schmersal PSC1 Series Installation Manual
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schmersal PSC1 Series Installation Manual

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PSC1-C-10
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HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx
Page 1 of 177
Version: 38F

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  • Page 1 Installation manual Installation manual PSC1 modules Series PSC1-C-10 PSC1-C-10-SDMx PSC1-E-3x HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 1 of 177 Version: 38F...
  • Page 2 Installation manual HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 2 of 177 Version: 38F...
  • Page 3 Information and specifications may be changed at any time. Please obtain information on the latest version at: www.schmersal.net. Devices manufactured by K. A. Schmersal GmbH & Co. KG Möddinghofe 30 42279 Wuppertal HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx...

  • Page 4: Table Of Contents

    Installation manual Contents IMPORTANT NOTES ..................... 7 Definitions .............................. 7 Reference documents ..........................8 Abbreviations used ..........................9 SAFETY INSTRUCTIONS ..................11 Intended use ............................11 Usage in regions with UL/CSA requirement ..................11 General safety instructions ........................12 Operating and service ........................... 13 Transport/storage ..........................
  • Page 5 Installation manual 4.3.5 Digital outputs I/O (IQQx) ..................... 79 4.3.5.1 Classification of the I/O (IQQx) on usage as an output ............ 79 4.3.5.2 Example circuits for safe digital outputs I/O (IQQx) ............80 4.3.5.3 Overview of achievable PL for digital safety outputs ............85 CONNECTION AND INSTALLATION ..............
  • Page 6 Installation manual 7.3.3.1 Example reset function with protection against incorrect usage ........132 LED indication ............................. 135 Parameter configuration........................136 Function check ............................ 136 Validation ............................136 SAFETY-RELATED CHECK ................137 SERVICING ......................138 Modification / dealing with changes to the device ................138 Replacement of a module ........................

  • Page 7: Important Notes

    Installation manual 1 Important notes Definition of the individual target groups Designers of safe drive systems: Engineers and technicians Mounting, electrical installation, maintenance and device replacement Industrial electricians and service engineers Commissioning, operation and configuration: Technicians and engineers 1.1 Definitions The term PSC1 is used as the generic term for all derivatives of the PSC1 product line.

  • Page 8: Reference Documents

    Installation manual 1.2 Reference documents Description Reference Configuration of the PSC1 module SafePLC2 programming manual using the program "SafePLC2" (System CD) Validation report on the parameter Safety-related test with acceptance configuration implemented and the report PLC program Acceptance for general safety-related Certificate on the type test for safety applications control according to Machinery directive...

  • Page 9: Abbreviations Used

    Installation manual 1.3 Abbreviations used Abbreviation Meaning Alternating Current Instruction List Berufsgenossenschaft (German employer's liability insurance association) Clock Central Processing Unit Direct Current I00..I13 Digital Input Deutsches Institut für Normung Digital Output Emergency Monitoring Unit ElectroMagnetic Compatibility Emergency Limit Control European Norm HISIDE Output that switches to positive with 24 VDC nominal level...
  • Page 10 Installation manual Abbreviation Meaning SMMC Safe Master-Master Communication HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 10 of 177 Version: 38F...

  • Page 11: Safety Instructions

    Cf. Appendix EC declaration of conformity 2.2 Usage in regions with UL/CSA requirement Modules in the PSC1 series that do not have UL/CSA approval can be used in the USA and Canada under the following conditions: The switching voltage on the output relay is to be limited to max. 24 V.

  • Page 12: General Safety Instructions

    Installation manual 2.3 General safety instructions Safety instructions:  To prevent injury and damage, only qualified personnel are allowed to work on the device. Qualified personnel are personnel who have electrical engineering training and who are familiar with the applicable rules and standards of electrical engineering. The qualified person must become familiar with the operating instructions (cf.

  • Page 13: Operating And Service

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

  • Page 14: Device Types

    Installation manual 3 Device types The series PSC1-C-10 comprises The basic devices PSC1-C-10, PSC1-C-10-SDM1, PSC1-C-10-SDM2 The expansion modules PSC1-E-31…, PSC1-E-33… The decentral expansion module PSC1-E-37… The integrated communication interface (optionally with safe fieldbus) PSC1-C-10-…- Basic devices The series PSC1-C-10 is a compact safety controller with optionally integrated drive monitoring for one (PSC1-C-10-SDM1) or two (PSC1-C-10-SDM2) axes.
  • Page 15 Installation manual HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 15 of 177 Version: 38F...

  • Page 16: Module Overview

    Installation manual 3.1 Module overview Basic modules Expansion modules PSC1-C- PSC1-C- Designation PSC1-C- PSC1-E-31-12DI- PSC1-E-33-12DI- PSC1-E-37-14DI- 10-SDM1 10-SDM2 10(-FBx 10DIO 6DIO-4RO 4DO-2RO-RIO (-FBx (-FBx General data Max. number of expansion modules Safe digital inputs Safe digital I/O Safe digital outputs switching / pp switching Safe analogue inputs Relay outputs...

  • Page 17: Device Characteristic Data

    Installation manual 3.2 Device characteristic data 3.2.1 Basic modules 3.2.1.1 PSC1-C-10 (-FBx Type designation Device version Version of the module with following peripherals: digital inputs pulse outputs relay outputs pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED...
  • Page 18 Installation manual  Quit/start/reset button can be operated on the front  Optional: communication interface o Standard and safe fieldbus protocols for communication with a higher-level controller o Safe cross-communication for the exchange of data between several basic devices o Safe remote IO communication for the exchange of data with distributed IO systems See: section 3.2.4 Optional universal communication interface ...

  • Page 19: Psc1-C-10 (-Fbx (1) )

    Installation manual Tech. characteristic data PSC1-C-10 (-FBx Safety-related characteristic data PL according to EN 13849 PL e PFH / architecture 6,3 * 10 / CAT 4 1-channel per Relay 1 * 10 2-channel per Relay 5 * 10 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max.

  • Page 20: Psc1-C-10-Sdm1 (-Fbx )

    Installation manual 3.2.1.2 PSC1-C-10-SDM1 (-FBx Type designation Device version Version of the module with following peripherals: axis encoder interfaces digital inputs pulse outputs relay outputs pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED status LEDs for inputs status LEDs for relay outputs...
  • Page 21 Installation manual  Switchable safe outputs pn, pp switching for safety-related functions  The mechanical layout of the PSC1-C-10 (-FBx ) is different to the figure. (See mechanical data) HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 21 of 177 Version: 38F...
  • Page 22 Installation manual Tech. characteristic data PSC1-C-10-SDM1 (-FBx Safety-related characteristic data PL according to EN 13849 PL e PFH / architecture 6,3 * 10 / KAT 4 1-channel per Relay 1 * 10 2-channel per Relay 5 * 10 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max.
  • Page 23 Installation manual HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 23 of 177 Version: 38F...

  • Page 24: Psc1-C-10-Sdm2 (-Fbx )

    Installation manual 3.2.1.3 PSC1-C-10-SDM2 (-FBx Type designation Device version Version of the module with following peripherals: axes encoder interfaces digital inputs pulse outputs relay outputs pn or pp switching outputs signal outputs diagnostics and configuration interface function button 7-segment display status LED status LEDs for inputs status LEDs for relay outputs...
  • Page 25 Installation manual  Monitored relay outputs for safety-related functions  Switchable safe outputs pn, pp switching for safety-related functions  The mechanical layout of the PSC1-C-10-SDM2 (-FBx ) is different to the figure. (See mechanical data) HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 25 of 177 Version: 38F...
  • Page 26 Installation manual Tech. characteristic data PSC1-C-10-SDM2 (-FBx Safety-related characteristic data PL according to EN 13849 PL e PFH / architecture 6,3 * 10 / KAT 4 1-channel per Relay 1 * 10 2-channel per Relay 5 * 10 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max.

  • Page 27: Central Expansion Modules

    Installation manual 3.2.2 Central expansion modules 3.2.2.1 PSC1-E-31 and PSC1-E-33 Type designation Device version Version of the module with following peripherals: digital inputs 10/6 digital I/O pulse outputs signal outputs relay outputs (PSC1-E-33) status LEDs for inputs status LEDs for relay outputs 10/6 status LEDs for I/O status LEDs for outputs...
  • Page 28 Installation manual Properties of the module:  12 safe inputs, OSSD support  10 safe I/O - can be configured as input or output o PSC1-E-33 with a total of 4 relay outputs and 6 I/O  Cross-circuit monitoring  Contact multiplication or contact rating increase by means of external contactors in conjunction with integrated monitoring possible ...
  • Page 29 Installation manual Tech. characteristic data: PSC1-E-31 and PSC1-E-33 Safety-related characteristic data PL according to EN 13849 PL e PFH / architecture 4,6 * 10 / CAT 4 + bei PSC1-E-33 1-kanalig pro Relais 1 * 10 2-kanalig pro Relais 5 * 10 SIL according to EN 61508 SIL 3 Proof test interval...

  • Page 30: Decentral Expansion Modules

    Installation manual 3.2.3 Decentral expansion modules 3.2.3.1 PSC1-E-37 Type designation Device version Version of the module with following peripherals: digital inputs pulse outputs relay outputs pn or pp switching outputs signal outputs 7-segment display status LED status LEDs for inputs status LEDs for relay outputs status LEDs for outputs Properties of the module:...
  • Page 31 Installation manual  Tech. characteristic data: PSC1-E-37 Safety-related characteristic data PL according to EN 13849 PL e PFH / architecture 4,6 * 10 / CAT 4 1-channel pro Relay 1 * 10 2-channel pro Relay 5 * 10 SIL according to EN 61508 SIL 3 Proof test interval 20 years = max.

  • Page 32: Optional Universal Communication Interface

    Memory card microSD) Storage medium for safety program Properties of the universal communication interface:  Optional version of the communication interface for the PSC1 series  The different versions can be combined. See "Possible combinations".  For more detailed information, please refer to the installation manuals for the related fieldbus modules.
  • Page 33 Installation manual Tech. characteristic data: Optional universal communication interface Safety-related characteristic data PL according to EN 13849 n.a. PFH / architecture n.a. SIL according to EN 61508 n.a. Proof test interval n.a. General data Decentral communication interfaces 2x RJ 45* (in preparation) Fieldbus interfaces -FB1...

  • Page 34: Possible Combinations

    Installation manual 3.2.4.1 Possible combinations Options -FB1 -FB2 SDDC SMMC preparation) PSC1-C-10 PSC1-C-10-SDM1 PSC1-C-10-SDM2 PSC1-E-31 PSC1-E-33 PSC1-E-37 Always with option -FB1/2 or integrated into the PSC1-E-37 (in preparation) Always with option -FB1 / 2 (in preparation 3.2.4.2 Using the memory card Any industrial microSD card between 8 MB to 32 GB with FAT16 or FAT32 file system can be used.
  • Page 35 Installation manual Tech. characteristic data: Optional universal communication interface Safety-related characteristic data PL according to EN 13849 n.a. PFH / architecture n.a. SIL according to EN 61508 n.a. Proof test interval n.a. General data Decentral communication interfaces 2x RJ 45* Fieldbus interfaces -FB1 2x RJ 45**...

  • Page 36: Encoder Specifications

    Installation manual 3.2.5 Encoder specifications Encoder Connection Diagnostics Value type SIN/COS; TTL X1; X2 Max. frequency 200 kHz X3; X4 (n.a.) Max. frequency 250 kHz Amplitude SIN/COS 1 Vpp +/- 0.3 V Type of connection Sub-D 9-pin SSI absolute X1; X2 Clock frequency Master mode 150 kHz / slave mode max.

  • Page 37: Marking

    Q4...Q5 (Relay): 240 VAC / 24 VDC / 2 A Y0...Y1 (Auxilary): 24 VDC / 0,25 A K.A. Schmersal GmbH & Co. KG, DE-42279 Wuppertal www.schmersal.com see operating manual for the response time Type plate PSC1-C-10 (image enlarged) HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx...

  • Page 38: Items Supplied

    Installation manual 3.3.2 Items supplied Included in the items supplied: PSC1 module:  Connectors for all signal terminals not including encoder connection Not included in the items supplied:  SafePLC2 configuration software CD with  Installation manual  Programming manual ...

  • Page 39: Safety-Related Features

    Installation manual 4 Safety-related features 4.1 General layout, safety-related architecture and characteristic data The internal layout of the PSC1 series comprises two separate channels with mutual result comparison. High-quality diagnostics are undertaken in each of the two channels for fault detection.

  • Page 40: Safety-Related Characteristic Data And Circuitry For Sensors Connected

    Installation manual Characteristic data:  Max. achievable safety class SIL 3 as per EN61508  Category 4 as per EN945-1  Performance Level e as per EN ISO 13849-1 System structure 2-channel with diagnostics (1002) according to EN 61508 Architecture category 4 according to EN 13849 Design of the operating mode "High demand"...

  • Page 41: Digital Sensors

    Installation manual 4.2.1 Digital sensors: The digital inputs are of completely redundant design with the exception of the electromechanical input terminals. The details for the categorisation, the DC and the achievable PL or SIL are listed in the following. 4.2.1.1 Characteristics of the sensors / input elements Sensor Aktuator Dual-channel input element in parallel circuit (cat.
  • Page 42 Installation manual Cross comparison: The inputs on the PSC1 modules are in principle designed internally as dual-channel. The status of the input signals is continuously cross compared. Only with a high signal in both input sub-systems is the high status of the input detected, if the signal level varies between the two channels, the input is set to low status.
  • Page 43 Installation manual The operative/organisational tests can also be used for a combination of hardware inputs and functional inputs (input information transmitted via standard fieldbus). The exclusive usage of functional inputs is however excluded in this respect (combination of two or more functional inputs) The PSC1 modules therefore provide wide-ranging diagnostic functions for the input sub- system.
  • Page 44 Installation manual For the safety-related assessment of the overall system, it is therefore possible in principle to use the following diagnostics for the input sensors: Characteristic Tests that can be Definition of the Comment s of the input configured / operative measure element tests...

  • Page 45: Classification Of The Safe Digital Inputs

    Installation manual Safety instructions:  For a safety-related assessment of the sensor sub-system, the information from the manufacturer (MTTFD, FIT figures etc.) is to be used.  The DC values stated in the table are to be used conservatively and compliance with the boundary conditions (see "Comments"...
  • Page 46 Installation manual 4.2.1.3.2 Digital inputs I/O (IQIx) Digital inputs Achievable Remark Performance Level Without pulse, single-channel static signal -> Signal input Without pulse, dual-channel static signal At least one demand/day due to PL e application Fault detection only on demand Without pulse, dual-channel static signal PL d Less than one demand/day due to...

  • Page 47: Connection Examples, Digital Sensors

    Installation manual 4.2.1.4 Connection examples, digital sensors 4.2.1.4.1 Single-channel sensor, without cross-circuit testing Figure: Single-channel sensor, without cross-circuit testing The single-channel sensor is connected to the PSC1 without test pulses, and without cross- circuit testing. This design is not recommended for safety applications. Max. PL b according to EN ISO 13849-1 can be achieved.
  • Page 48 Installation manual The usage of a single-channel sensor with test pulses detects: Short-circuit to the supply voltage DC 24 V Short-circuit to DC 0 V Cable break (interruption of power is safe state!) Caution is required, on the other hand, if there is a cable short-circuit between the two connections for the sensor, as this will not be detected! A short-circuit between T0 and I00 is also not detected.
  • Page 49 Installation manual 4.2.1.4.3 Dual-channel sensor without time monitoring with cross-circuit testing Faults are detected as a minimum on demand. The DC is medium and can be changed to the high category by using cyclic tests (start tests, operative/organisational tests) depending on the test frequency.
  • Page 50 Installation manual Safety instructions:  PL d or higher according to EN ISO 13849-1 is achieved on the usage of switching elements / sensors with positively opening contacts or positive actuation according to EN 60947-5-1. When using sensors with non-positively driven opening contacts, the macro (group) "Universal input module"...
  • Page 51 Installation manual 4.2.1.4.4 Dual-channel sensor with time monitoring and cross-circuit testing By using two independent test pulse signals on the homogeneous sensor, all cross-circuits and connections to DC 24 V and DC 0 V can be detected. PL d or higher according to EN 13849-1 can be achieved on: - The usage of sensors / switching elements with positive actuation.

  • Page 52: Overview Of Achievable Pl For Digital Safety Inputs

    Installation manual 4.2.1.5 Overview of achievable PL for digital safety inputs Type of Input Tests that can be Achieva Fault exclusion for Condition for input sensor / configured / ble PL input element element input operative tests accordi element ng to EN1384 Input element proven in operation...
  • Page 53 Installation manual Type of Input Tests that can be Achieva Fault exclusion for Condition for input sensor / configured / ble PL input element element input operative tests accordi element ng to EN1384 Short-circuit on the Connection in the switch input/signal wire cabinet or protected laying Stuck / positive opening...

  • Page 54: Sensors For Speed And/Or Position Acquisition

    Sensors for speed and/or position acquisition 4.2.2.1 General safety-related layout of sensor interface for position and/or speed Optionally, the basic modules in the PSC1 series have a (PSC1-C-10-SDMx) encoder interface per axis. Different safety levels can be achieved depending on the encoder type and encoder combination.

  • Page 55: General Diagnostic Measures For Encoder Interface

    4.2.2.2 General diagnostic measures for encoder interface For fault detection in the sensor system, a series of diagnostic measures are implemented in the PSC1 series depending on the encoder type selected and their combination. The measures are activated automatically with the selection of the encoder type.

  • Page 56: Encoder Types And Their Combinations, Diagnostic Characteristic Data

    Installation manual 4.2.2.3 Encoder types and their combinations, diagnostic characteristic data Type Type Type Safe Safe Safe Fault exclusion speed directio position Encoder on Encoder on Encoder on interface interface X 23 1-channel 2-channel 2-channel X1/2 X3/4 sub-system sub-system sub-system dynamic non- dynamic...
  • Page 57 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed directio position Encoder on Encoder on Encoder on interface interface X 23 1-channel 2-channel 2-channel X1/2 X3/4 sub-system sub- sub-system system non- dynamic dynamic (standstill monitoring) Incremental n.a. 90-95% Fault exclusion mech.
  • Page 58 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed directio position Encoder on Encoder on Encoder on interface interface X 23 1-channel 2-channel 2-channel X1/2 X3/4 sub-system sub- sub-system system non- dynamic dynamic (standstill monitoring) SIN/COS n.a. 95-99% 2 x proximity n.a.
  • Page 59 Installation manual Type Type Type Safe Safe Safe Fault exclusion speed directio position Encoder on Encoder on Encoder on interface interface X 23 1-channel 2-channel 2-channel X1/2 X3/4 sub-system sub- sub-system system non- dynamic dynamic (standstill monitoring) 2 x proximity n.a.

  • Page 60: Specific Diagnostic Measures In Relation To The Encoder Type Used

    Installation manual 4.2.2.4 Specific diagnostic measures in relation to the encoder type used Encoder type Incremental SIN/COS Proximity switch 2 x count input Proximity switch 1 x count input Incremental SIN_COS Only in the high-resolution mode HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 60 of 177 Version: 38F...

  • Page 61: Safety-Related Shutdown Thresholds, Encoder Systems For Position And Speed Acquisition

    Installation manual 4.2.2.5 Safety-related shutdown thresholds, encoder systems for position and speed acquisition As a basic measure, plausibility tests between the two measurement channels A and B for speed and position on the PSC1 module are undertaken with the actual values for position and speed and tested against configured thresholds.
  • Page 62 Installation manual Value Value Acceleration [rev/min/s] Resolution Graph of acceleration resolution, rotary (values in rev/min/s) Acceleration [mm/s ] and [m/s ² ² Resolution Graph of acceleration resolution, linear (values in mm/s and m/s²) Safety instructions:  The error can be optimised by the suitable selection of the sensor resolution for the related application.
  • Page 63 Installation manual  The filter time can be set to between 0 and 64 in steps of 8. The dimension is "msec". To determine the response time of the overall system, the filter times must be added to the response times stated for the PSC1 system (see section 11). Safety instructions: ...

  • Page 64: Safety-Related Assessment Of The Encoder Types And Their Combination

    Installation manual 4.2.2.6 Safety-related assessment of the encoder types and their combination Due to the monitoring functions implemented in the PSC1 series, in applications with encoder systems there are initially no special requirements on the internal layout of the encoder electronics, i.e.
  • Page 65 Installation manual In general the following faults in the external encoder system are detected by the PSC1 module:  Short-circuits between the safety-related signal wires  Open circuit in the safety-related signal wires  Stuck at 0 or 1 on one or all safety-related signal wires Further specific diagnostics for the detection of faults in the external encoder system are allocated to each encoder type.

  • Page 66: Safety-Related Characteristic Data And Circuitry For The Outputs

    Installation manual 4.3 Safety-related characteristic data and circuitry for the outputs The PSC1 modules have safe outputs of a different type. In the circuitry the related characteristic as per the description below is to be taken into account. 4.3.1 Characteristics of the output elements Aktuator Single-channel output PSC1 and single-channel actuator without diagnostics Aktuator...

  • Page 67: Diagnostics In The Shutdown Circuit

    Installation manual dual-channel actuator with dual-channel diagnostics Aktuator Dual-channel output PSC1 and dual-channel actuator with single-channel diagnostics Aktuator Dual-channel output PSC1 and dual-channel actuator with dual-channel diagnostics 4.3.2 Diagnostics in the shutdown circuit The shutdown circuits have diagnostic functions with a fixed implementation and diagnostic functions that can be configured.

  • Page 68: Overview Of Dc In Relation To Selected Diagnostic Functions

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

  • Page 69: Permissible Capacitive And Inductive Load On Safe Outputs

    Installation manual 4.3.3 Permissible capacitive and inductive load on safe outputs The safe outputs on the PSC1 are of an OSSD character. I.e. the outputs are shut down cyclically to test the shutdown capability and the status read back. The test on the shutdown capability is undertaken based on the following criteria / functions: After the shutdown of the output, the output voltage is allowed to be max.
  • Page 70 Installation manual  PSC1-E-31-..., PSC1-E-33-..., PSC1-E-37-... each have identical outputs. The PSC1 series provides different types of outputs that can be connected together either separately or in groups. Output Architecture Remark according to EN ISO 13849-1 Combination Complete shutdown channel...
  • Page 71 Installation manual Safety instructions:  For applications with frequent demand for the safety shutdown, testing should be at short intervals, e.g. at the start of the shift, 1 x per week. However, a test should be undertaken cyclically at least 1 x per year. ...

  • Page 72: Example Circuits, Basic Outputs

    Installation manual 4.3.4.1 Example circuits, basic outputs 4.3.4.1.1 Single-channel switching relay or semiconductor output without testing For interfacing to multiple phase applications or if higher current is required, external contactors can be used. With single-channel connection without external testing it is to be noted that sticking of one or more external contacts will not be detected by the PSC1-C-10-x module.
  • Page 73 Installation manual 4.3.4.1.2 Single-channel switching relay or semiconductor output with external switching amplifier and testing On the usage of an external switching amplifier, or downstream electromechanical, pneumatic or hydraulic components, a device for testing the complete chain and a signalling/warning device on the detection of a fault are required to achieve PL c or higher.
  • Page 74 Installation manual 4.3.4.1.3 Single-channel switching relay or semiconductor output with dual-channel external circuit with testing For safety applications from PL c according to EN ISO 13849-1 it is recommended or required to operate two external shutdown elements. In addition, a device for testing the complete chain and a signalling/warning device on the detection of a fault are required to achieve PL c or higher –...
  • Page 75 Installation manual Q1_PP Q2_PN Q3_PP Q4_PN Figure: Single-channel switching output Q1_PP with dual-channel external circuit as combination of electromechanical element and hydraulic/pneumatic valve monitoring on two inputs Safety instructions:  Only recommended to a limited extent for safety applications! On this topic see also the information in EN 13849-1 on usage and the fault exclusions necessary.
  • Page 76 Installation manual 4.3.4.1.4 Dual-channel switching relay output with external monitoring - collective feedback For safety applications from PL d according to EN ISO 13849-1, two relays are used in the PSC1-C-10-x module and two external contactors. Q5.1 Q5.2 Q6.1 Q6.2 Figure: Dual-channel switching relay output with external monitoring –...
  • Page 77 Installation manual Each of the two external shutdown paths is monitored. An adequately high test rate as well as MTTF = high for the external circuit are required for PL e according to EN ISO 13849-1. Q1_PP Q2_PN Q3_PP Q4_PN Q5.1 Q5.2 Q6.1...
  • Page 78 Installation manual 4.3.4.1.7 Dual-channel output with semiconductor output and external control circuit in PL e For safety applications from PL d and higher according to EN ISO 13849-1. The external circuit is operated using two channels via semiconductor outputs. PL e is required for the external circuit for PL e according to EN ISO 13849-1.

  • Page 79: Digital Outputs I/O (Iqqx)

    Installation manual 4.3.5 Digital outputs I/O (IQQx) The expansion modules PSC1-E-31-… and PSC1-E-33-… have configurable safe digital I/O (see section 3 Module overview). Configured as an output, this connection acts as a safe digital pp switching output (IQQx). 4.3.5.1 Classification of the I/O (IQQx) on usage as an output Classification Achievable PL Remark...

  • Page 80: Example Circuits For Safe Digital Outputs I/O (Iqqx)

    Installation manual 4.3.5.2 Example circuits for safe digital outputs I/O (IQQx) 4.3.5.2.1 Single-channel circuit without testing On the usage of a dual-channel output (IQQx) in combination with an external single-channel circuit without external testing, it is to be noted that sticking of one or more external contacts will not be detected by the PSC1-C-10-x module.
  • Page 81 Installation manual 4.3.5.2.2 Single-channel circuit with testing On the usage of a dual-channel output (IQQx) in combination with an external single-channel circuit with testing. In particular, positively driven auxiliary contacts are required for electromechanical devices, or valve position signal contacts are required for this purpose for hydraulic or pneumatic components.
  • Page 82 Installation manual 4.3.5.2.3 Circuit with safe shutdown circuit For safety applications from PL c and higher according to EN ISO 13849-1. The external circuit is operated directly using a dual-channel output. The achievable PL according to EN ISO 13849-1 is dependent on the usage of dynamic testing (see 4.3.2.1 DC) as well as the PL for the downstream device.
  • Page 83 Installation manual 4.3.5.2.5 Redundant dual-channel output Suitable for PL d or higher according to EN ISO 13849-1. Usage of two outputs IQQx in combination with a dual-channel external circuit. 4.3.5.2.5.1 Dual-channel circuit in same group IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07 IQQ08...
  • Page 84 Installation manual 4.3.5.2.5.2 Dual-channel circuit in different groups IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07 IQQ08 IQQ09 IQQ10 Figure: Redundant dual-channel outputs in different groups in combination with dual-channel shutdown circuit Safety instructions:  For safety-related assessment of the output sub-system, on the usage of external elements in the shutdown circuit, e.g.

  • Page 85: Overview Of Achievable Pl For Digital Safety Outputs

    Installation manual 4.3.5.3 Overview of achievable PL for digital safety outputs Output Actuator / Catego MTTF Achie Boundary condition Fault PSC1 external actuat vable exclusion shutdown accord circuit ing to accor EN138 ding 49-1 to EN 13849- Single- Single-channel Cat. B Medium Contactor and channel...
  • Page 86 Installation manual Output Actuator / Catego MTTF Achiev Boundary condition Fault PSC1 external actuat able exclusion shutdown accord circuit ing to accord EN138 ing to 49-1 13849- Dual-channel Dual-channel Cat. 3 Monitori Medium Contactor and Short-circuit without Contactor, valve, ng in or high downstream actuators on external...

  • Page 87: Connection And Installation

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

  • Page 88: Installation And Mounting Psc1 Module

    It is possible to mount several PSC1 modules on a DIN rail in conjunction with the backplane bus. These modules can be combined with a communication expansion. In this case the backplane bus must be configured by SCHMERSAL on placing the order and supplied to suit the related application.

  • Page 89: Arrangement Examples

    Installation manual 5.3.1 Arrangement examples 5.3.1.1 PSC1-C-10-SDM1 + PSC1-C-10-SDM1 + PSC1-C-10-SDM1-FBx PSC1-C-10-SDM1 PSC1-C-10-SDM1 PSC1-C-10-SDM1-FBx 5.3.1.2 PSC1-C-10-SDM2 + PSC1-C-10-SDM1-FBx PSC1-C-10-SDM2 PSC1-C-10-SDM1-FBx HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 89 of 177 Version: 38F...

  • Page 90: Mounting The Modules

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

  • Page 91: Mounting On Backplane Bus

    Installation manual 5.4.2 Mounting on backplane bus After mounting the backplane bus, the devices can be mounted. For this purpose the module is fitted to the connector at an angle from above and snapped to the C-rail Fit module at an angle from above Snap down onto the C rail HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 91 of 177...

  • Page 92: Installation And Configuration Of Master <-> Master (Smmc) And Master <-> Slave (Sddc)

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

  • Page 93: Network Topology

    Installation manual 5.5.1 Network topology SMMC SDDC CAN (Zentral) SDDC ETH (decentral) Communication of an PSC1 compact with  Central expansion modules via SDDC CAN backplane bus  SMMC via Ethernet Communication of an PSC1 modular with  Central expansion modules via SDDC CAN backplane bus ...

  • Page 94: Installation Of I/O Expansion

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

  • Page 95: Terminal Assignment

    Installation manual 5.7 Terminal assignment 5.7.1 Terminal assignment PSC1-C-10 Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs From release (/2) 3 – A2.1 Device power supply 0 VDC 4 –...

  • Page 96: Terminal Assignment Psc1-C-10-Sdm1

    Installation manual 5.7.2 Terminal assignment PSC1-C-10-SDM1 CPU-ENC Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs From release (/2) 3 – A2.1 Device power supply 0 VDC 4 –...

  • Page 97: Terminal Assignment Psc1-C-10-Sdm2

    Installation manual 5.7.3 Terminal assignment PSC1-C-10-SDM2 CPU-ENC Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs From hardware 11-xx 3 – A2.1 Device power supply 0 VDC 4 –...
  • Page 98 Installation manual 4 – I 12 Terminal assignment Unit Terminal Description Note 1 – UE2+ Encoder power supply +24 V DC X32 1 – UE2- Encoder power supply 0V DC X32 3 – NC No function 4 – NC No function 1 –...

  • Page 99: Terminal Assignment Psc1-E-31

    Installation manual 5.7.4 Terminal assignment PSC1-E-31 Terminal assignment Unit Terminal Description Note 1 - U24_EXT1 Device power supply +24 V DC From release (/2) Attention: see: "External 24 VDC 2 - U24_EXT2 Device power supply +24 V DC power supply" 3 - GND_EXT Device power supply 0V DC 4 - GND_EXT...

  • Page 100: Terminal Assignment Psc1-E-33

    Installation manual 5.7.1 Terminal assignment PSC1-E-33 EXT-REL Terminal assignment Unit Terminal Description Note 1 – 1.11 Readback contact relay 1 2 – 1.12 3 – 2.11 Readback contact relay 2 4 – 2.12 1 – 3.11 Readback contact relay 3 2 –...
  • Page 101 Installation manual 4 – IQ 10 Terminal assignment Unit Terminal Description Note 1 – NC No function 2 – NC 3 – Y1 Signal outputs 4 – Y1 1 – I 01 2 – I 02 3 – I 03 4 –...

  • Page 102: Terminal Assignment Psc1-E-37

    Installation manual 5.7.1 Terminal assignment PSC1-E-37 Terminal assignment Unit Terminal Description Note 1 – A1.1 Device power supply +24 VDC 2 – A1.2 Device power supply +24 VDC outputs From release (/2) 3 – A2.1 Device power supply 0 VDC 4 –...
  • Page 103 Installation manual Terminal assignment Unit Terminal Description Note 1 - SD_BUS_24V Power supply SD-BUS +24 V DC 2 - SD_BUS_GND Power supply SD-BUS 0V DC 3 - SD_BUS_OUT SD-BUS output 4 - FUNC_EARTH Function earth 1 – NC No function 2 –...

  • Page 104: Terminal Assignment Psc1-C-10-X-Fbx

    Installation manual 5.7.2 Terminal assignment PSC1-C-10-x-FBx For the terminal assignments on the individual communication modules, please refer to the related installation manuals. HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 104 of 177 Version: 38F...

  • Page 105: External 24 Vdc Power Supply

    Installation manual 5.8 External 24 VDC power supply The PSC1 module required a power supply of 24 VDC (on this topic see SELV or PELV, EN50178). During the planning and installation of the power supply unit to be used, attention is to be paid to the following boundary conditions: It is imperative the minimum and maximum tolerance on the supply voltage is observed.
  • Page 106 Installation manual CPU-ENC EXT-ENC EXT-ENC GND- GND- GND- GND- Encoder Encoder Encoder Encoder SMX12-2 SMX31 HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 106 of 177 Version: 38F...

  • Page 107: Connection Of The External Encoder Supply

    Installation manual 5.9 Connection of the external encoder supply 5.9.1 Incremental, HTL, SIN/COS, SSI UE1- UE2- UE1+ UE2+ Voltage monitoring of the external encoder supply voltages Only PSC1-C-10-SDM2 The PSC1 module supports encoder voltages of 5 V, 8 V, 10 V, 12 V, 20 V and 24 V that are monitored internally as per the configuration selected.

  • Page 108: Connection Of The Digital Inputs

    Installation manual 5.10 Connection of the digital inputs The PSC1 has 14 (PSC1-C-10(-SDMX)(-FBx)) or 12 (PSC1-E-31/33) safe digital inputs. These are suitable for the connection of single or dual-channel signals with and without test pulses, or without cross-circuit testing. The signals connected must have a "high" level of DC 24 V (DC +15 V...+ DC 30 V) and a "low"...

  • Page 109: Connection Of Position And Speed Sensors

    Installation manual 5.11 Connection of position and speed sensors 5.11.1 General instructions Depending on the module type, the PSC1 module (PSC1-C-10-SDMx) has external encoder interfaces for the connection of the usual industrial incremental and absolute encoders. The encoder interfaces can be configured as incremental, SIN/COS, or as absolute SSI encoders. In addition, it is possible to connect 2 sensors that generate incremental signals (for instance proximity switches) to the counter inputs on the PSC1 module.
  • Page 110 Installation manual Attention: The encoder connections are not allowed to be connected or disconnected in operation. Electrical components on the encoder may be irreparably damaged. Disconnect from the electrical supply the encoders connected and the PSC1 module before connecting or disconnecting the encoder connections. For externally supplied encoders, pay attention to shutting down the external supply voltage (e.g.

  • Page 111: Encoder Interface Assignment

    Installation manual 5.11.2 Encoder interface assignment X1/X2 Only PSC1-C-10-SDM2 HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 111 of 177 Version: 38F...

  • Page 112: Connection Variants

    Installation manual 5.11.3 Connection variants 5.11.3.1 Connection of an absolute encoder as master n.c. Pin 1 Ground Pin 2 GND for the supply voltage 24 V DC Pin 3 n.c. Pin 4 CLK- Sub-D- Pin 5 DATA+ Absolut- Stecker Encoder (9 polig) (Master-Betrieb) Pin 6...

  • Page 113: Connection Of An Absolute Encoder As Slave

    Installation manual 5.11.3.2 Connection of an absolute encoder as slave n.c. Pin 1 Pin 2 Ground Pin 3 n.c. Pin 4 CLK- Sub-D- Pin 5 DATA+ Absolut- Stecker Encoder (9 polig) (Slave-Betrieb) Pin 6 DATA- n.c. Pin 7 CLK+ Pin 8 Pin 9 Versorgungsspannung GND for the supply voltage...

  • Page 114: Connection Of An Incremental Encoder With Ttl Signal Level

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

  • Page 115: Connection Of A Sin/Cos Encoder

    Installation manual 5.11.3.4 Connection of a SIN/COS encoder n.c. Pin 1 Pin 2 Ground GND for the supply voltage 24 V DC Pin 3 n.c. Pin 4 COS- Sub-D- Pin 5 SIN+ SIN/COS Stecker Geber (9 polig) Pin 6 SIN- n.c.
  • Page 116 Installation manual HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 116 of 177 Version: 38F...

  • Page 117: Connection Of Proximity Switch Psc1-C-10-Sdm1/2

    Installation manual 5.11.3.5 Connection of proximity switch PSC1-C-10-SDM1/2 Connection is via the connector X23 to the digital inputs I4 …I7. The exact pin assignment is dependent on which encoder type is used and is given in the connection diagram in the programming software user interface. Note: On the usage of HTL encoders, it is to be noted that the tracks A+ and B+ or A- and B- must be combined correspondingly.

  • Page 118: Configuration Of The Measurement Sections

    Installation manual 5.12 Configuration of the measurement sections 5.12.1 General description of the encoder configuration The most important input variables for the module's monitoring functions are safe position, speed and acceleration. These are generated from the sensor systems connected using two channels.
  • Page 119 Installation manual SSI format parameter configuration: ClkN Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Index Daten Index Status K Daten O Status Status information Status Status Status Status ..Error Maske Mask Mask Mask Mask 0 = dont´t care ..

  • Page 120: Incremental Encoder

    Installation manual 5.12.2.2 Incremental encoder: Physical layer. RS-422 compatible Measured signal A/B. Track with 90 degree phase difference Maximum input pulse frequency 200 kHz or 500 kHz Diagnostics: Diagnostics Parameter Fault threshold Supply voltage monitoring Fixed values +/- 20% +/-2% (measuring 5 V, 8 V, 10 V, 12 V, 20 V, tolerance) 24 V...

  • Page 121: Expanded Monitoring, Proximity Switch / Proximity Switch

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

  • Page 122: Response Times Of The Psc1

    Installation manual 6 Response times of the PSC1 The response time is an important safety-related property and must be taken into account for each application / application-related safety function. In the following section the response times for individual functions, in some case also as a function of other parameters, are listed. If this information is inadequate for a specific application, the actual response is to be validated against the required behaviour by means of separate measurements.
  • Page 123 Installation manual Response Explanation Function time [ms] If a monitoring function is already activated via ENABLE, the module requires one cycle to calculate Response of an already activated the actual speed value. In the next cycle, after the monitoring function including calculation of the monitoring function, the information PLC processing for position and is further processed and output by the PLC, i.e.

  • Page 124: Response Time For Fast_Channel

    Installation manual 6.2 Response time for FAST_CHANNEL FAST_CHANNEL refers to a property of the PSC1 to react faster to speed requirements that is possible on processing the safety program in the normal cycle (= 8 msec). The sampling time of the FAST_CHANNEL is 2 msec. The following response times can be stated: ...
  • Page 125 Installation manual Resp Resp Fault Diagram: Behaviour of the drive with / without overspeed distance For the V and s curves there are the following relationships without overspeed distance: Parameter Acceleration method Remark Value PSC1 response time data Delay in external shutdown chain Resp + delay in external shutdown chain from relay / contactor, brake...

  • Page 126: Response Times On Usage Of The Psc1-E-3X

    Installation manual For the V and s curves with overspeed distance the following applies: Parameter Acceleration method Remark Value PSC1 response time data Delay in external shutdown chain Resp + delay in external shutdown chain from relay / contactor, brake manufacturer data etc.
  • Page 127 Installation manual TOTAL Example 1: Input on expansion module, activation of SLS and processing in PLC, output on basic module = 18 ms + 8 ms + 0 ms = 24 ms; TOTAL IN_31 OUT_Base Example 2: Input on basic module, activation of SLS and processing in PLC, output on expansion module = 10 ms + 8 ms + 8 ms = 26 ms;...

  • Page 128: Commissioning

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

  • Page 129: Reset Behaviour

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

  • Page 130: Reset Timing

    Installation manual 7.3.2 Reset timing The timing of the signal on the reset input for the internal reset is monitored in the "RUN" mode. An internal reset is triggered with the falling edge of the reset input with the condition T <...
  • Page 131 Installation manual V_Ist > SOS_V_Max V_Ist SOS_Result Reset_In Max. 3 sec Max. 3 sec Process value (speed) => no change to the output status on reset in the alarm state Max. 3 sec Max. 3 sec Max. 3 sec Q =I1 AND I2 Q =I1 AND I2 Q =I1 AND I2 IN_Result...

  • Page 132: Example Reset Function With Protection Against Incorrect Usage

    Installation manual 7.3.3.1 Example reset function with protection against incorrect usage Function: On a machine, the hazard area is to be protected in normal operation by a guard and in the setting mode by an enable button in conjunction with standstill monitoring and safely limited speed.
  • Page 133 Installation manual Application-related measure: Using an operator in the PLC program, the activation of the outputs while bypassing the alarm state for this time is prevented. Example 1: The enable function for the outputs (ID 88) is also linked to a "reset timer". This operator prevents the activation of the outputs for t >...
  • Page 134 Installation manual Example 2: The enable function for the outputs (ID 88) is also linked to FF. This operator prevents the activation of the outputs after a reset if there is a fault present in the input circuit. The outputs are only enabled after an error-free input signal has been applied once.

  • Page 135: Led Indication

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

  • Page 136: Parameter Configuration

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

  • Page 137: Safety-Related Check

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

  • Page 138: Servicing

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

  • Page 139: Technical Data

    Installation manual 10 Technical data 10.1 Ambient conditions Degree of protection IP 20 Ambient temperature 0 °C* ... 50 °C Climatic class 3k3 according to DIN 60 721 Service life 90000 h in 50 °C environment 10.2 Safety-related characteristic data Max.

  • Page 140: Switch Types

    Installation manual 11 Switch types Switch symbol Truth table Logic function Function block Function LD E.1 Schließer, nur in Darstellung Öffner ST IE.X Öffner Ausgang eSwitch_1o LD E.1 Normally open contact, like type Öffner ST IE.X Ausgang sSwitch_1s LD E.1 UND operation both inputs Öffner 1 AND E.2...
  • Page 141 Installation manual HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 141 of 177 Version: 38F...
  • Page 142 Installation manual Switch symbol Truth table Function LD E.1 Monitoring for NO = inactive AND NOT E.2 and NC = active Öffner ST IE.X Schließer Ausgang eSwitch_1s1o LD E.1 Time monitoring Like 5, however with time OR NOT E.2 MET1..MET4 monitoring of state changes.
  • Page 143 Installation manual Switch symbol Truth table Function LD E.1 Time monitoring Like 6, however with time OR E.2 MET1..MET4 monitoring of state changes. Öffner 1 OR NOT E.3 On signal change on NO ST META_EN.1 (attention common wire!) or NC, Öffner 2 complementary signal must LD E.1...
  • Page 144 Installation manual LD E.1 Time monitoring Like 8, however with time NC1 NC2 NC OR E.2 MET1..MET4 monitoring of state changes. Öffner 1 OR E.3 On signal change on one of the ST META_EN.1 NC inputs the other inputs must Öffner 2 follow within time t=3 s.
  • Page 145 Installation manual Switch symbol Truth table Function LD NOT E.1 Two-hand Monitoring for NO1*NO2 = OR E.2 control inactive and NC1*NC2 = active Öffner 1 OR NOT E.3 + time monitoring of this state. OR E.4 I.e. if there is a signal change on ST MEZ_EN.1 an NO from 1->0 or NC from 0- >1 then the other signals (i.e.
  • Page 146 Installation manual LD E.1 Selector switch Unambiguous operator for the AND NOT E.2 permissible switch positions Öffner ST IE.X1 Schließer LD NOT E.1 AND E.2 ST IE.X2 Ausgang eMode_1s1o LD E.1 Selector switch Unambiguous operator for the AND NOT E.2 permissible switch positions Schalter 1 AND NOT E.3...

  • Page 147: Notes For Designing, Programming, Validating And Testing Safety-Related Applications

    Installation manual 12 Notes for designing, programming, validating and testing safety- related applications The following notes describe the procedures for designing, programming, validating and testing safety-related applications The notes are intended to assist the user in arranging, clearly understanding and applying all steps from the risk assessment to the system test.
  • Page 148 Installation manual Risk assessment according to EN ISO 13849-1 S – severity of injury S1 = slight, reversible injury S2 = serious, irreversible injury F – frequency and/or exposure to hazard F1= seldom, not cyclic F2 = frequent to continuous and/or exposure time is long, cyclic operation P –...

  • Page 149: Technical Documentation Required

    Installation manual EN 14121 Safety of machinery - Risk assessment EN 12100 Safety of machinery - General principles for design enthalten. Measures that applied to reduce the hazards identified must correspond as a minimum to the same level as the hazard. Such measures and the requirements on them are also given in examples in the directives and standards listed above.

  • Page 150: Steps Required For Designing, Realisation And Testing

    For the realisation of such functions with the aid of safety-related control and monitoring functions, the PSC1 series offers efficient support in the form of the system architecture (architecture cat. 4 according to EN ISO 13849-1) and above all also the programming language and tested safety functions.

  • Page 151: Phases Of The V Model

    Installation manual 12.3.1 Phases of the V model Name Description Design phase Validation phase Specification and Specification of all safety Check on all passive and active validation of all measures to be taken such as safety measures for their correct passive and active covers, barriers, max.

  • Page 152: Specification Of The Safety Requirements (Breakdown)

    Installation manual 12.3.2 Specification of the safety requirements (breakdown) The safety requirements are to analysed in detail based on the standards to be applied, e.g. product standards. Source: General specifications, extract BGIA Report 2/2008 on EN ISO 13849-1 HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 152 of 177 Version: 38F...
  • Page 153 Installation manual Example for an automatic handling system: Functional description: The automatic handling system is used to pick up varying height lorry cabs automatically. After pick-up the height of the cab is safely acquired so that the cab cannot be lowered below a certain height in the working area.
  • Page 154 Installation manual Example for a hazard analysis: HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 154 of 177 Version: 38F...

  • Page 155: Specification Of The Functional Safety System

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

  • Page 156: Example - Specification Of The Safety Functions In Tabular Form

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

  • Page 157: Software Specification

    Installation manual 12.3.4 Software specification The software specification relates to the prior specification of the safety functions. It can also be replaced by a correspondingly prepared specification of the safety functions if this contains all specifications (see example in 12.3.3.3). However, it is recommended to prepare an extracted list.
  • Page 158 Installation manual Example software specification Safety function Measured New solution Input/activation Response/output . no. value /sensor Monitoring V_rope in Digital Monitoring using tested function SLS Continuous Operating stop relation to V_required incremental + SAC with comparison of speed Monitoring of the encoder, ranges / analogue value range = SF 1.3.1...

  • Page 159: Hardware Specification

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

  • Page 160: Examples For Hardware Specification

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

  • Page 161: Consideration Of Systematic Failures

    Installation manual 12.3.5.3 Consideration of systematic failures In addition, systematic failures are also to be considered in the hardware specification. Example of measures against systematic failures: Loss of power during operation. If there is a hazard here, a power loss must be considered like an operating state.

  • Page 162: Hardware And Software Design

    Installation manual 12.3.6 Hardware and software design The specifications from the hardware and software specification are implemented in the actual system design. The specifications for the components to be used and their circuitry from the hardware specification are to be met as are the specifications for the fault exclusions. Both are to be safeguarded using suitable means and are to be documented.
  • Page 163 Installation manual As an example, a calculation according to EN ISO 13849-1 is shown: Safety function: Safely limited speed with open access door Schematic layout: Sensor Eink. Teilsyst. Zweik. Teilsyst. Spur A Mech.+ Sendeopt. Spur B Umrichter Sensor Aktuator Aktuator Safety-related schematic layout: Schütz Geschw.
  • Page 164 Installation manual Calculation according to EN 13849-1: Channel A – shutdown via mains contactor: Component MTTFD [years] Door locking B10d = 100000 Nop = 30/AT = 9270/year (309 AT/year)??? DCSwitch = 99% B10d MTTFD = = 100 Jahre 9270 years 0,1∗Nop SIN/COS MTTFD_SinCos = 30 years...
  • Page 165 Installation manual Channel B – shutdown via STO/converter: Component MTTFD [years] Door locking B10d = 100000 DCSwitch = 99% Nop = 30/AT = 9270/year (309 AT/year)??? B10d MTTFD = = 100 Jahre 9270 years 0,1∗Nop SIN/COS MTTFD_SinCos = 30 years DCEncoder = 99% encoder PFH = 1.4 * 10...

  • Page 166: Verification Of Software (Program) And Parameters

    Installation manual Note: It is also possible to determine the PL using the programming tool "Sistema" from the BGIA, among others. 14.1.1 Verification of software (program) and parameters The verification is undertaken in two steps: Check on the FUP in relation to the specified functionality Check on the FUP against the IL listing in the validation report, and the parameters specified against those listed in the validation report.
  • Page 167 Installation manual Safety function: Running gear shutdown Running gear shutdown and deactivation of brakes Running gear shutdowns The running gear is shutdown via two outputs (EAA1.5 ID 257 and 1.6 ID 261). The brakes are shutdown via two outputs (EAA1.3 ID 253 and 1.4 ID 249). A message is sent to the PLC via bit 40 (ID 600).

  • Page 168: Validating Fup Against Il And Parameters Using Validation Report

    Installation manual 14.1.1.2 Validating FUP against IL and parameters using validation report The programming in the FUP is to be compared with the IL listing in the validation report. Example IL listing in the validation report Validation report PLC program Index Command Operand Validated...
  • Page 169 Installation manual SLS - Selected axis: Speed threshold: Acceleration threshold: 2 SLS - Selected axis: Speed threshold: SSX ramp assigned: HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 169 of 177 Version: 38F...
  • Page 170 Installation manual Example encoder configuration Validation report Axis configuration / sensor interface Axis 1 General parameters Measurement section: Type: Rotary Position processing: Active Maximum speed: 2000 Incremental shutdown: 10000 Shutdown speed: Sensors Type: SSI standard SSI standard Format: Binary Binary Direction of rotation: Increasing Increasing...

  • Page 171: Undertaking The System Test / Fit (Fault Injection Test)

    Installation manual 14.1.2 Undertaking the system test / FIT (fault injection test) For the FIT the manufacturer must prepare a complete list of functions to be tested. This list includes the safety functions defined as well as fault tests for checking the correct response of the SRP/CS to these faults.

  • Page 172: Appendix

    Installation manual Appendix 14.2 Appendix A – categorisation of the switch types General note: The individual switches for the following input elements can be assigned as required to the digital inputs DI1 to DI8. Enable button Switch type Remark PL categorisation SIL categorisation according to EN ISO according to EN 61508...
  • Page 173 Installation manual 2 normally open Door monitoring for PL e SIL 3 contact + 2 normally increased requirement closed contact 2 normally open Monitored door monitoring PL e SIL 3 contact + 2 normally closed contact time monitored 3 normally closed Door monitoring for PL e SIL 3...
  • Page 174 Installation manual Two-hand button Switch type Remark Category SIL categorisation categorisation 2 change-over Two-hand button for Type III C PL e SIL3 contacts increased requirement 2 normally open Monitored two-hand button Type III A PL e SIL1 contacts Note: On these input elements there is a fixed pulse assignment that the user cannot change! Light curtain Switch type Remark...
  • Page 175 Installation manual 1 normally open Monitored sensor input PL e SIL 3 contact + 1 normally closed contact time monitored HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 175 of 177 Version: 38F...
  • Page 176 Installation manual Start / reset element Switch type Remark Category SIL categorisation categorisation 1 normally open Simple alarm reset (edge contact evaluation) 1 normally open Simple logic reset PL d SIL 2 contact 1 normally open Simple start monitoring contact (special function) Note: The alarm reset input can be operated with a continuous voltage of 24 V and is edge controlled.
  • Page 177 Installation manual EC declaration of conformity for safety components in the context of the EC directive HB-37350-810-01-38F-DE PSC1-C-10 Installation manual V1.1.docx Page 177 of 177 Version: 38F...

This manual is also suitable for:

Psc1-c-10 seriesPsc1-c-10-sdm seriesPsc1-e-3 series

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