6,2 * 10 architecture class 4 SIL acc. to EN 61508 SIL 3 Proof test interval 20 years = max. utilization period General data Max.
Page 18: Extension Modules
Installation manual Extension modules 3.1.1.4 PSCBR-E-31-12DI-10DIO Type designation Device design Design of module with the following periphery: digital inputs I/O optionally configurable as input or output pulse outputs signal outputs status LEDs for inputs status LEDs for I/O backplane bus interface Characteristics of the module: ...
Page 19 Installation manual Technical characteristic data: Safety related characteristic data Pl acc. to EN 13849 Pl e -9 1) PFH / architecture Type 2.6 * 10 / Class 4 SIL acc. to EN 61508 SIL 3 Proof test interval 20 years = max. utilization period General data Safe digital I 12 incl.
Page 20: Communication Modules
Installation manual 3.1.2 Communication modules 3.1.2.1 PSCBR-F Type designation Device design Design of module with the following periphery: CAN-BUS interface – PSCBR-F CANopen – PSCBR-F-PB Profibus – PSCBR53 backplane bus interface status LED for operating status status LED CAN-communication Characteristics of the module: ...
Page 21 Installation manual Technical characteristic data: Safety related characteristic data Pl acc. to EN 13849 PFH / architecture n.a. SIL acc. to EN 61508 n.a. Proof test interval n.a. General data Field bus interface Type of connection Standard acc. to field bus type Max.
Page 22: Identification
Installation manual 3.2 Identification The type plate is located on the left side wall of the module and contains the following information: Type designation Part number Serial number Identification of hardware release Identification of software release Safety category Input characteristics Output characteristics Date of manufacture (week/year) Page 22 of204...
Page 23: Scope Of Delivery
Installation manual 3.3 Scope of delivery The scope of delivery contains: PSCBR module:  Plug for all signal terminals without encoder connection Not included in the scope of delivery:  SafePLC configuration software CD with  Installation manual  Programming manual ...
Page 24: Safety Related Characteristics
Installation manual 4 Safety related characteristics 4.1 General design, safety related architecture and characteristic data The internal structure of the PSCBR-series consists of two separate channels with reciprocal comparison of results. High quality diagnoses for fault detection are made in each of the two channels.
Page 25 Installation manual Characteristic data:  Max. obtainable safety class SIL 3 acc. to EN61508  Category 4 acc. to EN945-1  Performance-Level e acc. to EN ISO 13849-1 System structure 2-channel with diagnose /1002) acc. to EN 61508 Architecture category 4 acc. to EN 13849 Rating of operating mode "high demand"...
Page 26: Safety Related Characteristic Data And Wiring For The Connected Sensors
Installation manual 4.2 Safety related characteristic data and wiring for the connected sensors The PSCBR modules have completely separated signal processing paths for each safety input. This applies for both the digital and the analog inputs. Furthermore, measures for achieving the highest possible DC-values have been implemented. 4.2.1 Digital sensors: Digital inputs and outputs are generally of a completely redundant design, except the electro- magnetic input terminal.
Page 27: Dc Digital Sensors/Inputs
Installation manual Single channel input element and dual channel processing with low to medium DC by signal processing in two channels and diagnose by means of cyclic testing, PI / SIL depending on permissible fault exclusions and test rate for input element. 4.2.1.2 DC digital sensors/inputs The PSCBR modules ensure far reaching diagnostics functions for the input element.
Page 28 Installation manual Same test as before, but additional monitoring of the input signals for compliance with the defined level connections within a time window of 0.5 seconds. Defining the levels over a time period of > 0.5 seconds triggers a module alarm. Start test: Each time the safety module (=PSCBR module) is switched on, the input element must be tested in direction of the Low signal status (defined Safe State), e.g.
Page 29 Installation manual The following diagnoses for input sensors can generally be used for the safety related assessment of the entire system: Input element Parameterized / Definition of measure Note characteristic operational tests Single-channel Cyclic test pulse by dynamic A sufficiently high test >60 change of input signals rate must be ensured.
Page 30: Classification Of Digital Inputs
Installation manual Safety note:  The manufacturer's data (MTTFD, FIT-numbers, etc.) must be used for a safety related assessment of the partial system "Sensors".  The DC-values listed in the table must be used conservatively and compliance with the boundary conditions (see table under "Remarks") must be ensured. ...
Page 31 Installation manual 4.2.1.3.2 Expansion inputs EAE1 … EAE10 Digital inputs Achievable Comment performance level Without pulse, single channel static signal -> auxiliary input Without pulse, dual channel static signal At least one request/day required by PL e application Fault detection only upon request Without pulse, dual channel static signal PL d Less than one request/day required by...
Page 32: Exemplary Connections Of Digital Sensors
Installation manual 4.2.1.4 Exemplary connections of digital sensors 4.2.1.4.1 Single-channel sensor, without cross-shorting test DI13 DI14 Fig.: Single-channel sensor, without cross-shorting test The single-channel sensor is connected to the PSCBR without clocking or without cross- shorting test. This design is not recommended for safety applications. Pl b acc. to EN ISO 13849-1 can maximally be reached.
Page 33 Installation manual When using a single-channel sensor with clock one output is connected to the clock output P1 or P2. The clock must subsequently be assigned to the PSCBR. The use of a single-channel sensor with clock detects: short-circuit to supply voltage DC 24 V short-circuit to DC 0 V cable interruption (current interruption is safe state!) ) However, be cautious in case of a cable short between the two sensor connections, because...
Page 34 Installation manual 4.2.1.4.3 Dual-channel sensor without timeout with cross-shorting test Faults are at least detected when requested. The DC is medium and by using cyclic tests (start test, operational/organizational tests) can be changed up to high level. depending on the test frequency.
Page 35 Installation manual Safety note:  Pl d or higher in accordance with EN ISO 13849-1 is achieved by using switching elements / sensors with positively opening contacts or positive actuation acc. to EN 60947-5-1  Using devices for which the fault exclusion double fault for the intended safety level can be specified for the switching elements, is permitted.
Page 36 Installation manual 4.2.1.4.4 Dual-channel sensor with time-out and cross-shorting test Cross-shorting as well as connections to DC 24 V and DC 0 V can be detected by using two independent clock signals on the homogeneous sensor. Only normally closed contacts should be used for safety related applications. PI d or higher acc.
Page 37 Installation manual 4.2.1.4.5 Dual-channel sensor with time-out and cross-shorting test Cross-shorting as well as connections to DC 24 V and DC 0 V can be detected by using two independent clock signals on the homogeneous sensor. Pl d or higher acc. to EN 13849-1 can be achieved when: - using sensors / switching elements with positive actuation.
Page 38: Overview Of Achievable Pi For Digital Safety Inputs
Installation manual 4.2.1.5 Overview of achievable PI for digital safety inputs Type of InPort Parameterized / Achievable Fault exclusion Condition for input sensor / operational tests PI acc. to for input element input EN 13849-1 element element Operation proven input element DI1..D14 All faults at the...
Page 39 Installation manual Type of InPort Parameterized / Achievable Fault exclusion Condition for input sensor / operational tests PI acc. to for input element input EN 13849-1 element element Short-circuit at Connection in control cabinet input/signal line or protected routing Getting caught / positively MTTF = medium...
Page 40: Sensors For Speed And/Or Position Detection
Installation manual 4.2.2 Sensors for speed and/or position detection 4.2.2.1 General safety related structure of the sensor interface for position and/or speed The basic modules of the PSCBR series can be optionally equipped with one (PSCBR-C-10- SDM1/12) or two encoder interfaces (PSCBR-C-10-SDM1-12/12-2) per axis. Depending on encoder type and combination, different safety levels can be reached.
Page 41: General Diagnostic Measures For Encoder Interface
Installation manual 4.2.2.2 General diagnostic measures for encoder interface For fault detection in the sensor system the PSCBR series has a number of diagnostic measures implemented, depending on the chosen encoder type or its combination. These are automatically activated when choosing the encoder type. With respect to their type and effectiveness diagnostic measures can generally be classified using the following table: Diagnoses for sensors for position and/or speed detection:...
Page 42: Encoder Types And Their Combination, Diagnostic Data
Installation manual 4.2.2.3 Encoder types and their combination, diagnostic data Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system non- dynamic...
Page 43 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) Incremental Resolver n.a.
Page 44 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) SIN/COS n.a.
Page 45 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) Fault exclusion mech. shaft breakage, positive 80-90% encoder shaft connection required 2 x Bero 90°...
Page 46: Specific Diagnostic Measures With Regard To The Encoder Type Used
Installation manual 4.2.2.4 Specific diagnostic measures with regard to the encoder type used Encoder type Incremental SIN/COS Bero 2 x counting input Bero 1 x counting input Incremental Resolver SIN_COS Only in High-Resolution Mode Page 46 of204...
Page 47: Safety Relevant Cut-Off Thresholds Encoder Systems For Position And Speed Detection
Installation manual 4.2.2.5 Safety relevant cut-off thresholds encoder systems for position and speed detection Plausibility tests with the current position and speed values are performed between both measuring channels A and B of the PSCBR module as a basic measure, which are then checked against parameterizable thresholds.
Page 48 Installation manual The digital acceleration resolution is limited by a maximum peak time of 256 ms and the encoder resolution. The graphs below show the lowest measurable acceleration in dependence on the resolution in revolutions/min, mm/s² and m/s². Value Value Acceleration [rev/min/s] Acceleration [mm/s ] and [m/s...
Page 49 Installation manual  The DC-values listed in the table must be used conservatively and compliance with the boundary conditions (see table under "Remarks") must be ensured.  in order to determine the DC-value for safety functions with standstill monitoring a frequency assessment of the dynamic status may be required. A DC of 90 % may here be used a s a guide value.
Page 50: Safety Related Assessment Of Encoder Types Or There Combination
Installation manual 4.2.2.6 Safety related assessment of encoder types or there combination Due to the monitoring functions implemented in the PSCBR-series, no special demands are initially made on the internal design of the encoder electronics in applications with encoder systems, i.e. standard encoders can normally be used. A safety related assessment of the overall arrangement must generally be made.
Page 51 Installation manual The PSCBR module generally detects the following faults in the external encoder system:  Short-circuits between safety relevant signal lines  Interruptions in safety relevant signal lines  Stuck at 0 or 1 on one or all safety relevant signal lines Each encoder type has further specific diagnoses for fault detection in the external encoder system assigned.
Page 52: Analog Sensors
Installation manual 4.2.3 Analog sensors The basic modules PSCBR-C-10-SDM2A have two analog inputs with two input channels each. Only 2-channel sensors can generally be connected to this interface. The internal signal processing takes place separately in the two channels with cross-comparison of the results.
Page 53: Exemplary Connection Of Analog Sensors
Installation manual Safety note:  The manufacturer's data (MTTF , FIT-numbers, etc.) must be used for a safety related assessment of the partial system "Sensors".  The DC-values listed in the table must be used conservatively and compliance with the boundary conditions (see table under "Remarks") must be ensured.
Page 54: Safety Related Characteristic Data And Wiring Of The Outputs
Installation manual 4.3 Safety related characteristic data and wiring of the outputs PSCBR modules all have safe outputs of various types. For wiring, the corresponding characteristic as specified in the following description, must be accounted for 4.3.1 Characteristic of the output elements Aktuator Actuator Single-channel output PSCBR and single-channel actuator without diagnostics...
Page 55: Diagnoses In The Cut-Off Circuit
Installation manual Actuator Aktuator Single-channel output PSCBR with internal dual-channel processing and dual-channel actuator with dual- channel diagnose Actuator Aktuator Dual-channel output PSCBR and dual-channel actuator with single-channel diagnose Actuator Aktuator Dual-channel output PSCBR and dual-channel actuator with dual-channel diagnose 4.3.2 Diagnoses in the cut-off circuit The cut-off circuit is equipped with durably implemented and parametrizable diagnostics functions.
Page 56: Overview Dc With Respect To The Chosen Diagnostics Functions
Installation manual The current status of the actuator is detected by correspondingly suitable auxiliary contacts or position indicators and compared with the nominal status. Any deviation is thereby clearly recognized. Note: The DC depends on a single-channel or dual-channel diagnose as well as on the switching frequency.
Page 57: Basic Outputs
Installation manual 4.3.3 Basic outputs The modules  PSCBR-C-10, PSCBR-C-10-SDM1, PSCBR-C-10-SDM1-1, PSCBR-C-10-SDM2, PSCBR-C-10-SDM2-  PSCBR-E-31-12DI-10DIO all have basic outputs of identical design. The PSCBR module provides a total of 8 outputs, which can be interconnected individually or in groups. Output Architecture acc.
Page 58 When used in elevator technology acc. to EN81, the outputs of the internal relays must not be used for switching voltages higher than 24V, because this would contradict the specifications of EN81. Non-compliance will lead to the loss of all warranty claims and Schmersal will not be liable for compensation. Page 58 of204...
Page 59: Wiring Examples Basic Outputs
Installation manual 4.3.3.1 Wiring examples basic outputs 4.3.3.1.1 Single-pole switching relay or semi-conductor output without test For the connection of multi-phase applications or for higher current demands external contactors may be used. For a single-pole connection without external test please bear in mind that the PSCBR1X module will not recognize bonding of one or several external contacts.
Page 60 Installation manual 4.3.3.1.2 Single-pole switching relay or semi-conductor output with external switching amplifier and testing When using external switching amplifiers or downstream electro-mechanical, pneumatic or hydraulic components, the setup for testing the complete chain and a message/warning feature for detected faults is required in order to achieve PI c or higher. Positively guided auxiliary contacts are especially needed for electro-mechanical devices and message contacts for the valve position are required for hydraulic or pneumatic components.
Page 61 Installation manual 4.3.3.1.3 Single-pole switching relay or semi-conductor output with dual-channel external circuit with testing For safety applications from PI c and higher acc. to EN ISO 13849-1 we strongly recommend or even demand the control of two external cutout elements. Furthermore, the setup for testing the complete chain and a message/warning device for an detected fault is required for achieving PI c or higher - see also remarks under 4.3.3.1.2.
Page 62 Installation manual DO0_P DO0_M DO1_P DO1_M DI13 DI14 DO.1 DO.2 Fig.: Single-channel switching output DO0_P with dual-channel external circuit as combination of electro-mechanical element and hydraulic/pneumatic valve and monitoring at two inputs Safety note:  Only conditionally recommended for safety applications! In this context see also the notes in EN 13849-1 concerning the application and the required fault exclusions.
Page 63 Installation manual 4.3.3.1.4 Two-channel switching relay output with external monitoring - group feedback For safety related applications from Pl d acc. to EN ISO 13849-1 two relays on the PSCBR1X module and two external power contactors are used. DI13 DI14 Two-channel switching relay output with external monitoring –...
Page 64 Installation manual 4.3.3.1.5 Dual-channel output with relay output and semi-conductor output – external control circuit with monitoring For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via a relay and a semi-conductor output. Each of the two external cutout paths is monitored.
Page 65 Installation manual 4.3.3.1.7 Dual-channel output with semi-conductor output and external control circuit in PI e For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via the semi-conductor outputs. For PL e acc. to EN ISO 13849-1 PI e is demanded for the external circuit DO0_P Pl e...
Page 66: Configurable I/O As Outputs
Installation manual 4.3.4 Configurable I/O as outputs The extension module PSCBR-E-31-12DI-10DIO has 10 configurable safe I/O EAA1...EAA10 (see chapter 3 Module overview). Parameterized as an output this connection acts as a safe digital Hi-Side output (DO_P). 4.3.4.1 Classification of the I/O when used as output Architecture Performance Level Comment...
Page 67 Installation manual Safety note:  Not recommended for safety applications! In this context see also the notes in EN 13849-1 concerning the application and the required fault exclusions. 4.3.4.2.2 Wiring single-channel with testing Use of one output EAA1...40 in connection with a single-channel external wiring for testing. Positively guided auxiliary contacts are especially needed for electro-mechanical devices and message contacts for the valve position are required for hydraulic or pneumatic components.
Page 68 Installation manual 4.3.4.2.3 Single-channel output in connection with a safe shut-down circuit For safety applications from PI c and higher acc. to EN ISO 13849-1. The external circuit is controlled directly via an output. The achievable PL acc. to EN ISO 13849-1 depends on the use of dynamic testing (see 4.3.2.1 DC) and the PL of the downstream device.
Page 69 Installation manual Suitable for PI d and higher acc. to EN ISO 13849-1. Use of two outputs EAA1...40 in connection with a dual-channel external wiring. 4.3.4.2.6 Wiring dual-channel in same group EAA1 EAA2 EAA3 EAA4 EAA5 EAA6 EAA7 EAA8 EAA9 EAA10 4.3.4.2.7 Wiring dual-channel in different group EAA1...
Page 70 Installation manual Safety note:  For a safety related assessment of the partial system output the data issued by the respective manufacturer (MTTF , FIT-numbers, B10d-value, etc.) must be used when using external elements, e.g. for switching amplification, in the shut-down circuit. ...
Page 71: Overview Of Achievable Pi For Digital Safety Outputs
Installation manual 4.3.4.3 Overview of achievable PI for digital safety outputs Output Actuator / Catego MTTF Achie Boundary Fault PSCBR external shut- ry acc. Actuat vable conditions exclusion down circuit PI acc. EN138 to EN 49-1 13849- Single- Single-channel Cat. B Medium Contactor and channel...
Page 72 Installation manual Output Actuator / Catego MTTF Achiev Boundary Fault PSCBR external shut- ry acc. Actuat able PI conditions exclusion down circuit acc. to EN138 49-1 13849- Dual-channel Dual-channel Cat. 3 90 % Monitori Medium Contactor and Short circuit without Contactor, valve, ng in or High...
Page 73: Connection And Installation
Installation manual 5 Connection and installation General notes on installation Strictly follow the safety regulations when installing! Degree of protection IP52 Route all signal lines for the interfacing of digital inputs and contact monitoring separately. You should in any case disconnect 230VAC voltages from low voltage power lines, if these voltages are used in connection with the application.
Page 74 Installation manual  All contactors in the environment of the power converter must be equipped with appropriate suppressor circuits.  Suitable measures to protect against overvoltages must be applied. Additional safety regulations when using as PESSRAL acc. to EN81  Install the device at a distance of at least 200 mm from the HF-transmitting facility (WLAN, GSM, etc.).
Page 75: Installation And Assembly Of The Pscbr Module
PSCBR-C-10-SDM2A) on one top hat rail in connection with the backplane bus system is also possible. These modules can be combined with a communication extension. In this case the backplane bus system needs to be configured by Schmersal when placing the order and delivered in accordance with the application in question.
Page 76: Arrangement Examples
Installation manual 5.3.1 Arrangement examples 5.3.1.1 PSCBR-C-10-SDM1 + PSCBR-C-10-SDM1 + PSCBR-C-10-SDM1 + PSCBR-F PSCB PSCB PSCB PSCBR R-C- R-C- R-C- There is no TB2 between the last PSCBR-C-10-SDM1 module and the communication module PSCBR-F, because the power supply for the PSCBR-F is fed in through the backplane bus system.
Page 77: Assembling The Modules
Installation manual 5.4 Assembling the modules The modules are mounted on C-standard rails by means of snap-on latches. 5.4.1 Assembly on C-rail The devices are inserted into the rail under an oblique angle and then snapped on downwards. For disassembling use a screwdriver, insert it into the slot of the downwards pointing latch and then move it up.
Page 78: Assembly On Backplane Bus
Installation manual 5.4.2 Assembly on backplane bus After assembling the backplane bus the device can be installed. For this purpose insert the module from above into the plug connection under a oblique angle and snap it onto the C-rail. Insert the module from above under an oblique angle. Snap-on downwards on to the C-rail.
Page 79: Installation And Configuration I/O-Extension Pscbr-E-31-12Di-10Dio
Installation manual The backplane plug connection can later be extended. The system configuration can thus be extended by additional modules. Snap the backplane bus element into the C-rail and insert it into the counter-piece by sliding it sideways. 5.5 Installation and configuration I/O-extension PSCBR-E-31-12DI-10DIO 5.5.1 Log on PSCBR-E-31-12DI-10DIO to basic group After starting the "Safe PLC"...
Page 80: Physical Address Configuration Pscbr-E-31-12Di-10Dio
Installation manual 5.5.2 Physical address configuration PSCBR-E-31-12DI-10DIO On the PSCBR-E-31-12DI-10DIO module the bus address must be set with the help of the address switch. This setting is made on the back of the module Note:  Address range of the PSCBR-E-31-12DI-10DIO module from 1...15. ...
Page 81 Installation manual  Group1 EAAx.1-EAAx.6 or group1 EAAx.7-EAAx.10: When using these outputs one can choose between safety and standard outputs. Page 81 of204...
Page 82: Terminal Assignment
Installation manual 5.6 Terminal assignment 5.6.1 Terminal assignment PSCBR-C-10 CPU board Printed circuit board 5.6.2 Terminal assignment PSCBR-C-10-SDM1 CPU board Printed circuit board Page 82 of204...
Page 83: Terminal Assignment Pscbr-C-10-Sdm2
Installation manual 5.6.3 Terminal assignment PSCBR-C-10-SDM2 Axis 1 Axis 2 CPU board Printed circuit board Axis 1 Axis 1 Axis 2 Axis 2 HTL encoder connection: A+,B+ HTL encoder connection: A+,A- /B+,B- Printed circuit board CPU board Page 83 of204...
Page 84: Terminal Assignment Pscbr-E-31-12Di-10Dio
Installation manual 5.6.4 Terminal assignment PSCBR-E-31-12DI-10DIO IO board CPU board 5.7 External 24 VDC – power supply The PSCBR module requires a 24 VDC power supply with PELV characteristic in accordance to EN50178. Please comply with the following boundary conditions when planning and installing the specified power supply unit: Strictly comply with the minimum and maximum supply voltage tolerance.
Page 85 Installation manual Safety note:  The PSCBR module must be individually protected by a 2A/24VDC back-up fuse. single- pole thermal magnetic circuit breaker with rapid acting characteristic  The power supply has to measure up with PELV standard in accordance to EN50178 Comments: Reliable galvanic isolation from the 230 VAC or 400 VAC network must be guaranteed in any case.
Page 86: Connection Of The External Encoder Supply
Installation manual 5.8 Connection of the external encoder supply 5.8.1 Incremental, HTL, SIN/COS, SSI L-_ENC1-2 L-_ENC2-2 L+_ENC1-2 L+_ENC2-2 L-_ENC1 L-_ENC2 L+_ENC1 L+_ENC2 Monitoring of Spannungs- external encoder überwachung der externen supply voltages Geber- versorgungs- spannungen Only PSCBR-C-10-SDM1-2 and PSCBR-C-10-SDM2-2 Only PSCBR-C-10-SDM2 and PSCBR-C-10-SDM2-2 Only PSCBR-C-10-SDM2-2 The PSCBR module supports encoder voltages of 5V, 8V, 10 V, 12V and 24V, which are internally monitored in accordance with the chosen configuration.
Page 87: Resolver
Installation manual 5.8.2 Resolver L-_ENC1-2 L-_ENC1-2 L+_ENC1-2 L+_ENC1-2 Reference Reference Referenz- Referenz- signal signal Signal- Signal- generation generation generierung generierung Only PSCBR-C-10-SDM1-2 and PSCBR-C-10-SDM2-2 Only PSCBR-C-10-SDM2-2 When using resolvers in Master-Mode an additional 24V DC power supply is required for generating the reference signal.
Page 88: Connection Of Digital Inputs
Installation manual 5.9 Connection of digital inputs The PSCBR comes with 14 (PSCBR-C-10/11/12) or 12 (PSCBR-E-31-12DI-10DIO) safe digital inputs. These are suitable for connecting single or two-channel signals with and without cycling, or without cross-shorting test. The connected signals must have a "High"-level of DC 24 V (DC +15 V...+ DC 30 V ) and a "Low"-level of (DC -3 V...DC +5 V, type 1 acc.
Page 89: Connection Of Analog Inputs
Installation manual 5.10 Connection of analog inputs The version PSCBR-C-10-SDM2 with analog processing is able to reliably process max. 2 analog signals. The analog inputs can be connected as follows: Voltage -7VDC +10VDC Note: The module is equipped with the fixed loading resistor of 500 Ohm as standard. This resistor can be omitted is required (voltage input).
Page 90: Connection Of Position And Speed Sensors
Installation manual 5.11 Connection of position and speed sensors 5.11.1 General notes Depending on module type the PSCBR module (PSCBR-C-10-SDM1/PSCBR-C-10-SDM2) has (1/2) external encoder interfaces for the connection of industrial incremental and absolute encoders. The encoder interfaces can be configured as incremental, SIN/COS, or as absolute SSI-encoders.
Page 91 Installation manual Attention: The sensor connections must neither be plugged on nor pulled off during operation. This could cause damage to electrical components of the encoder. Always de-energize connected encoders and the PSCBR module before plugging on or pulling off encoder connections. Lines twisted in pairs for signal transmission acc.
Page 92: Assignment Of Encoder Interface
Installation manual 5.11.2 Assignment of encoder interface X31/X32 Sensor assignment Absolute encoder only PSCBR-C-10-SDM2 X33/X34 Sensor assignment SSI – Absolute SSI – Absolute X 33/X 34 X 31/X 32 only PSCBR-C-10-SDM2-2 Page 92 of204...
Page 93: 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 24 V DC Supply GND Pin 3 n.c. Pin 4 CLK- Pin 5 Sub-D plug Sub-D- DATA+ Absolut- Absolute Stecker (9 pin) Encoder encoder (9 polig)
Page 94: 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 plug Sub-D- Pin 5 DATA+ Absolut- Absolute Stecker (9 pin) Encoder encoder (9 polig) PSCBR (Slave-Betrieb) (Slave mode) Pin 6 DATA- n.c.
Page 95: Connecting An Incremental Encoder With Ttl-Signal Level
Installation manual 5.11.3.3 Connecting an incremental encoder with TTL-signal level n.c. Pin 1 Pin 2 Ground 24 V DC Supply GND Pin 3 n.c. Pin 4 Sub-D plug Sub-D- Pin 5 Incremental Inkremental (9 pin) Stecker Encoder encoder (9 polig) PSCBR Pin 6 n.c.
Page 96: 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 24 V DC Supply GND Pin 3 n.c. Pin 4 COS- Sub-D plug Sub-D- Pin 5 SIN+ SIN/COS SIN/COS Stecker (9 pin) encoder Geber (9 polig) PSCBR Pin 6 SIN-...
Page 97: Connection Of A Resolver As Master
Installation manual 5.11.3.5 Connection of a resolver as master Reference Out + Pin 1 Reference Out - Pin 2 Reference In + Pin 3 Pin 4 COS - 24 V DC Supply GND Pin 5 Sub-D plug Sub-D- SIN + Stecker Resolver (9 pin)
Page 98: Connection Of A Resolver As Slave
Installation manual 5.11.3.6 Connection of a resolver as slave Pin 1 Monitor Reference Pin 2 Voltage GND Reference In + Pin 3 Pin 4 COS - Sub-D- Sub-D plug Pin 5 SIN + Stecker Resolver Resolver (9 pin) (9 polig) (Slave-Betrieb) (Slave mode) PSCBR...
Page 99: Connection Of Proximity Switch Pscbr-C-10-Sdm1/2
Installation manual 5.11.3.7 Connection of proximity switch PSCBR-C-10-SDM1/2 tion is via p u to X23 on t i ita inputs DI5 … DI8. The exact pin assignment depends on the encoder type and is shown in the connecting plan of the programming interface.
Page 100: Configuration Of Measuring Distances
Installation manual 5.12 Configuration of measuring distances 5.12.1 General description of encoder configuration The most important input variables for the monitoring functions of the module are safe position, speed and acceleration. These are obtained by dual-channel generation from the connected sensor system.
Page 101 Installation manual Parameterization of SSI-format: ClkN Number Clk Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Index Index Daten Data Index Index Status Status K Daten O Status K Data O Status Status information Status Status Status Status Status information ..
Page 102 Installation manual Example: SSI-Frame length: 28 cycles Data length: 22 bit Status: 5 bit, 3 bit Fault + 2 bit Warning/ready for operation Number Clk ClkN Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Clk 24 Clk 25 Clk 26 Clk 27 Clk 28...
Page 103: Incremental Encoder
Installation manual 5.12.2.2 Incremental encoder: Physical Layer: RS-422 compatible Measuring signal A/B. Track with 90 degree phase difference maximum frequency of input cycles 200 KHz or 500 kHz Diagnoses: Diagnose Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20 % +/-2 %(measuring 5 V, 8V, 10V, 12V, 20V, tolerance) Monitoring of differential level...
Page 104: Proximity Switch
Installation manual 5.12.2.5 Proximity switch Signal level. 24V/0V Max. counting frequency. 10kHz Circuit logic de-bounced Diagnoses: Diagnose Parameters Fault threshold Supply voltage Fixed values +/- 20 % +/-2 %(measuring monitoring 5 V, 8V, 10V, 12V, 20V, tolerance) Page 104 of204...
Page 105: Extended Monitoring Proximity Switch / Proximity Switch
Installation manual 5.12.2.6 Extended monitoring proximity switch / proximity switch The extended monitoring uncovers the following faults: a) Supply voltage failure b) Failure of output signal in driver direction c) Malfunction of High signal proximity switch d) Interruption of signal path e) Mechanical de-adjustment of proximity switch / excessive switching distance of proximity switch For diagnostic purposes both status conditions of the counting signal are additionally recorded...
Page 106: Htl - Sensor
Installation manual 5.12.2.7 HTL - Sensor Signal level. 24V/0V Physical Layer: Push/Pull Measuring signal A/B track with 90° phase difference Max. counting pulse frequency: 200 kHz on X27/28 or X29/30 (only PSCBR-C-10-SDM1/2) Diagnoses: Diagnose Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20 % +/-2 %(measuring 5 V, 8V, 10V, 12V, 20V, 24V...
Page 107: Response Times Of The Pscbr
Installation manual 6 Response times of the PSCBR The response time is a very important safety related characteristic and must be strictly observed for each application / application related safety function. The following chapter lists the response times for individual functions, probably also in dependence on further parameters. If these data are insufficient for a specific application you should validate the actual time behaviour against the nominal behaviour by means of separate measurements.
Page 108: Response Time For Fast_Channel
Installation manual Response Explanation Function time [ms] With a monitoring function that has already been activated via ENABLE, the module requires one cycle Response of an already activated to calculate the current speed value. During the next monitoring function including cycle after calculation of the monitoring function the PLC editing in case of position and information is further processed and output by the...
Page 109: Response Times For Fault Distance Monitoring
Installation manual 6.3 Response times for fault distance monitoring The following calculation schematic applies for calculating the Worst Case condition. System speed to the sampling instant V(t) System speed in case of PSCBR response: Monitoring threshold (SLS or SCA): = constant for all t Parameterized filter value: XF = constant for all t Maximum possible acceleration of the application:...
Page 110 Installation manual Response Response Fault V m. Overspeed V w. overspeed Distanz [m/s] Distance [m/s] V ohne Overspeed V w/o. overspeed Distanz [m/s] Distance [m/s] s w. overspeed s m. Overspeed Distance [m/s] Distanz [m] s ohne Overspeed s w/o. overspeed Distanz[m] Distance [m/s] Diagram:...
Page 111: Response Times When Using Pscbr-E-31-12Di-10Dio
Installation manual With overspeed distance the following connections result for the course of V and s. Parameters Calculation methods Comment Value for response time data PSCBR + Deceleration time in external shut-off Response deceleration time in external shut-down chain derived from relay/contactor chain and brake data, etc.
Page 112 Installation manual Designation Response Explanation Function time [ms] Activation or deactivation of an Activation / deactivation digital output in the extension module output in extension module via PSCBR-E-31-12DI-10DIO after OUT_31 PAA in basic module changes to the PAA in the basic module.
Page 113: Start-Up
Installation manual 7 Start-up 7.1 Procedure Start-up must only be performed by qualified personnel! Strictly follow the safety regulations when commissioning! 7.2 Making sequences The following phases are passed through and displayed by the front side seven segment display after each new start and fault-free running of the module: 7 segment display Mode Description...
Page 114: Reset-Function
Installation manual 7.3 Reset-Function The reset-function is divided into a startup-function after a power cycle (power off / on) and a status-/alarm-reset = internal reset-function. The internal reset is called by pushing the “Reset”- button on the PSCBR front panel or by a input port, configured as “Reset-Element” with active “Alarmreset”.
Page 115: Reset-Timing
Installation manual 7.3.2 Reset-Timing The reset-input for a internal reset is time monitored in „RUN“-mode. A internal reset is called by a falling edge of the reset-input under the pre-condition of T<3sec between raising / falling edge. Max. 3 sec Max.
Page 116 Installation manual V_Ist > SOS_V_Max V_Ist SOS_Result Reset_In Max. 3 sec Max. 3 sec Example 2 for process value based safe monitoring function (SOS with speed monitoring) => no change in output status after reset if speed exceeds the parameterized limits. Max.
Page 117: Example Reset-Function With Safeguarding Against False Utilization
Installation manual 7.3.3.1 Example Reset-Function with safeguarding against false utilization Function: On a machine for normal operation mode, the hazardous area shell be protected by a mechanical guard system. If in setup mode, the safety level is kept by a release button in conjunction with standstill monitoring respective safe limited speed.
Page 118 Installation manual Applicative measure: By logic combination within the PLC-program the activation of the outputs by false utilization of the reset-function is prevented Example 1: The release function of the outputs (ID 88) is additionaly AND combined with a “Reset-Timer“. This timer prevents activation of the outputs for T> 3sec after a call of the reset-function.
Page 119 Installation manual Example 2: The release function of the outputs (ID 88) is additionaly AND combined with a FF (Flip-Flop) . This FF-element prevents activation of the outputs after a reset with still applied failures on the inputs. Just after a first correct detection of the input signals – both input lines on “HIGH”...
Page 120: Led Display
Installation manual 7.4 LED display Colour Mode Description System OK, configuration green "flashing" validated System OK, configuration yellow "flashing" not yet validated "flashing" Alarm "permanent" Fatal Fault Note: For all operating states except RUN the outputs are rendered passive by the firmware, i.e. safely switched off.
Page 121: Parameterization
Installation manual 7.5 Parameterization Parameterization takes place via the program SafePLC PSCBR. The transmission of these data to the module requires a programming adapter, the drivers of which must first be installed by the user. Parameterization is described in the programming manual. 7.6 Function test As a measure to ensure the safety of the module, the reliability of all safety functions must be checked once every year.
Page 122 Installation manual In order to assure the reliability of the implemented safety functions the user must check and document the parameters and links after the start-up and parameterization has taken place. This is supported by the parameterization software SafePLC PSCBR (see programming manual). On the first page one can enter general system data.
Page 123: Maintenance
Installation manual 9 Maintenance 9.1 Modification / handling changes to the device Maintenance work must solely be carried out by qualified personnel. Regular maintenance work is not required. Repair The devices must always be replaced as whole units Repair work on the device can only be performed in the factory. Warranty By opening the module without permission the warranty will become null and void.
Page 124: Environmental Conditions
Installation manual 10.1 Environmental conditions Class of protection IP 52 Ambient temperature 0 °C* ... 50 °C Climatic category 3 acc. to DIN 50 178 Lifetime 90000h at 50 °C ambient 10.2 Safety related characteristic data  Max. obtainable safety class SIL 3 acc.
Page 125: Fault Types Pscbr
Installation manual 11 Fault types PSCBR The PSCBR generally differentiates between two types of faults as per assignment below: Effect on Reset Fault type Description the system condition Severe exceptional fault caused by the program run in the PSCBR. Cyclic program All outputs Reset possible sequence is no longer possible for safety...
Page 126: Alarm List Pscbr
Installation manual 11.2 Alarm List PSCBR A 2101 / A 2102 Alarm message Timeout receive message PSCBR-E-31-12DI-10DIO (address 1) Cause Message from expansion module not received in time Remedy Check connection to expansion module A 2105 / A 2106 CRC fault transmission message PSCBR-E-31-12DI-10DIO (address Alarm message Cause Transmission message faulty...
Page 127 Installation manual A 2121 / A 2122 Alarm message Timeout receive message PSCBR-E-31-12DI-10DIO (address 2) Cause Message from expansion module not received in time Remedy Check connection to expansion module A 2125 / A 2126 CRC fault transmission message PSCBR-E-31-12DI-10DIO (address Alarm message Cause Transmission message faulty...
Page 128 Installation manual  Check the configuration of the digital input acc. to planning and Remedy circuit diagram  Check wiring A 3039 / A 3040 Alarm message Pulse2 plausibility fault on expansion inlet EAEx.2 Cause Configured Pulse2 voltage not applied to this input. ...
Page 129 Installation manual A 3051 / A 3052 Alarm message Pulse2 plausibility fault on expansion inlet EAEx.4 Cause Configured Pulse2 voltage not applied to this input.  Check the configuration of the digital input acc. to planning and Remedy circuit diagram ...
Page 130 Installation manual A 3065 / A 3066 Alarm message Fauklty 24V signal on EAEx.6 Cause No permanent 24V voltage applied to this input  Check the voltage on the digital input!  Remedy Check the wiring!  Check whether Pulse1 or Pulse2 is applied A 3067 / A 3068 Alarm message Pulse1 plausibility fault on expansion inlet EAEx.7...
Page 131 Installation manual A 3079 / A 3080 Alarm message Pulse1 plausibility fault on expansion inlet EAEx.9 Cause Configured Pulse2 voltage not applied to this input.  Check the configuration of the digital input acc. to planning and Remedy circuit diagram ...
Page 132 Installation manual A 3103 / A 3104 Alarm message Pulse1 plausibility fault on input DI2 Cause Configured Pulse1 voltage not applied to this input.  Check the configuration of the digital input acc. to planning and Remedy circuit diagram  Check wiring A 3105 / A 3106 Alarm message...
Page 133 Installation manual A 3117 / A 3118 Alarm message Pulse2 plausibility fault on input DI1 Cause No Pulse2 voltage applied to this input  Check the configuration of the digital input acc. to planning and Remedy circuit diagram  Check wiring A 3119 / A 3120 Alarm message Pulse2 plausibility fault on input DI2...
Page 134 Installation manual A 3131 / A 3132 Alarm message Pulse2 plausibility fault on input DI8 Cause No Pulse2 voltage applied to this input  Check the configuration of the digital input acc. to planning and Remedy circuit diagram  Check wiring A 3133 / A 3134 Alarm message Pulse1 plausibility fault on input DI9...
Page 135 Installation manual A 3147 / A 3148 Alarm message Pulse2 plausibility fault on input DI9 Cause Configured Pulse2 voltage not applied to this input.  Check the configuration of the digital input DI9 acc. to planning Remedy and circuit diagram ...
Page 136 Installation manual A 3161 / A 3162 Alarm message Faulty 24V signal on DI2 Cause No permanent 24V voltage applied to this input  Check the voltage on the digital input!  Remedy Check wiring  Check whether Pulse1 or Pulse2 is applied A 3163 / A 3164 Alarm message Faulty 24V signal on DI3...
Page 137 Installation manual A 3175 / A 3176 Alarm message Faulty 24V signal on DI9 Cause No permanent 24V voltage applied to this input  Check the voltage on the digital input!  Remedy Check wiring  Check whether Pulse1 or Pulse2 is applied A 3177 / A 3178 Alarm message Faulty 24V signal on DI10...
Page 138 Installation manual A 3197 / A 3198 Alarm message Faulty OSSD input test Cause OSSD test faulty  Remedy 24V check the input voltage on all OSSD inputs A 3209 / A 3210 Fault message Encoder supply voltage X31 faulty. ...
Page 139 Installation manual A 3231 / A 3232 Fault message Plausibility test for analog inputs faulty  Cause Fault in analog input signal  Check connection of analog inputs Remedy  Analog input voltage out of range A 3233 / A 3234 Fault message Open-circuit monitoring AIN1 has triggered ...
Page 140 Installation manual Check the theory of the distance using the configured data or the sensor setting Remedy Check the position signal, if necessary correct the offset Use the SCOPE function to read out the position and to set into relation to configured values A 3309 / A 3310 Alarm message Plausibility fault because of faulty speed axis 1...
Page 141 Installation manual Check the theory of the distance using the configured data or the sensor setting Check the position signal Remedy Are all signals correctly connected to the 9-pole encoder plug? Check the encoder plug for correct wiring. If proximity switches are used, these are correctly connected. Use the SCOPE function to adjust superimposable position signals A 3327 / A 3328 Alarm message...
Page 142 Installation manual A 3409 / A 3410 Alarm message Difference level RS485Treiber2 fault INC_A or SSI_DATA faulty  No encoder connection Cause  Wrong encoder type connected  Check encoder connection Remedy  Check encoder wiring A 3411 / A 3412 Fault message Fault Sine/Cosine plausibility X31 ...
Page 143 Installation manual A 3461 / A3462 The PIC reports a general status fault, e.g. when setting up a Fault message connection or because a timeout occurred during processing.  Cause Internal fault  Power cycle of the device Remedy  Check the extension board A 3463 / A3464 Plausibility test between the analog sine signal abd the TTL-level at...
Page 144 Installation manual  Cause Counting signals of the encoder are incorrect  Check the encoder connection  Remedy Check the encoder signal  Check the extension board A 3505 / A 3506 Fault message Read head fault WCS encoder system axis 1 ...
Page 145 Installation manual  Check the encoder connection  Remedy Check the encoder signal  Replace the SSI-encoder A 3561 / A3562 Fault message SSI_ECE STATUS 2. axis SSI Ext Encoder  Cause Evaluation of the 1st status bit is faulty ...
Page 146 Installation manual A 3573 / A3574 Fault message SSI STATUS 1. axis SSI Encoder  Cause Evaluation of the 2nd status bit is faulty  Check the encoder connection  Remedy Check the encoder signal  Replace the SSI-encoder A 3575 / A3576 Fault message SSI STATUS 1.
Page 147 Installation manual Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on A 3809 / A3810 Fault message Faulty switching of output EAAx.5 Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on A 3811 / A3812 Fault message Faulty switching of output EAAx.6 Cause...
Page 148 Installation manual In programming make sure that only one "Enable" is activated at a Remedy time A 4601 / A 4602 Alarm message Monitoring range left and right of SLP1 activated at the same time Cause Multiple activation In programming make sure that only one "Enable" is activated at a Remedy time A 4603 / A 4604...
Page 149: Fatal Fault List Pscbr
Installation manual A 4901 / A 4902 Alarm message CCW and CW rotation monitoring SLI1 activated at the same time Cause Multiple activation In programming make sure that only one "Enable" is activated at a Remedy time A 4903 / A 4904 Alarm message CCW and CW rotation monitoring SLI2 activated at the same time Cause...
Page 150 Installation manual F 1007 Fault message Device not programmed with the correct programming desktop Program or configuration data transferred to the device using the Cause wrong programming desktop Check the module design and parameterize again with a valid Remedy programming desktop. Then switch device off/on. F 1307 Fault message Fault when deleting configuration data from the Flash Memory...
Page 151 Installation manual F 1601 / F 1602 Fault message Range test of device description is faulty. F 1603 / F 1604 Fault message Range test of Access Data faulty F 1605 / F 1606 Fault message Range test of EMU faulty F 1607 / F 1608 Fault message Range test SCA faulty...
Page 152 Installation manual F 1627 / F 1628 Fault message Range test of outputs faulty F 1629 / F 1630 Fault message Range test of digital inputs faulty. F 1631 / F 1632 Fault message Range test of analog input F 1633 / F 1634 Fault message Range test of encoder type faulty F 1635 / F 1636...
Page 153 Installation manual F 1655 / F 1656 Fault message Range test SAC faulty F 1657 / F 1658 Fault message Range test of diagnose faulty F 2001 / F 2002 Internal fault – please contact the manufacturer! Fault message F 2003 / F 2004 Fault message Timeout when transmitting configuration and firmware data F 2005...
Page 154 Installation manual  Check device supply voltage! Remedy  Switch device off/on. F 3204 Fault message Internal supply voltage 5.7V faulty  Supply voltage for module not correct! Cause  Component fault in module  Check device supply voltage! Remedy ...
Page 155 Installation manual Remedy Switch device off/on F 3605 / F 3606 Fault message Faulty switching of relay K2 Cause Internal triggering of relay faulty Remedy Switch device off/on F 3609 Fault message Faulty switching of "0V" driver DO1_L Cause Switching state of output faulty Remedy Switch device off/on F 3610...
Page 156 Installation manual F 3616 Fault message Faulty testing of "24V" driver DO2_H Cause Short-circuit of outPort with "24V" Remedy Switch device off/on F 3617 Internal fault – please contact the manufacturer! Fault message F 3618 Internal fault – please contact the manufacturer! Fault message F 3619 Internal fault –...
Page 157 Installation manual F 3827 Fault message Faulty switching of output EAAx.4 Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on F 3829 Fault message Faulty switching of output EAAx.5 Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on F 3831...
Page 158 Installation manual F 3845 / F 3846 Fault message Faulty testing of output EAAx.3 Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on F 3847 / F 3848 Fault message Faulty testing of output EAAx.4 Cause Short-circuit of outPort with "24V" or "0V" Remedy Switch device off/on F 3849 / F 3850...
Page 159 Installation manual F 3874 Internal fault – please contact the manufacturer! Fault message F 3892 Internal fault – please contact the manufacturer! Fault message F 3894 Internal fault – please contact the manufacturer! Fault message F 4501 / F 4502 Alarm message Faulty calculation of SSX brake ramp Cause...
Page 160 Installation manual Internal fault – please contact the manufacturer! Fault message F 8205 / F 8206 Internal fault – please contact the manufacturer! Fault message F 8207 / F 8208 Internal fault – please contact the manufacturer! Fault message F 8213 / F 8214 Internal fault –...
Page 161 Installation manual F 9013 / F 9014 Internal fault – please contact the manufacturer! Fault message F 9015 / F 9016 Internal fault – please contact the manufacturer! Fault message F 9017 / F 9018 Internal fault – please contact the manufacturer! Fault message Page 161 of204...
Page 162: Encoder Types
Installation manual 12 Encoder types Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) 1 x Bero...
Page 163 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) Incremental Resolver n.a.
Page 164 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) SIN/COS n.a.
Page 165 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed direction position Encoder to Encoder to Encoder to 1-channel 2-channel 2-channel interface interface X 23 partial partial partial X31/32 X31/34 system system system dynamic non- dynamic (standstill monitoring) Fault exclusion mech. shaft breakage, positive 80-90% encoder shaft connection required 2 x Bero 90°...
Page 166: Switch Types
Installation manual 13 Switch types Type Graphic symbols Truth table Logic function Function block Function Normally Ö LD E.1 Normally open, only shown Öffner ST IE.X normally closed closed contact Ausgang Output eSwitch_1o Normally LD E.1 Normally open, as type 1 Öffner closed ST IE.X...
Page 167 Installation manual Graphic symbols Truth table Function Normally Ö LD E.1 Monitoring for S=inactive and AND NOT E.2 Ö=active closed Öffner ST IE.X contact Normally Schließer open contact Ausgang Output eSwitch_1s1o Normally LD E.1 Time monitoring Like 5, but with time monitoring Ö...
Page 168 Installation manual Graphic symbols Truth table Function S1 Ö Ö2 LD E.1 Time monitoring Like 6, but with time monitoring Normally OR E.2 MET1..MET4 of state changes. Öffner 1 closed 1 OR NOT E.3 In case of signal changes at S Normally ST META_EN.1 (Attention: Bus line) or Ö...
Page 169 Installation manual LD E.1 Time monitoring Like 8, but with time monitoring Ö1 Ö2 Ö3 Normally OR E.2 MET1..MET4 of state changes. closed 1 Öffner 1 OR E.3 In case of signal change on one ST META_EN.1 of the Ö-inputs the other inputs Normally Öffner 2 must follow within a period of...
Page 170 Installation manual Graphic symbols Truth table Function Ö Ö LD NOT E.1 Two-hand Monitoring for S1*S2=inactive Normally OR E.2 operation and Ö1*Ö2=active + temporal Öffner 1 closed 1 OR NOT E.3 monitoring of this status. This OR E.4 means that in case of a signal ST MEZ_EN.1 change of an S from 1->0 or Ö...
Page 171 Installation manual ST IE.X eTwoHand_2s Normally LD E.1 Selector switch Clear linkage of permissible S1 S2 A AND NOT E.2 switch positions closed Öffner ST IE.X contact Normally Schließer LD NOT E.1 open AND E.2 contact ST IE.X2 Ausgang Output eMode_1s1o S1 S2 S3 A LD E.1...
Page 172: Notes On Designing, Programming, Validating And Testing Safety Related Applications
Installation manual 14 Notes on designing, programming, validating and testing safety related applications The following notes describe the procedure for designing, programming, validating and testing safety related applications The information should help the user to classify, to easily understand and to use all steps from risk assessment all the way to the system test.
Page 173 Installation manual Risk assessment as per EN ISO 13849-1 S – Severe physical injury Low contribution to risk S1 = minor, reversible injury reduction S2 = severe, irreversible injury F – Frequency and/or duration of exposure to danger Starting point F1= rarely, not cyclic F2 = frequently up to permanent and/or long duration, cyclic operation...
Page 174: Required Technical Documents
Installation manual Further information concerning the risk assessment and the safe design of machines can be found in the standards EN 14121 Safety of machines - risk assessment EN 12100 Safety of machines - basic terms, general design guidelines Measures to be applied in order to reduce identified risks must at least be of the same level as the danger itself.
Page 175: Necessary Steps For Draft, Realization And Testing
Installation manual 14.3 Necessary steps for draft, realization and testing The realization of plant sections with safety related function requires special attention in planning, realization and testing. Also for this the standards (see ISO 13849-2 or EN ISO 61508) contain specific guidelines. The effort thereby is orientated on the complexity of the task for system components with safety related function.
Page 176 Installation manual Phases of the V-model Designation Description Design phase Validation phase Specification and Specification of all safety Testing of all passive and active validation of all measures to be applied, such safety measures for correct passive and active as covers, barriers, max. implementation and effectiveness.
Page 177: Specification Of Safety Requirements (Structural Schematic)
Installation manual 14.3.1 Specification of safety requirements (structural schematic) The safety requirements must be individually analysed on the basis of applicable standards, e.g. product standard. Page 177 of 204...
Page 178 Installation manual Page 178 of 204...
Page 179 Installation manual Source General specification, excerpt from BGIA Report 2/2008 concerning EN ISO 13849-1 Page 179 of 204...
Page 180 Installation manual Example for an automatic handling machine: Description of function: The automatic handling machine serves the purpose of automatically picking up truck cabins of different heights. After being picked up, the height of the cabin is correctly detected, so that within the working area the cabin cannot be lowered below a certain height.
Page 181 Installation manual Example for a risk analysis: Gefahrenanalyse Risk analysis Page 181 of 204...
Page 182: Specification Of The Functional Safety System
Installation manual 14.3.2 Specification of the functional safety system Derived from the general danger and risk analysis for the machine, the active safety functions must be identified and specified. Active safety functions are, e.g. safely reduced speed under certain system conditions, monitored stop and standstill functions, area monitoring facilities, processing of monitoring facilities like light grid, switching mats, etc.
Page 183: Example - Specification Of Safety Functions In Form Of A Table
Installation manual Example – Specification of safety functions in form of a table 14.3.2.3 Cons Safety function Measuring Implementation of Nominal Input/activation Response/ .-No. value /sensor software parameters output Limitation of max. 1 x WCS Monitoring by means of 550mm/s Permanently Operation travel speed to...
Page 184: Software Specification
Installation manual 14.3.3 Software specification The software specification refers to the previous specification of the safety functions. It can also be replaced by a correspondingly worked out specification of the safety functions, as far as this contains all specifications (see example under 14.3.2.3). However, it is recommended to prepare an extracted list.
Page 185 Installation manual Example of software specification Safety function Measuring Solution new Input/activation Response/output value /sensor Monitoring V_Rope to Digital Monitoring by means of tested Permanently Operation stop V_Nominal incremental function SLS + SAC with comparison Monitoring of differences encoder, of speed ranges /analog value SF 1.3.1 between speed of main ranges = comparison for diagnose of...
Page 186: Hardware Specification
Installation manual 14.3.4 Hardware specification The hardware specification should describe the entire system design and, in particular, the components used with their specific characteristic data. The hardware specification serves as basis for the determination of the achieved safety level based on the architecture and the characteristic data of all devices involved in a safety function.
Page 187: Example For Hardware Specification
Installation manual 14.3.4.2 Example for hardware specification Safety function Safely reduced speed SF 2.2 Safely monitored limited speed with door open Type Designation Function Design Characteristic data Note Archite MTTFD B10d Source Source cture [Years] [1/h] Door lock – Monitoring of the Sensor Sensor 1 A 3.1...
Page 188: Consideration Of Systematic Failures
Installation manual 14.3.4.3 Consideration of systematic failures Within the hardware specification one must also consider systematic failures. Examples for measures against systematic failures: Power drop during operation. If this causes a danger, a power drop must be considered a operating status. The SRP/CD must be able to cope with this condition, so that a safe state is maintained.
Page 189: Hard And Software Design
Installation manual 14.3.5 Hard and software design The performance targets from the hardware and software specification are implemented in the actual system design. The performance targets for the components to be used and their wiring from the hardware specification must also be met, the same applies for the performance targets for fault exclusions.
Page 190 Installation manual A calculation acc. to EN ISO 13849-1 shall serve as an example: Safety function: Safely reduced speed with access door open Structural diagram: Sensor Sensor Single channel partial system Dual-channel partial system Eink. Teilsyst. Zweik. Teilsyst. Track A Spur A Mech.
Page 191 Installation manual Calculation acc. to EN 13849-1: Channel A – shut-down via mains contactor: Component MTTFD [years] Door closer B10d = 100000 DCSwitch = 99% Nop = 30/AT = 10000/year(309 AT/year) SIN/COS MTTFD_SinCos = 30 years DCEncoder = 99% encoder: PFH = 1.4 * 10-8 DCPES = 99% Mains...
Page 192 Installation manual Channel B – shut-down via STO/inverter: Component MTTFD [years] Door closer B10d = 100000 DCSwitch = 99% Nop = 30/AT = 10000/year(309 AT/year) SIN/COS MTTFD_SinCos = 30 years DCEncoder = 99% encoder: PFH = 1.4 * 10-8 DCPES = 99% STO/ inverter MTTFD_STO = 150 years DCPES = 90%...
Page 193: Verification Software(Program) And Parameters
Installation manual 14.3.7 Verification software(program) and parameters Verification takes place in two steps. Checking the FUP with respect to the specified functionality. Checking the FUP against the AWL-listing of the validation report, or the default parameters against the one listed in the validation report. 14.3.7.1 Checking FUP The programmed FUP must be compared with the defaults in the specification.
Page 194 Installation manual Shut down on carriage Emergency stop Gap available Release brake Release brake The carriage is switched off via two outputs (EAA1.5 ID 257 and 1.6 ID 261). The brakes are released via two outputs (EAA1.3 ID 253 and 1.4 ID 249). The PLC receives a message concerning bit 50 (ID 600) In case of an emergency stop the shut-down takes place immediately.
Page 195: Validation Of Fup Against Awl And Parameters By Means Of Validation Report
Installation manual 14.3.7.2 Validation of FUP against AWL and parameters by means of validation report. The programming that took place in the FUP must be compared with the AWL-listing of the validation report. Example AWL-listing in validation report Validation report OLC-program Name: <leer>...
Page 196 Installation manual After checking the program one must also check the parameters against the targets set in the specifications by means of comparison. Example SLS: Validation report Safe Limited Speed (SLS) Index Parameters Value validated SLS - Chosen axis: Speed threshold: SLS - Chosen axis: Speed threshold:...
Page 197 Installation manual Example encoder configuration: Validation report Axis configuration / sensor interface Axis 1 General parameters Measuring distance: Type: Rotational Position processing: Active Maximum speed: 2000 Incremental shut-down: 10000 Shut-down speed: Sensors Type: SSI-standard SSI-standard Format: Binary Binary Direction of rotation: Ascending Ascending Supply voltage:...
Page 198: Performance Of The System Test / Fit (Fault Injection Test)
Installation manual 14.3.8 Performance of the system test / FIT (fault injection test) For the FIT the manufacturer must prepare a complete list of the functions to be tested. This list includes the defined safety functions as well as the fault test for checking the right response of the SRP/CS to this fault Example test list: Setup...
Page 199: Appendix
Installation manual Appendix Appendix A – Classification of switch types General note: The individual switches of the following input elements can be assigned to the digital inputs DI1 to DI8 as desired. Enable switch Switch type Comment Classification PI acc. Classification SIL acc.
Page 200 Installation manual Page 200 of 204...
Page 201 Installation manual Two-hand button Switch type Comment Classification Classification SIL category 2 two-way switch Two-hand button higher Type III C Pl e SIL3 requirements 2 normally open Two-hand button Type III A Pl e SIL1 monitored Note: With these inPort elements a fixed pulse assignment takes place, which cannot be influenced by the user! Light curtain Switch type...
Page 202 Installation manual Start / reset element Switch type Comment Classification Classification SIL category 1 normally open Alarm reset standard (evaluation of edge) 1 normally open Logic reset standard Pl d SIL 2 1 normally open Start monitoring standard (optional function) Note: The alarm reset input can be operated with 24V continuous voltage and is edge triggered.
Page 203 EC-directive  Maschines 2006/42/EG Appendix IV The safety component Manufacture: ACE Schmersal Eletroeletrônica Industrial Ltda. Type: PSCBR-C-10, PSCBR-C-10-SDM1, PSCBR-C-10- SDM1-2, PSCBR-C-10-SDM2, PSCBR-C-10-SDM2-2, PSCBR-C-10-SDM2A, PSCBR-E-31-12DI-10DIO has been developed, designed and manufactured in compliance with the above mentioned directive as well as the EC-directive ...
Page 204 Part 1: General design principles  EN ISO 13850:2008 Safety of machines; EMERGENCY Stop, design principles  EN 574:1996 + A1:2008 Safety of machines; two-hand controls, functional aspects, design principles  EN 55 011 : 2007 Industrial, scientific and medical equipment - radio interferences - limit values and measuring methods The following non-harmonised standards were also applied: ...

schmersal PSCBR-C-10 Series Installation Manual

Quick Links

Need help?

Questions and answers

Related Manuals for schmersal PSCBR-C-10 Series

Summary of Contents for schmersal PSCBR-C-10 Series

Table of Contents