Page 1 Installation Manual English SMX series SMX Compact 2. Generation Read and obverse installation manual before initial commissioning/ integration of the module! Observe safety instructions! Keep for future use!
Page 2 Information Installation manual for SMX series devices SMX Compact of the 2. Generation (SMXGen2) Status: 08/2021 Valid from FW-Release: 05.00.00.01 INFORMATION The German version is the original version of the installation manual.  Contact the manufacturer immediately if the instructions are missing! ...
Page 3 Information Responsible for the compilation of documents: Gerhard Bauer, Managing Director BBH Products This document is subject to German copyright law. Duplication, processing, distribution and any form of commercialization of such material beyond the scope of the copyright law shall require the prior written consent of its respective author or creator.
Page 4: Table Of Contents
Information Contents Contents ....................4 General information ................10 1.1. Identification 1.2. Important information of use 1.3. Warranty claims 1.4. Liability exclusion 1.5. Copyright 1.6. Definitions 1.7. Supplied documents 1.8. Abbreviations used Safety regulations .................. 17 Intended use Use in regions with UL/CSA requierments General safety information Transport/Storage Electrical connection...
Page 5 Information 3.4.1 Type plate 3.4.2 Scope of delivery Safety related characteristics ..............69 General design, safety related architecture & characteristic data 69 Safety related characteristic data and wiring for the connected sensors 4.2.1 Digital sensors 4.2.1.1 Characteristics of sensors /input elements 4.2.1.2 DC digital sensors/inputs 4.2.1.3 Classification of safe digital inputs 4.2.1.3.1...
Page 6 Information 4.3.4.2.3 Single-channel switching relay or semi-conductor output with dual-channel external circuit with testing 4.3.4.2.4 Two-channel switching relay output with external monitoring - group feedback 4.3.4.2.5 Dual-channel output with relay output and semi-conductor output – external control circuit with monitoring 4.3.4.2.6 Dual-channel output with relay output and external control circuit in PI e 4.3.4.2.7...
Page 7 Information 5.6.6 Terminal assignment SMX12-1-PXV/2 5.6.7 Terminal assignment SMX12-2/2 5.6.8 Terminal assignment SMX12-2A/2 5.6.9 Terminal assignment SMX31/2 5.6.10 Terminal assignment SMX31R/2 5.6.11 Terminal assignment SMX31R-4/2 5.6.12 Terminal assignment COM External 24 VDC – voltage supply Connection of external encoder supply 5.8.1 Incremental, HTL, SIN/COS, SSI 5.8.2...
Page 8 Information Response time of the SMX ..............202 Response time in standard operation Response time for FAST_CHANNEL Response time for Fault distance monitoring Response time when using SMX31x/2 Response time when using SCA Extended Commissioning and start ..............209 Procedure Switch-on sequence Reset Function 7.3.1...
Page 9 Information 12.3.4 Software specification 12.3.5 Hardware specification 12.3.5.1 Selection of SRP/CS and operating means 12.3.5.2 Example for default HW 12.3.5.3 Consideration of systematic failures 12.3.6 Hard and software design 12.3.7 Testing of hardware designs 12.3.7.1 Iterative testing of the achieved safety level 12.3.8 Verification Software (program) and parameters 12.3.8.1 Checking FUP...
Page 10: General Information
- Relay Firmware version: The firmware version is noted on the device type plate. Hardware version: The hardware version is indicated on the device type plate. BBH Products GmbH Böttgerstraße 40 92637 Weiden GERMANY Phone: +49 961 / 4 82 44 0...
Page 11: Important Information Of Use
Liability exclusion Observance of this documentation and the documentation on the connected devices from BBH Products GmbH is a basic prerequisite for safe operation and for achieving the specified product properties and performance characteristics. BBH Products GmbH assumes no liability for personal injury, property damage or financial loss resulting from non-observance of the documentation.
Page 12: Definitions
General information 1.6. Definitions The designation SMX is used as generic term for all derivatives from the SMX product range. Wherever this description refers to a certain derivative, the complete designation is used. The term "safe" used in the following text in any case refers to the classification as a safe function for application up to Pl e acc.
Page 13: Supplied Documents
General information 1.7. Supplied documents Description Reference Configuration of the SMX module for HB-37480-820-01-xxF-EN Programming stand-alone applications without field- manual SafePLC2.pdf bus interfacing with the program (System CD) "SafePLC2" Validation report for implemented Safety inspection with acceptance protocol parameterization and PLC-program Acceptance for general safety relevant Certificate for type approval test as safety applications...
Page 14 General information NOTICE: • Thoroughly read the manuals before you start the installation and the commissioning of the SMX module. • Paying attention to the documentation is a prerequisite for trouble-free operation and fulfilment of possible warranty claims. For PXV variants of the SMX assemblies, the following also applies “TS-37000-410-01-810-01-xxF SMX-x-PXV Installationshandbuch.pdf”...
Page 15: Abbreviations Used
General information 1.8. Abbreviations used Abbreviation Meaning Alternating voltage AWL (IL) Instruction list ELIA Employer's liability insurance association Clock (cycle) Central Processing Unit Direct voltage I1..I14 Digital Input Deutsches Institut für Normung (German Institut for Standardization) Digital Output Emergency Monitoring Unit Electromagnetic compatibility Emergency Limit Control European Standard...
Page 16 General information Abbreviation Meaning Verband der Elektrotechnik, Elektronik und Informationstechnik e. V. (association for electrical engineering, electronics and information technology) Auxiliary Output G.P. General purpose (General use) (1) Module address x = 0 ….. 2 Channel address y = 1 ….. 40 HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 16/264...
Page 17: Safety Regulations
Safety regulations Safety regulations Intended use The devices of the SMX10/11/12 series of the 2nd generation (SMXGen2) are programmable safety controllers for the production of safety cut-offs and functions. The devices are intended for usein Emergency stop devices, as safety related components according to Machine Directive 2006/42/EG,, as PES for zur risk reduction according to IEC 61508, in safety circuits EN 60204-1 u.
Page 18: Use In Regions With Ul/Csa Requierments
Safety regulations Use in regions with UL/CSA requierments The SMXGen2 series has cULus approval in accordance with the following standards:: Base standard(s): UL 61010-1, 3rd Edition, May 11, 2012, Revised July 15 2015, CAN/CSAC22.2 No. 61010-1-12, 3rd Edition, Revision dated July 2015 Additional Standards: UL/CSA 61010-2-201: 2014 (First Edition) HB-37352-810-02-61F-EN SMX Gen2 Installation Manual...
Page 19: General Safety Information
Safety regulations General safety information SAFETY NOTICE: • 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 20: Transport/Storage
Safety regulations Transport/Storage The information concerning transport, storage and appropriate handling must be observed. The climatic conditions indicated in the chapter “Characteristic data of deviceseinzuhalten. Electrical connection When working on live appliances, the applicable national accident prevention regulations (e.g. BGV A3) must be observed. The electrical installation must be carried out in accordance with the relevant regulations (e.g.
Page 21: Esd Information
Safety regulations ESD information Electronic components are generally at risk from electrostatic discharge (ESD). Electrostatic discharge can occur during any moving activity. Electrostatic discharge can occur during any moving activity. ESD can occur with every touch. Most discharges are so small that they are not perceived. However, they can still endanger or destroy unprotected electronic components.
Page 22: Operation And Service
Safety regulations Operation and service The module must always be de-energized before installation and removal, or before disconnecting signal lines. For this purpose all live supply lines to the device must be checked for safe isolation from supply. The fact that the operation LED and other display elements go out is not a sufficient indicator that the appliance has been disconnected from the mains and is de-energized.
Page 23: Device Types
Device types Device types The series SMX10/11/12 (SMXGen2) consists of Basic devices SMX10/2, SMX11/2 and SMX12/2 optional with integrated communication interface with standard or safe fieldbus SMXxx-x/2(/x) and expansion modules SMX3x/2 The following device types are available as SMXGen2: Basic devices Expansion modules SMX10/2 SMX31/2...
Page 24 Device types Basic devices The 2nd generation SMX10/11/12 series (SMXGen2) is a compact safety controller with optional integrated drive monitoring for one (SMX11/2, SMX11-2/2) or two (SMX12/2, SMX12-2/2) axes. The device is freely programmable for the safe processing of EMERGENCY-STOP button, two-hand operation, light curtains, operating mode selector switches, etc.
Page 25: Module Overview
Device types Module overview Base units Expansion units Designation SMX12/2, SMX11/2, SMX10/2, SMX12A/2, SMX11-2/2 SMX31/2, SMX10A/2, SMX12-1-PXV/2, SMX11-PXV/2 SMX31R/2, SMX10R/2, SMX12-2/2, SMX11-WCS/2 SMX31R-4/2 SMX12-2A/2 Max. no. of expansion modules Safe digital inputs Safe digital I/O 10/2/6 Safe digital outputs pn- 2, 4 2, 4 2, 4...
Page 26: Characteristic Data Of Devices
Device types Characteristic data of devices 3.2.1 Basic modules 3.2.1.1 SMX10/2, SMX10A/2, SMX10R/2 (/x Type designation Device design Design of module with the following periphery: Digital inputs Pulse outputs Relay outputs (6x SMX10R/2) pn- or pp-switching outputs Auxiliary outputs Analog inputs (SMX10A/2, SMX10A/2) Diagnostic- and configuration interface Function button 7-Segment display...
Page 27 Device types • Assembly on top hat rail • SMX 10A/2 (Analog) – with 2 safe analog inputs • SMX 10R/2 (Relay) – with total 6 relay outputs and no pn-, pp-switching outputs • Relay outputs and no pn-, pp-switching outputs •...
Page 28 Device types Technical characteristic data SMX10/2, SMX10A/2, SMX10R/2 (/x Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 Plus with SMX10R 1-channel per Rel 20 FIT (max. 4) 2-channel per Rel 1,0 FIT (max. 2) SIL acc.
Page 29 Device types Max. total current (pn or pp) Auxiliary outputs 24 VDC; 250mA (G.P.) Rated data Normally open 24 VDC; 2A (Pilot Duty) relay outputs 120 VAC; 2A (Pilot Duty) Normally closed 24 VDC; 2A (Pilot Duty) (Read back contact) Environmental data Temperature 0°C …...
Page 30: Smx11/2
Device types 3.2.1.2 SMX11/2 (/x Type designation Device design Design of module with the following periphery: Axis Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary 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 31 Device types • Coded status display via front-side 7 segment display and status LEDs • Multifunction buttons (quit, start, reset) can be operated from the front side • Optional: universal communication interface Standard and safe field bus protocols for communication with a higher level controller Safe cross communication (SMMC) for data exchange between multiple base devices Safe remote I/O communication for data exchange with distributed I/O systems see: chapterl 3.2.3.1 “Optional integrated communication interface”...
Page 32 Device types Technical characteristic data SMX11/2 (/x Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operating period General data Max.
Page 33 Device types Protection class IP 20 Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Degree of pollution Mechanical data Dimensions...
Page 34: Smx11-Pxv/2
Device types 3.2.1.3 SMX11-PXV/2 (/x Type designation Device design Design of module with the following periphery: Axis Encoder interface (safePXV) Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary outputs Diagnostic- and configuration interface Function button 7-Segment display Status LED Status LEDs for inputs Status LEDs for pulse outputs...
Page 35 Device types • Pulse outputs for cross-shorting detection of digital input signals • External contact monitoring of connected switchgear (EMU) • Switchable safe semi-conductor outputs pn-, pp- switching for safety-relevant functions • Monitored relay outputs for safety relevant functions • Parameter management for expansion modules in base device •...
Page 36 Type of connection connection Axis monitoring 1 / 1 * (axes / encoder interfaces) Encoder interfaces RS 485, X35: (D-Sub / screw terminals) PXV100AS-F200-R4-V19-BBH Electrical data Supply voltage 24 VDC; 2 A (tolerance) (-15%, +20%) Fuse X11.1 max. 30 VDC; 3,15 A X11.2...
Page 37 Device types Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Mechanical data Dimensions SMX11-PXV/2 = 100x115x67,5 (HxDxW [mm]) SMX11-PXV/2 (/x ) = 100x115x90 Weight SMX11-PXV/2 = 390...
Page 38: Smx11-Wcs/2
Device types 3.2.1.4 SMX11-WCS/2 (/x Type designation Device design Design of module with the following periphery: Axis WCS encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary outputs Diagnostic- and configuration interface Function button 7-Segment display Status LED Status LEDs for inputs Status LEDs for pulse outputs...
Page 39 Device types • Comprehensive diagnostics functions integrated • Coded status display via front-side 7 segment display and status LEDs • Multifunction buttons (quit, start, reset) can be operated from the front side • Optional: Integrated communication interface Standard and safe field bus protocols for communication with a higher level controller (PROFIBUS, PROFINET, DeviceNet, CANopen, EtherNET/IP, EtherCAT, Modbus TCP/IP, FSoE) Safe cross communication (SMMC) for data exchange between multiple base devices...
Page 40 Device types Technical characteristic data SMX11-WCS/2 (/x Safety releated characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operating period General data Max.
Page 41 Device types Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m Overvoltage category Mechanical data Dimensions SMX11-WCS/2 = 100x115x67,5 (HxDxW [mm]) SMX11-WCS/2 (/x ) = 100x115x90 Weight SMX11-WCS/2 = 390...
Page 42: Smx11-2/2
Device types 3.2.1.5 SMX11-2/2 (/x Type designation Device design Design of module with the following periphery: Axis Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary 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 43 Device types • Comprehensive diagnostics functions integrated • Coded status display via front-side 7 segment display and status LEDs • Multifunction buttons (quit, start, reset) can be operated from the front side • Optional: Integrated communication interface Standard and safe field bus protocols for communication with a higher level controller (PROFIBUS, PROFINET, DeviceNet, CANopen, EtherNET/IP, EtherCAT, Modbus TCP/IP, FSoE) Safe cross communication (SMMC) for data exchange between multiple base devices...
Page 44 Device types Technical characteristic data SMX11-2/2 (/x Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operating period General data Max.
Page 45 Device types Rated data Normally open 24 VDC; 2A (Pilot Duty) relays 120 VAC; 2A (Pilot Duty) Environmental data Temperature 0°C … +50°C operation -25C° … +70C° storage, transport Protection class IP 20 Climatic category 3k3 nach DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation)
Page 46: Smx12/2, Smx12A/2
Device types 3.2.1.6 SMX12/2, SMX12A/2 (/x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary outputs Analog inputs (SMX12A/2) Diagnostic- and configuration interface Function button 7-Segment display Status LED Status LEDs for inputs...
Page 47 Device types • Multifunction buttons (quit, start, reset) can be operated from the front side • optional: integrated communication interface Standard and safe field bus protocols for communication with a higher level controller Safe cross communication (SMMC) for data exchange between multiple base devices Safe remote I/O communication for data exchange with distributed I/O systems see: chapter 3.2.3.1 Optional integrated communication interface •...
Page 48 Device types Technical characteristic data SMX12/2, SMX12A/2 (/x Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operating period General data Max.
Page 49 Device types Environmental data Temperature 0°C … +50°C operation -25°C … +70°C storage, transport Protection class IP 20 Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m...
Page 50: Smx12-1-Pxv/2
Device types 3.2.1.7 SMX12-1-PXV/2 (/x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces (with 1 safePXV encoder interface) Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary outputs Diagnostic- and configuration interface Function button 7-Segment display Status LED...
Page 51 Device types • Coded status display via 7-segment display on the front and status LEDs • Multifunction button (Quit, Start, Reset) can be operated from the front • Configurable with SafePLC² via USB serial adapter or Ethernet-based fieldbus • Extended functionality: safePXV encoder interface •...
Page 52 (D-Sub / screw terminals / RS485) SSI-Absolut, SinCos, Incremental-TTL D-SUB X33: SSI-Absolut,SinCos (HighRes), Incremental-TTL, Resolver Terminal X23: Incremental-HTL (10kHz) Terminals X27, X28: Incremental-HTL (200kHz) RS485, X35: PXV100AS-F200-R4-V19-BBH Electrical data Supply voltage 24 VDC; 2A (tolerance) (-15%, +20%) Fuse X11.1 max. 30 VDC; max. 3,15A X11.2 max.
Page 53 Device types pp-switching Temperature 24 VDC; 2A Rating 30°C (G.P.) Temperature 24 VDC; 1,8A Rating 50°C (G.P.) Max. total current (pn or pp) Auxiliary outputs 24 VDC; 250mA (G.P.) Rated data • 24 VDC; 2A (Pilot Duty) Normally open relay outputs 120 VAC;...
Page 54: Smx12-2/2, Smx12-2A/2
Device types 3.2.1.8 SMX12-2/2, SMX12-2A/2 (/x Type designation Device design Design of module with the following periphery: Axes Encoder interfaces Digital inputs Pulse outputs Relay outputs pn- or pp-switching outputs Auxiliary outputs Analog inputs (SMX12-2A/2) Diagnostic- and configuration interface Function button 7-Segment display Status LED Status LEDs for inputs...
Page 55 Device types Standard and safe field bus protocols for communication with a higher level controller Safe cross communication (SMMC) for data exchange between multiple base devices Safe remote I/O communication for data exchange with distributed I/O systems see: chapter 3.2.3.1 “Optional integrated communication interface” •...
Page 56 Device types Technical characteristic data SMX12-2/2, SMX12-2A/2 (/x Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 12,6 FIT /Cat 4 SIL acc. to IEC 61508 SIL 3 Proof test interval 20 years = max. operation period General data Max.
Page 57 Device types Max. total current (pn or pp) Auxiliary outputs 24 VDC; 250mA (G.P.) Rated data Normally open 24 VDC; 2A (Pilot Duty) relay outputs 120 VAC; 2A (Pilot Duty) Environmental data Temperature 0°C … +50°C operation -25°C … +70°C storage, transport Protection class IP 20 Climatic category...
Page 58: Central Expansion Modules
Device types 3.2.2 Central expansion modules 3.2.2.1 SMX31/2, SMX31R/2, SMX31R-4/2 Type designation Device design Design of module with the following periphery: Digital inputs Digital I/Os Pulse outputs Auxiliary outputs Relay outputs (SMX31x) Status LEDs for inputs Status LEDs for I/O Characteristic of the module: •...
Page 59 Device types Technical characteristic data SMX31/31R/31R-4/2 Safety related characteristic data PL acc. to EN ISO 13849-1 PL e PFH / architecture 9,2 FIT /Cat 4 Plus with SMX31R/31R-4 1-channel per Rel 20 FIT (max. 8) 2-channel pro Rel 1,0 FIT (max. 4) SIL acc.
Page 60 Device types Environmental data Temperature 0°C … +50°C operation -25°C … +70°C storage, transport Protection class IP 20 Climatic category 3k3 acc. to DIN 60 721-3 Min-, Maximum relative humidity 5% - 85% (no condensation) EN 61000-6-2, EN 61000-6-4, EN 61000-6-7, EN 61800-3, EN 61326-3, EN 62061 Operating altitude 2000m...
Page 61: Communication Interface
Storage medium for safety program Properties of the integrated communication interface: • Optional specification of the communication interface of the SMX series • Subsequent expansion capability from standard to safe fieldbus possible via additional mini SD card on the rear of the module. (/xNx and /xBx) •...
Page 62: Combination Options
Device types 3.2.3.1.1 Combination options Specifications /DxM /DNM /xNM /xxM /DBM /xBM SMX10/2 SMX10A/2 SMX10R/2 SMX11/2 SMX11-2/2 SMX11-PXV/2 SMX11-WCS/2 SMX12/2 SMX12A/2 SMX12-1-PXV/2 SMX12-2/2 SMX12-2A/2 SMX31/2 SMX31R/2 SMX31R-4/2 Technical characteristic data: Optional universal communication interface Safety related characteristic data Pl acc. to EN ISO 13849-1 n.a.
Page 63 Device types Weight (g) Mounting To snap on top-hat rail Number of T-Bus Min. terminal cross-section / AWG 0,2 mm² / 24 Max. terminal cross-section / AWG 2,5 mm² / 12 Optional for SDDC or SMMC (**) Available fieldbuses PROFINET (PROFIsafe), EtherCAT (FSoE), Modbus TCP/IP and EtherNet/IP (***) Available fieldbuses PROFIBUS (PROFIsafe), DeviceNet and CANopen...
Page 64: Encoder Specifications
Device types 3.2.4 Encoder specifications Incremental-TTL Physical Layer RS-422 compatible Measuring signal A/B Track with 90 degree phase difference Max. frequency of input cycles 250 kHz / 500 kHz (X31, X32 / X33, X34) Type of connection D-SUB 9pole Sin / Cos Physical Layer RS-422 compatible Measuring signal A/B...
Page 65 Device types Proxi – Extended mnitoring Signal level 24V / 0V Max. counting pulse frequency 4 kHz (switching logic debounced) Physical Layer PUSH / PULL Measuring signal A/B Track with 90 degree phase difference Type of connection (X23) Plug-in terminals with spring or screw connection HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 65/264...
Page 66: Derating Outputs
Device types Derating Outputs Maximum current load based on temperature. The maximum total current is 10A. Device Temperature 30°C / 50°C SMX1x/2/x Q1 – Q4 2A / 1,8A SMX31/2 IQ 6 – IQ 10 2A / 1,8A SMX31R-4/2 IQ 6 2A / 1,8A HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 66/264...
Page 67: Identification
Device types Identification The type plate is located on the left side wall of the module and contains the following information: 3.4.1 Type plate • Type designation • Part number • Serial number • Identification of Hardware (HW)-Release • Identification of Software (FW)-Release •...
Page 68: Scope Of Delivery
Device types 3.4.2 Scope of delivery The scope of delivery contains: SMX module: • Plug (screw terminals) for all signal terminals without encoder connection Not included in the scope of delivery: • SafePLC2 configuration software with Installation manual ➢ Programing manual ➢...
Page 69: Safety Related Characteristics
Safety related characteristics General design, safety related architecture & characteristic data The inner structure of SMX series consist of two separate channels with reciprocal comparison of results. High quality diagnoses for fault detection are made in each of the two channels.
Page 70 Safety related characteristics The specific safety related characteristic data of the corresponding module can be taken from the technical characteristic data in chapter 3.2. The characteristic data specified in chapter 3 (e.g. PI e and PFH-value acc. to table as evidence acc. to EN 13849) for the partial system PES can be used for the safety related assessment of the overall system.
Page 71 Safety related characteristics Safety technical characteristic data: Max. obtainable safety class • SIL 3 acc. to IEC 61508 • Category 4 acc. to EN ISO 13849-1 • Performance-Level e acc. to EN ISO 13849-1 System structure 2- channel with diagnostics (1002) acc. to IEC 61508 Architecture category 4 acc.
Page 72: Safety Related Characteristic Data And Wiring For The Connected
Safety related characteristics Safety related characteristic data and wiring for the connected sensors The SMX modules have completely separated signal processing paths for each safety input. This applies for both the digital and the analogue inputs. Furthermore, measures for achieving the highest possible DC-values have been implemented.
Page 73: Dc Digital Sensors/Inputs
Safety related characteristics Sensor Actuator Aktuator Fig. 5: 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 SMX modules ensure far reaching diagnostics functions for the input element.
Page 74 Safety related characteristics Sensors / input elements with 2- or multi-pole contacts without time monitoring: Several contacts can be assigned to the sensors / input elements. These are therefore compatible with at least 2-channel elements. A High level of the sensor/input element requires a logic series connection of both contacts.
Page 75 Safety related characteristics 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 76 Safety related characteristics 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 77: Classification Of Safe Digital Inputs
Safety related characteristics 4.2.1.3 Classification of safe digital inputs 4.2.1.3.1 Digital inputs I01 … I14 Digital inputs Achievable Comment performance level Suitable for any kind of input elements, with / without I01 … I04 pulse, achievable PL depending on the MTTF of the input PL e I09 …...
Page 78: Digital Inputs I01
Safety related characteristics 4.2.1.3.2 Digital inputs I/Os (IQIx) 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 application PL e Fault detection only upon request Without pulse, dual-channel static signal PL d Less than one request/day required by...
Page 79: Exemplary Connections Of Digital Sensors
Safety related characteristics 4.2.1.4 Exemplary connections of digital sensors 4.2.1.4.1 Single-channel sensor, without cross-shorting test Fig. 6: Single-channel, without cross-shorting test The single-channel sensor is connected to the SMX 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 80 Safety related characteristics When using a single-channel sensor with clocking, the power supply of the switching element is attached to the clock exit T1 or T2. The clock must subsequently be assigned to the SMX. 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!)
Page 81: 4.2.1.4.3 Dual-Channel Sensor Without Timeout With Cross-Shorting Test
Safety related characteristics 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. Only normally closed contacts should be used for safety related applications.
Page 82: Dual-Channel Sensor With Time-Out And Cross-Shorting Test
Safety related characteristics SAFETY NOTICE  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 83 Safety related characteristics SAFETY NOTICE  Pl d or higher in accordance with EN ISO 13849-1 is achieved by using switching elements / sensors with positively actuation  When using two independent sensors with independent actuation, PI d or higher acc.
Page 84: Overview Of Achievable Pl For Digital Safety Inputs
Safety related characteristics 4.2.1.5 Overview of achievable PL for digital safety inputs Type of Input Parameterized / Achievabl Fault exclusion Condition for input Sensor / operational tests e PI acc. for input element element Input to EN ISO element 13849-1 Operation proven input element All faults at the...
Page 85 Safety related characteristics Type of Input Parameterized / Achievabl Fault exclusion Condition for input Sensor / operational tests e PI acc. for input element element Input to EN ISO element 13849-1 Short-circuit at Connection in control input/signal line cabinet or protected routing Getting caught / positively MTTF...
Page 86: Sensors For Speed And/Or Position Detection
Safety related characteristics 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 base modules of the SMXGen2 series can be optionally equipped with one ( (SMX11/2, SMX12/2), or two encoder interfaces (SMX11-2/2, SMX12-2/2) per axis.
Page 87 Safety related characteristics The SMX-PXV module has an encoder interface for connecting a Safe connection of a Safe PXV sensor PXV100AS-F200-R4-x-BBH. The use of the Safe PXV sensor ensures the maximum safety level to be achieved, as listed in the technical characteristics.
Page 88: 4.2.2.1 General Diagnostic Measures For Encoder Interface
Safety related characteristics 4.2.2.1 General diagnostic measures for encoder interface For fault detection in the sensor system the SMX 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.
Page 89: Encoder Type And Their Combination, Diagnostic Data
Safety related characteristics 4.2.2.2 Encoder type and their combination, diagnostic data Safe 2-channel Safe 2-channel partial 1-channel Encoder A Encoder B Safe speed absolute Fault exclusion partial direction system non- partial Position system dynamic (standstill system dynamic monitoring) 1 x Proxi 1 x Proxi Actuation actuator ***)
Page 90 In order to make a safety-related assessment of the overall arrangement, the parameters from the "Technical characteristics" table can be used, as these already represent the combination of an SMX-PXV with a Safe PXV sensor PXV100AS-F200-R4-x-BBH. HB-37352-810-02-61F-EN SMX Gen2 Installation Manual...
Page 91: Specific Diagnostic Measures With Regard To The Encoder Type Used
Safety related characteristics 4.2.2.3 Specific diagnostic measures with regard to the encoder type used Encoder type Incremental SIN/COS Proxi 2 x counting input Proxi 1 x counting input Incremental Resolver SIN/COS Only in High-Resolution Mode Diagnostic measures for encoder interface Safe PXV: - Checking the transmission of the safe position using CRC32 - Analysis and evaluation of the encoder's error bits - Plausibility check of the code band using dynamic color switching...
Page 92 Safety related characteristics The following diagnostic options are available with WCS: Redundancy with cross comparison (1oo2) Diversity of the sensor systems (due to different counting directions) + fixed offset between the sensor units Monitoring of the encoder supplies Monitoring for maximum limits (position, speed) Hardware separation of the transmission paths and point-to-point connection Time maintenance, time stamp Checking the checksum...
Page 93: Safety Relevant Cut-Off Thresholds Encoder Systems For Position And Speed Detection
Safety related characteristics 4.2.2.4 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 SMX module as a basic measure, which are then checked against parameterizable thresholds.
Page 94 Safety related characteristics Value Acceleration [U/min/s] Wert resolution Graph acceleration, rotary (Values in rev/min/s)) ² ² Acceleration [mm/s ] and [m/s resolution Graphic Acceleration resolution, linear (values in mm/s and m/s²) SAFETY NOTICE  The error can be optimized by selecting a suitable sensor resolution for the respective application.
Page 95 Safety related characteristics components of the sensors. However, this is achieved at the expense of an increased response time of the overall system.  The filter time can be variably set between 0 and 64 in steps of 8. The dimension is "msec".
Page 96: Safety Related Assessment Of Encoder Types, Resolver Or There Combination
Safety related characteristics 4.2.2.5 Safety related assessment of encoder types, resolver or there combination Due to the monitoring functions implemented in the SMX-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.
Page 97 Safety related characteristics  When using compact encoders with internal dual-channel structure, such as e.g. SSI + incremental/SinCos, you must strictly follow the instructions of the manufacturer concerning safety related characteristics, diagnostic measures, mechanical connection and measures concerning the electric power supply. The safety level of the encoder must at least meet the intended safety level of the overall arrangement.
Page 98: Analog Sensors
Safety related characteristics 4.2.3 Analog sensors The base modules SMX10A/2, SMX12A/2, SMX12-2A/2 have two analog inputs with two input channels each. Only 2-channel sensors can be connected to this interface. The internal signal processing takes place separately in the two channels with cross-comparison of the results.
Page 99: Exemplary Connection Of Analog Sensors
Safety related characteristics SAFETY NOTICE  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 100: 4.2.3.1.2 Voltage Sensor With Test Pulse
Safety related characteristics 4.2.3.1.2 Voltage sensor with test pulse 1 NC 2 NC 3 DO 0.1 4 DO 0.2 X25/26 1 -AI 1+ Voltage sensor with test input for 2 -AI 1- Signal stroke 3 -AI 2+ 4 -AI 2- 4.2.3.1.3 Current sensor with test pulse 1 NC 2 NC...
Page 101: Safety Related Characteristic Data And Wiring Of The Outputs
Safety related characteristics Safety related characteristic data and wiring of the outputs SMX 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 Characteristics of the output elements Aktuator Fig.
Page 102 Safety related characteristics Aktuator Fig. 15: Single-channel output SMX with internal dual-channel processing (IQQx) and dual-channel actuator with at least single-channel diagnose Aktuator Fig. 16: Single-channel output SMX with internal dual-channel processing (IQQx) and dual-channel actuator with dual-channel diagnose Aktuator Fig.
Page 103: Diagnoses In The Cut-Off Circuit
Safety related characteristics 4.3.2 Diagnoses in the cut-off circuit The cut-off circuit is equipped with durably implemented and parametrizable diagnostics functions. Certain diagnostics functions also include the external part of the cut-off channel. Depending on he use of these diagnostics functions, different DC-values will arise. 4.3.2.1 Diagnostic functions Permanently implemented diagnostic functions:...
Page 104: Overview Dc With Respect To The Chosen Diagnostic Functions
Safety related characteristics 4.3.2.2 Overview DC with respect to the chosen diagnostic functions Measure Note Monitoring of outputs b a 0-90% DC depending on switching Monitoring of electro- channel without dynamic frequency mechanical, pneumatic or test. hydraulic actuators / outputs When using elements for switching amplification external relays or contactors) only...
Page 105: Permissable Capacitive And Inductive Load At Safe Outputs
Safety related characteristics 4.3.3 Permissable capacitive and inductive load at safe outputs The safe outputs of the SMX exhibit an OSSD character. That is, the outputs are cyclically switched off for the test of the switching off ability and the status is read back. The examination of the switching off ability takes place according to the following criteria/functions: After switching the output off, the output voltage may max.
Page 106 Safety related characteristics  = R = 10  R resp. Typical values for capacity C are C=20 nF and for Longitudinal inductance L = 100 mH HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 106/264...
Page 107: Digital Outputs
Safety related characteristics 4.3.4 Digital outputs The modules • SMX10/2, SMX10A/2, SMX10R, SMX11/2, SMX11-PXV/2, SMX11-WCS/2, SMX11-2/2, SMX12/2, SMX12A/2, SMX12-1-PXV/2, SMX12-2/, SMX12-2A/2 • SMX31/2, SMX31R/2, SMX31R-4/2 each have the identical outputs. 4.3.4.1 Characteristic data of the basic outputs The SMXGen2 series provides different types of outputs that can be connected either individually or in groups.
Page 108 Safety related characteristics SAFETY  NOTICE For applications with frequent safety shut-down requests these tests should be performed more frequently, e.g. at the beginning of the shift, 1 x per week. However, a test should at least be carried out cyclically 1 x year. ...
Page 109 24V, as the specifications of EN 81-20/-50 or EN 81-1/-2 do not permit this. With an infringement, the guarantee expires and BBH does not pay compensation.
Page 110: Wiring Examples Basic Outputs
Safety related characteristics 4.3.4.2 Wiring examples basic outputs 4.3.4.2.1 Single-channel switching relay or semi-conductor output without testing 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 SMX1x/2 module will not recognize bonding of one or several external contacts.
Page 111: Single-Channel Switching Relay Or Semi-Conductor Output With External Switching Amplifier And Testing
Safety related characteristics 4.3.4.2.2 Single-channel 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.
Page 112: Single-Channel Switching Relay Or Semi-Conductor Output With Dual-Channel External Circuit With Testing
Safety related characteristics 4.3.4.2.3 Single-channel switching relay or semi-conductor output with dual- channel external circuit with testing For safety applications from PL c in accordance with EN ISO 13849-1, it is recommended or required to control two external switch-off elements. Furthermore, to achieve PL c or higher, a device for testing the complete chain and a signaling/warning device when a fault is detected is required - see notes under 4.3.4.2.2.
Page 113 Safety related characteristics Q1_PP Q2_PN Q3_PP Q4_PN Fig. 23: Single-channel switching output Q1_PP with dual-channel external circuit as combination of electro-mechanical element and hydraulic/pneumatic valve and monitoring at two inputs SAFETY Only conditionally recommended for safety applications! NOTICE  Only conditionally recommended for safety applications! In this context see also the notes in EN ISO 13849-1 concerning the application and the required fault exclusions.
Page 114 Safety related characteristics 4.3.4.2.4 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 SMX1xx module and two external power contactors are used. Q5.1 Q5.2 Q6.1 Q6.2...
Page 115: Dual-Channel Output With Relay Output And Semi-Conductor Output - External Control Circuit With Monitoring
Safety related characteristics 4.3.4.2.5 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 116: Dual-Channel Output With Semi-Conductor Output And External Control Circuit In Pi E
Safety related characteristics 4.3.4.2.7 Dual-channel output with semi-conductor output and external control circuit in PI e For safety applications from PL d and higher in accordance with EN ISO 13849-1. The external circuit is controlled in two channels via semiconductor outputs. For PL e in accordance with EN ISO 13849-1, PL e is required for the external circuit.
Page 117: Digital Outputs I/Os (Iqqx)
Safety related characteristics 4.3.5 Digital outputs I/Os (IQQx) The expansion of modules of the SMX31/31R/31R-4/2 have configurable safe digital I/Os (see chapter 3 module overview). This connection acts as safe digital pp-switching output parameterized as output. 4.3.5.1 Classification of the I/O‘s (IQQx) when used as output Classification Achievable Pl acc.
Page 118: Wiring Examples For Safe Digital Outputs I/O's (Iqqx)
Safety related characteristics 4.3.5.2 Wiring examples for safe digital outputs I/O‘s (IQQx) 4.3.5.2.1 Wiring single-channel without testing When using a two-channel output (IQQx) in connection with a single-channel external wiring without external examination it must be taken into account that and adherence of one or several external contacts of the SMX1x module is not recognized.
Page 119: 4.3.5.2.2 Wiring Single-Channel With Testing
Safety related characteristics 4.3.5.2.2 Wiring single-channel with testing When using a two-channel output (IQQx) in connection with a single-channel external wiring with 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. Furthermore, a message/warning device for indicating a failure is required.
Page 120: 4.3.5.2.3 Wiring With Safe Cut-Off Circuit
Safety related characteristics 4.3.5.2.3 Wiring with safe cut-off circuit For safety applications from PL c and higher in accordance with EN ISO 13849-1. The external circuit is controlled directly via a two-channel output. The achievable PL in accordance with EN ISO 13849-1 depends on the use of dynamic testing (see 4.3.2.1 DC) and the PL of the downstream .
Page 121: Redundant Dual-Channel Output
Safety related characteristics 4.3.5.2.5 Redundant dual-channel output Suitable for PL d or higher in accordance with EN ISO 13849-1. Use of two IQQx outputs in conjunction with a dual-channel external circuit. 4.3.5.2.5.1 Two-channel wiring in the same group IQQ01 IQQ02 IQQ03 IQQ04 IQQ05...
Page 122 Safety related characteristics 4.3.5.2.5.2 Two-channel wiring in different groups IQQ01 IQQ02 IQQ03 IQQ04 IQQ05 IQQ06 IQQ07 IQQ08 IQQ09 IQQ10 Fig. 31: Redundant dual-channel outputs in different groups in conjunction with dual-channel switch-off circuit SAFETY Not conditionally recommended for safety applications! NOTICE ...
Page 123: Overview Of Achievable Pi For Digital Safety Outputs
Safety related characteristics 4.3.5.3 Overview of achievable PI for digital safety outputs Output SMX Actuator / Category MTTFD Achie- Boundary Fault external acc. to Actuator vable conditions exclusion EN13849-1 shut-down acc. circuit to EN 13849- Single-channel Single- Cat. B Medium Contactor and without dynamic channel...
Page 124 Safety related characteristics diagnostics in at least one channel Actuator single- channel controlled with safety function Cat. 3 (e.g. STO) Single-channel Dual- Cat. 4 Monitoring High Contactor and with dynamic channel in both downstream output test Contactor, external actuators valve, brake shutdown suitably IQQ01..IQQ10...
Page 125 Safety related characteristics Dual-channel Dual- Cat. 4 Monitoring High Contactor and Q1 and Q2 channel in both downstream Contactor, external actuators valve, brake shut-down suitably etc. with circuits designed for Dual-channel direct safety with dynamic feedback for applications output test diagnostics Monitoring of in both...
Page 126: Connection And Installation
Connection and installation Connection and installation General notes of installation Strictly follow the safety regulations when installing! Protection class IP20 Route all signal lines for the interfacing of digital inputs and contact monitoring separately. You should in any case disconnect 230VAC (120VAC cULus) voltages from low voltage power lines, if these voltages are used in connection with the application.
Page 127 Connection and installation SAFETY  NOTICE Electric power supply lines of the SMX and "discontinuous-action lines" of the power converter must be isolated from each other.  Signal lines and power lines of the power converter must be routed through separate cable ducts.
Page 128: Installation And Assembly
SMX12-2/12-2A/2) on one top hat rail in connection with the backplane bus system is also possible. These modules can be combined with an I/O extension. In this case the backplane bus system needs to be configured by BBH when placing the order and delivered in accordance with the application in question.
Page 129: Arrangement Examples
Connection and installation 5.3.1 Arrangement examples 5.3.1.1 SMX11/2 + SMX31/2 + SMX31/2 SMX11/2 SMX31/2 SMX31/2 Basic device with two central I/O expansion modules, the power supply runs via the backplane bus. HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 129/264...
Page 130: Assembly Of The Modules
Connection and installation Assembly of 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 at an angle from above and snapped in at the bottom. For disassembling use a screwdriver, insert it into the slot of the downwards pointing latch and then move it up.
Page 131: Assembly On Backplane Bus
Connection and installation 5.4.2 Assembly on backplane bus After assembling the backplane bus the device can be installed. For this purpose, insert the module into the plug connection from above at an angle and snap it onto the C-rail. Insert the module from the top at an angle Snap-on downwards on to the C-rail The backplane connector can be subsequently extended.
Page 132: Installation And Configuration From Master <-> Master (Smmc) And Master <-> Slave (Sddc)
Connection and installation Snap the backplane bus element into the C-rail and insert it into the counter-piece by sliding it sideways. Installation and configuration from Master <–> Master (SMMC) and Master <-> Slave (SDDC) SMMC communication enables safe data exchange of 2 bytes between several SDDC masters. Communication takes place without a master to coordinate the data.
Page 133: Network Topology
Connection and installation 5.5.1 Network topology SMMC SDDC CAN (Zentral) SDDC ETH (Dezentral) Communication of a SMX modular with • Central expansion modules via SDDC CAN backplane bus • SMMC via Ethernet Communication of a SMX modular with • Central expansion modules via SDDC CAN backplane •...
Page 134: Installation I/O-Expansions
Connection and installation 5.5.2 Installation I/O-expansions NOTICE Installation of expansions A maximum of two SMX3x/2 modules can be operated with one base module. 5.5.2.1 Physical address configuration of the slave modules (central / decentral) On the SMX3x/2 modules, the bus address must be set using the address switch. The setting is made on the back of the module.
Page 135: Terminal Assignment
Connection and installation Terminal assignment 5.6.1 Terminal assignment SMX10/2 SMX10/2 Terminal assignment Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 •...
Page 136 Connection and installation Terminal assignment Unit Terminal Description Note • 1 - NC • No function • • 2 - NC • 3 - Y1 • Auxiliary outputs • • 4 - Y2 • 1 - I01 • 2 - I02 •...
Page 137: Terminal Assignment Smx10R/2
Connection and installation 5.6.2 Terminal assignment SMX10R/2 SMX10R/2 EXT-REL Terminal assignment Unit Terminal Description Note • 1 – 7.11 • Read back contact Relais 3 • • 2 – 7.12 • 3 – 8.11 • Read back contact Relais 4 •...
Page 138 Connection and installation Terminal assignment • Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 • Voltage supply device 0 VDC •...
Page 139: Terminal Assignment Smx10A/2
Connection and installation 5.6.3 Terminal assignment SMX10A/2 SMX10A/2 ENC- ANALOG Terminal assignment Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 •...
Page 140 Connection and installation • Terminal assignment Unit Terminal Description Note • 1 - NC • No function • • 2 - NC • 3 - Y1 • Auxiliary outputs • • 4 - Y2 • 1 - I01 • 2 - I02 •...
Page 141: Terminal Assignment Smx11/2
Connection and installation 5.6.4 Terminal assignment SMX11/2 SMX11/2 CPU-ENC Terminal assignment Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 •...
Page 142 Connection and installation Terminal assignment Unit Terminal Description Note • 1 – UE1+ Voltage supply encoder +24V DC X31 • 2 – UE1- Voltage supply encoder 0V DC X31 3 - Y1 • Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04...
Page 143: Terminal Assignment Smx11-Pxv/2
Connection and installation 5.6.1 Terminal assignment SMX11-PXV/2 SMX11-PXV/2 EXT-ENC Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC • 2 - A1.2 Voltage supply device +24 VDC Outputs • 3 - A2.1 Voltage supply device 0 VDC •...
Page 144 Connection and installation Terminal assignment Unit Terminal Description Note • 1 – NC • No function • 2 – NC • • 3 - Y1 Auxiliary outputs • 4 – Y2 • 1 - I01 • 2 - I02 • 3 - I03 •...
Page 145: Terminal Assignment Smx11-Wcs/2
Connection and installation 5.6.2 Terminal assignment SMX11-WCS/2 SMX11-WCS/2 X35-1 X35-2 Terminal assignment Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 •...
Page 146 Connection and installation Terminal assignment Unit Terminal Description Note • 1 – NC • No function • • 2 – NC • 3 - Y1 • Auxiliary outputs • • 4 - Y2 • 1 - I01 • 2 - I02 •...
Page 147: Terminal Assignment Smx11-2/2
Connection and installation 5.6.3 Terminal assignment SMX11-2/2 SMX11-2/2 CPU-ENC EXT-ENC Terminal assignment Unit Terminal Description Note • 1 - A1.1 • Voltage supply device +24 VDC • • 2 - A1.2 • Voltage supply device +24 VDC Outputs • • 3 - A2.1 •...
Page 148 Connection and installation Terminal assignment Unit Terminal Description Note • 1 – UE1+ • Voltage supply encoder +24V DC X31 • • 2 – UE1- • Voltage supply encoder 0V DC X31 • • 3 - Y1 • Auxiliary outputs •...
Page 149: Terminal Assignment Smx12/2
Connection and installation 5.6.4 Terminal assignment SMX12/2 SMX12/2 CPU-ENC Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 150 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE1+ Voltage supply encoder +24V DC X31 2 – UE1- Voltage supply encoder 0V DC X31 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 CPU-...
Page 151: Terminal Assignment Smx12A/2
Connection and installation 5.6.5 Terminal assignment SMX12A/2 SMX12A/2 ENC- CPU-ENC ANALOG Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 152 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE1+ Voltage supply encoder +24V DC X31 2 – UE1- Voltage supply encoder 0V DC X31 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 CPU-...
Page 153: Terminal Assignment Smx12-1-Pxv/2
Connection and installation 5.6.6 Terminal assignment SMX12-1-PXV/2 SMX12-1-PXV/2 CPU-ENC EXT-ENC EXT-ENC Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 154 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE1+ Voltage supply encoder +24V DC X31 2 – UE1- Voltage supply encoder 0V DC X31 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 CPU-...
Page 155 Connection and installation HTL encoder connection: A+/B+ HTL encoder connection: A+, A-/B+, B- HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 155/264...
Page 156: Terminal Assignment Smx12-2/2
Connection and installation 5.6.7 Terminal assignment SMX12-2/2 SMX12-2/2 CPU-ENC EXT-ENC EXT-ENC Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 157 Connection and installation Terminal assignment Unit Terminal Description Note • 1 – UE1+ • Voltage supply encoder +24V DC X31 • • 2 – UE1- • Voltage supply encoder 0V DC X31 • • 3 - Y1 • Auxiliary outputs •...
Page 158 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE4+ Voltage supply encoder +24V DC X34 2 – UE4- Voltage supply encoder 0V DC X34 3 – UR4 Reference voltage encoder X33 4 - NC No function 1 – H1A Encoder 24V 2 –...
Page 159: Terminal Assignment Smx12-2A/2
Connection and installation 5.6.8 Terminal assignment SMX12-2A/2 SMX12-2A/2 ENC- CPU-ENC EXT-ENC EXT-ENC ANALOG Terminal assignment Unit Terminal Description Note 1 - A1.1 Voltage supply device +24 VDC 2 - A1.2 Voltage supply device +24 VDC Outputs 3 - A2.1 Voltage supply device 0 VDC 4 - A2.2 1 - I13 Safe digital inputs...
Page 160 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE1+ Voltage supply encoder +24V DC X31 2 – UE1- Voltage supply encoder 0V DC X31 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 CPU-ENC...
Page 161 Connection and installation Terminal assignment Unit Terminal Description Note 1 – UE4+ Voltage supply encoder +24V DC X34 2 – UE4- Voltage supply encoder 0V DC X34 3 – UR4 Reference voltage encoder X34 4 - NC No function 1 – H1A Encoder 24V 2 –...
Page 162: Terminal Assignment Smx31/2
Connection and installation 5.6.9 Terminal assignment SMX31/2 SMX31/2 Terminal assignment Unit Terminal Description Note 1 - A1.3 Voltage supply device +24V DC outputs • 2 - A1.4 3 - A2.3 Voltage supply device 0V DC • 4 - A2.4 1 - IQ01 Safe digital inputs, outputs pp-switching •...
Page 163 Connection and installation Terminal assignment Unit Terminal Description Note 1 - NC No function 2 - NC 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 1 - I05 2 - I06 Safe digital inputs 3 - I07...
Page 164: Terminal Assignment Smx31R/2
Connection and installation 5.6.10 Terminal assignment SMX31R/2 SMX31R/2 EXT-REL EXT-REL Terminal assignment Unit Terminal Description Note 1 – 1.11 Read back contact Relais 1 • 2 – 1.12 3 – 2.11 Read back contact Relais 2 • 4 – 2.12 1 –...
Page 165 Connection and installation Terminal assignment Unit Terminal Description Note 1 – 1.11 Read back contact Relay 5 2 – 1.12 3 – 2.11 Read back contact Relay 6 4 – 2.12 1 – 3.11 Read back contact Relay 7 2 – 3.12 3 –...
Page 166 Connection and installation Terminal assignment Unit Terminal Description Note 1 - NC No function 2 - NC 3 - Y1 Auxiliary outputs 4 - Y2 1 - I01 2 - I02 3 - I03 4 - I04 1 - I05 2 - I06 Safe digital inputs 3 - I07...
Page 167: Terminal Assignment Smx31R-4/2
Connection and installation 5.6.11 Terminal assignment SMX31R-4/2 SMX31R-4/2 EXT-REL Terminal assignment Unit Terminal Description Note 1 – 1.11 Read back contact Relay 1 2 – 1.12 3 – 2.11 Read back contact Relay 2 4 – 2.12 1 – 3.11 Read back contact Relay 3 2 –...
Page 168 Connection and installation Terminal assignment Unit Terminal Description Note 1 - A1.3 Voltage supply device +24V DC outputs 2 - A1.4 3 - A2.3 Voltage supply device 0V DC 4 - A2.4 1 - IQ01 Safe digital inputs, outputs pp-switching 2 - IQ02 •...
Page 169: Terminal Assignment Com
Connection and installation 5.6.12 Terminal assignment COM SMXxx/2/xxx Placeholder for SMX base device Terminal assignment Unit Terminal Pin Release /2 Description Note 1 – SD_BUS_24V Voltage supply SD-BUS +24 VDC Only available 2 – SD_BUS_GND Voltage supply SD-BUS 0 VDC for fieldbus 3 –...
Page 170 Connection and installation Terminal assignment Unit Terminal Pin Release /2 Description Note The configuration of the individual SDDC ETH Ethernet connection for SDDC ETH ports can be SMMC and SMMC carried out in the SafePLC2. Fieldbus The configuration connection, Ethernet connection for fieldbus of the fieldbus can Ethernet-based be carried out in...
Page 171: External 24 Vdc - Voltage Supply
Connection and installation External 24 VDC – voltage supply The SMX module requires an external power supply of DC 24 V (SELV or PELV, EN50178). Nominal voltage DC 24 V Minimum: 24 VDC – 15% 20,4 VDC Maximum: 24 VDC + 20% 28,8 VDC Observe the following boundary conditions when planning and installing the intended power supply unit:...
Page 172 Connection and installation ATTENTION If using external power supply units, it must be ensured that no higher voltage than 60 V can occur in the event of a fault. The actual behavior of the power supply unit used must be checked with the respective manufacturer, as the EN 60950 standard permits up to 120 V in the event of a fault.
Page 173 Connection and installation CPU-ENC EXT-ENC EXT-ENC GND- GND- GND- GND- Encoder Encoder Encoder Encoder SMX12-2/2 SMX31/2 Internal connection e.g. between UE1- → 9 pole D-Sub X31 Pin 2 Interne Verbindung z.B.: zwischen UE1- -> 9-pol D-SUB X31 Pin 2 HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 173/264...
Page 174: Connection Of External Encoder Supply
Connection and installation Connection of external encoder supply 5.8.1 Incremental, HTL, SIN/COS, SSI UE3- UE4- UE4+ UE2- UE1- UE1+ UE2+ 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Terminals Klemmen Monitoring of external Spannungs-überwachung der externen Geber- encoder supply voltages versorgungs-...
Page 175 Connection and installation Monitoring of the supply voltage in accordance with the chosen nominal voltage: Nominal voltage Minimum voltage Maximum voltage 5 VDC 4,4 VDC 5,6 VDC 8 VDC 7 VDC 9 VDC 10 VDC 8 VDC 12 VDC 12 VDC 10 VDC 14 VDC 20 VDC...
Page 176: Resolver
Connection and installation 5.8.2 Resolver UE3+ UE4+ UE3- UE4- terminals Reference Reference Signal Signal generating generating D-SUB Encoder Only SMX 11-2/2), SMX 12-2/2 and SMX12-1-PXV/2 Only SMX 12-2/2 When using resolvers in Master-Mode an additional 24V DC power supply is required for generating the reference signal.
Page 177: Connection Of Digital Inputs
Connection and installation Connection of digital inputs The SMX has 14 (SMX10/2, SMX11/2, SMX12/2) or 12 (SMX3x/2) 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...
Page 178: Connection Of Analog Inputs
Connection and installation 5.10 Connection of analog inputs With the executions with analog processing. max. 2 analog signals to be processed safely: The analog inputs can be connected as follows: max. Voltage -10 VDC +10 VDC NOTICE Assemblies with analog inputs The modules can optionally be equipped with voltage and, or current inputs SAFETY ...
Page 179: Connection Of Position And Speed Sensors
Connection and installation 5.11 Connection of position and speed sensors 5.11.1 General notes Depending on module type the SMX module (SMX11/12) has 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 180 Connection and installation ATTENTION Sensor connections 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 SMX module before plugging on or pulling off encoder connections.
Page 181: Assignment Of Encoder Interfaces
Connection and installation 5.11.2 Assignment of encoder interfaces 5.11.2.1 X31/X32 Sensor assignment only SMX12/2 5.11.2.2 X33/X34 Sensor assignment only SMX11-2, SMX12-2/2 NOTICE With the terminals X33/X34 of the modules SMX11-2(/2) and SMX12-2(/2), the connection is inverse to the presented and to X31/X32 with application of a incremental counting system.
Page 182: X35
NOTICE The shielding is connected on both sides, i.e. on the control unit and on the read head. The earthing terminal (PCV-SC12-BBH), which is available as an accessory, enables simple inclusion in the equipotential bonding. HB-37352-810-02-61F-EN SMX Gen2 Installation Manual...
Page 183: X35-1/X35-2
The shielding is connected on both sides, i.e. on the control unit and on the path NOTICE coding system. The earthing terminal (PCV-SC12-BBH), which is available as an accessory, enables simple inclusion in the equipotential bonding. HB-37352-810-02-61F-EN SMX Gen2 Installation Manual...
Page 184: Connection Variants
Connection and installation 5.11.3 Connection variants 5.11.3.1 Connection of an absolute encoder as master n.c. Pin 1 Ground Pin 2 GND of the supply voltage 24 V DC Pin 3 n.c. Pin 4 CLK- Sub-D- Pin 5 Sub-D plug absolute DATA+ Absolut- Stecker...
Page 185: Connecting An Absolute Encoder As Slave
Connection and installation 5.11.3.2 Connecting 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+ absolute Absolut- (9 pin) SMX Stecker encoder Encoder (9 polig) (Slave mode) (Slave-Betrieb) Pin 6 DATA-...
Page 186: Connecting A Incremental Encoder With Ttl-Signal Level
Connection and installation 5.11.3.3 Connecting a incremental encoder with TTL-signal level n.c. Pin 1 Pin 2 Ground Pin 3 n.c. Pin 4 Incremental Sub-D plug Sub-D- Pin 5 Inkremental encoder (9 pin) SMX Stecker Encoder (9 polig) Pin 6 n.c. Pin 7 Pin 8 Pin 9...
Page 187: Connecting An Sin/Cos Encoder
Connection and installation 5.11.3.4 Connecting an SIN/COS encoder n.c. Pin 1 Pin 2 Ground GND of voltage supply 24V DC Pin 3 n.c. Pin 4 COS- Sub-D plug Sub-D- Pin 5 SIN+ SIN/COS SIN/COS (9 pin) SMX Stecker encoder Geber (9 polig) Pin 6 SIN-...
Page 188: 5.11.3.5 Connecting A Resolvers As Master
Connection and installation 5.11.3.5 Connecting a resolvers as master Reference Out + Pin 1 Reference Out - Pin 2 Reference In + Pin 3 Pin 4 COS - GND of supply voltage 24 V DC Sub-D plug Sub-D- Pin 5 SIN + Resolver (9 pin) SMX...
Page 189: Connecting A Resolver As Slave
Connection and installation 5.11.3.6 Connecting a resolver as slave Pin 1 Monitor Reference Pin 2 Voltage GND Reference In + Pin 3 Pin 4 COS - Sub-D plug Sub-D- Pin 5 SIN + (9 pin) Resolver Stecker Resolver (Slave mode) (9 polig) (Slave-Betrieb) Pin 6...
Page 190: Connection Of Proximiy Switch Smx1X/2
Connection and installation 5.11.3.7 Connection of proximiy switch SMX1x/2 Connection is made via connector X23 at the digital inputs I5 ...I8. The exact pin assignment depends on which encoder type is used and is displayed in the wiring scheme in the programing interface. NOTICE When using HTL encoders, please note that tracks A+ and B+ or A- and B- must be combined accordingly.
Page 191: 5.11.3.8 Connection Of Htl/Proximity Switch Smx11-2/2, Smx12-2/2
Connection and installation 5.11.3.8 Connection of HTL/proximity switch SMX11-2/2, SMX12-2/2 Connection via plug connectors X27 and X28, or X29 and X30. 5.11.3.8.1 HTL-encoder with A+/A- or B+/B- signal Terminal block Incremental Terminal Encoder block Supply voltage Terminal block Ground Power supply encoder SMX11-2/2 encoder 3 SMX12-2/2 encoder 4 HB-37352-810-02-61F-EN SMX Gen2 Installation Manual...
Page 192: Htl-Encoder With A+ Or B+- Signal
Connection and installation 5.11.3.8.2 HTL-encoder with A+ or B+- signal Terminal block Incremental Terminal Encoder block Supply voltage Terminal block Ground Power supply Encoder SMX11-2/2 encoder 3 SMX12-2/2 encoder 4 HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 192/264...
Page 193: Configuration Of Measuring Distances
Connection and installation 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. A category 4 compliant architecture, i.e.
Page 194: Sensor Type Diagnostics
Connection and installation 5.12.2 Sensor type diagnostics Absolute encoder and incremental measuring systems are possible, as well as counting pulse generating proximity switches. 5.12.2.1 Absolut encoder 5.12.2.1.1 Data interface: Serial Synchronous Interface (SSI) with variable data length from 12 to 28 Bit. Data format: Binary or Gray code Physical Layer:...
Page 195 Connection and installation Parameterization of SSI format: ClkN Number Clk Anzahl Clk = Framelength Start Clk 0 Clk 1 Clk 2 Index Index Data Daten Index Status K Data K Daten O Status Status information Status Status Status Status ..Error Maske Error mask Mask...
Page 196 Connection and installation Example: SSI-Frame length: 28 cycles Data-Length: 22 Bit Status: 5 Bit, 3 Bit Error + 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 197: Wcs (Wcs3B-Ls2Xx)
Connection and installation 5.12.2.1.2 WCS (WCS3B-LS2xx) Data interface: RS-485 interface Data format: Binary code (forward/backward) Protocol: Data protocol 2 Transmission rate: 62,5 kBits/s or 187,5 kBit/s (configurable) Measuring length: max. 314,563 m (393204 lines) Resolution: +/- 0,4 mm (1250 positions/m) On X35-1, X35-2 Parameters Fault threshold...
Page 198: Incremental Encoder
Connection and installation 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. 250 kHz on X31/32 on X33/34 Diagnostics: Diagnostic Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20% +/-2% 5 V, 8V, 10V, 12V, 20V, 24V...
Page 199: Sinecosie Encoder - High Resolution Mode
Connection and installation 5.12.2.4 SineCosie encoder – high resolution mode Physical Layer: +/- 0.5 Vss (without voltage offset) Measuring signal A/B: Track with 90 degree phase difference Maximum frequency of input clock pulses: 15 kHz Diagnostics: Diagnostic Parameters Fault threshold Supply voltage monitoring Fixed values +/- 20% +/-2%...
Page 200: Extended Monitoring Proximity Switch / Proximity Switch
Connection and installation 5.12.2.6 Extended monitoring proximity switch / proximity switch The extended monitoring uncovers the following faults: a) Supply voltage failure b) Failure of the output signal in the driver direction c) Malfunction Proxi for high signal d) Interruption of signal path Mechanical de-adjustment of proximity switch / excessive switching distance of proximity switch For diagnostic purposes, the two status states of the counter signals are also recorded synchronously and compared logically.
Page 201: Htl - Sensor
Connection and installation 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 SMX11-2/2, SMX12-2/2) Diagnostics: Diagnostic Parameters Fault threshold Supply voltage monitoring Fixed value 24 V +/- 20% +/-2% (Measuring tolerance)
Page 202: Response Time Of The Smx
Response time of the SMX Response time of the SMX 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.
Page 203: Response Time In Standard Operation
Response time of the SMX Response time in standard operation The cycle time of the SMX system serves as the basis for calculating response times. In operation, this is T_cycle = 8 ms. The specified response times comply with the corresponding maximum runtime for the specific application within the SMX module.
Page 204: Response Time For Fast_Channel
Response time of the SMX Response time for FAST_CHANNEL FAST_CHANNEL describes a characteristic of SMX to respond quicker to speed requirements than this would be possible with the execution of the safety programs in normal cycle (= 8 msec) The sampling time of FAST_CHANNEL is 2 msec.
Page 205 Response time of the SMX For the Worst Case assessment it is assumed that the drive will initially move exactly to the parameterized threshold with a speed V(k) and then will accelerate to the maximum possible value a0. React React error V w.
Page 206 Response time of the SMX With overspeed distance the following connections result for the course of V and s: Parameters Calculations methods Comment Value for response time data SMX + Deceleration time in external shut-off chain React deceleration time in external shut- derived from relay/contactor and brake down chain data, etc.
Page 207: Response Time When Using Smx31X/2
Response time of the SMX Response time when using SMX31x/2 The cycle time of the SMX system serves as basis for calculating the response times. In operation this is T_zyklus = 8 ms. The specified response times comply with the corresponding maximum running time for the actual application within the SMX module.
Page 208: Response Time When Using Sca Extended
Response time of the SMX Example 2: Input to base module, activation of SLS and processing in PLC, output to extension module. = 10 ms + 8 ms + 8 ms = 26 ms; TOTAL IN_Base OUT_31 Example 3: Input to extension module, activation of SLS and processing in PLC, output to extension module. = 18 ms + 8 ms + 8 ms = 34 ms;...
Page 209: Commissioning And Start
Commissioning and start Commissioning and start Procedure Commissioning must only be carried out by qualified personnel! Strictly follow the safety regulations when commissioning! Switch-on sequence After each restart of the module, the following phases are run through and displayed on the seven- segment display on the front if the module is running correctly: 7 segment Mode...
Page 210: Reset Function
Commissioning and start Reset Function The reset function is divided into a start-up function after voltage recovery = general reset and a status/alarm reset = internal reset function. The latter is triggered via the button on the front or a correspondingly configured input = reset element with activated "alarm reset"...
Page 211: Reset-Timing Reset
Commissioning and start 7.3.2 Reset-Timing Reset The reset-input for an 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<3 sec between raising / falling edge. Max.
Page 212 Commissioning and start V_Ist > SOS_V_Max V_Ist SOS_Result Reset_In Max. 3 sec Max. 3 sec Process value (speed) => no change of the output status with reset in the alarm condition Max. 3 sec Max. 3 sec Max. 3 sec Q =I1 AND I2 Q =I1 AND I2 Q =I1 AND I2...
Page 213: Example Reset-Function With Safeguarding Against False Uitlization
Commissioning and start 7.3.3.1 Example Reset-Function with safeguarding against false uitlization 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 Confirm button in conjunction with standstill monitoring respective safe limited speed.
Page 214 Commissioning and start Applicative measure: By linking within the PLC program, activation of the outputs by bypassing the alarm status is prevented. Example 1: The enable function of the outputs (ID 88) is also linked to a "reset timer". This prevents activation of the outputs for t >...
Page 215: Led Display
Commissioning and start LED display Colour Mode Description System OK, configuration green „Flashing“ validated System OK, configuration yellow „Flashing“ not yet validated „ Flashing “ Alarm „Permanent“ Fatal Fault System OK, configuration not yet validated, SMMC yellow - red „ Flashing “ configured however participant is missing System OK, configuration...
Page 216: Parameterization
Commissioning and start Parameterization Parameterization takes place via the program SafePLC . The transmission of these data to the module requires a programing adapter(SMX91), the drivers of which must first be installed by the user. Parametrization is described in: HB-37480-820-01-xxF-EN Programmierhandbuch SafePLC2.pdf Function test In order to guarantee safety of the module, the user must carry out a functional test of the safety functions at least once in a year.
Page 217: Safety Related Examination
Safety related examination Safety related examination To ensure the implemented safety functions, the user must check and document the parameters and links after commissioning and parameterization. This is supported by the parameterization software SafePLC2. (see HB-37480-820-01-xxF-EN Programing manual SafePLC2.pdf) General information about the system can be entered on the first two pages. On the following pages of the validation report, all functions used are printed with their parameters as individual proof of the safety test.
Page 218: Maintenance
Maintenance Maintenance Modification / Handling changes to the device Maintenance work must only be carried out by qualified personnel. Regular maintenance work does not have to be carried out. Repair NOTICE Devices must always be replaced completely. The appliance can only be repaired at the factory. ATTENTION Warranty Unauthorized opening of the module voids the warranty.
Page 219: Exchanging A Module
Maintenance Exchanging a module The following should be noted when exchanging a module: • Disconnect the electric power converter from the main supply. • Switch off the electric power supply for the device and disconnect. • Pull off the encoder plug. •...
Page 220: Technical Data
Technical data 10 Technical data 10.1 Environmental conditions Class of protection IP 20 Ambient temperature 0°C* ... +50°C Climatic category -25°C … +70°C Min-, Maximum relative humidity (no 3k3 acc. to DIN 60 721 condensation) Overvoltage category 5% - 85% Degree of contamination Operating materials Class of protection...
Page 221: 11 Switch Types
Switch types 11 Switch types Type Graphic symbols Truth table Logic function Function block Function LD E.1 Closing contact (S), Ö Normally Öffner ST IE.X only in display opening closed contact (O) contact Ausgang Output eSwitch_1o LD E.1 Normally open, as type 1 Normally ST IE.X Öffner...
Page 222 Switch types LD E.1 Monitoring for S=inactive Ö Normally AND NOT E.2 and Ö=active Open closed Öffner ST IE.X contact contact Normally Schließer open contact Ausgang Output eSwitch_1s1o Ö LD E.1 Time Monitoring Like 5, but with time Normally OR NOT E.2 monitoring of state closed Öffner...
Page 223 Switch types LD E.1 Time Monitoring Like 6, but with time Ö1 Ö2 Normally OR E.2 monitoring of state Öffner 1 closed 1 MET1..MET4 OR NOT E.3 changes. ST META_EN.1 Normally In case of signal Öffner 2 closed 2 changes at S (Attention: LD E.1 Bus line) or Ö...
Page 224 Switch types LD NOT E.1 Two-hand Monitoring for Ö Ö Normally OR E.2 operation S1*S2=inactive and Öffner 1 closed 1 OR NOT E.3 Ö1*Ö2=active + OR E.4 temporal monitoring of ST MEZ_EN.1 this status. This means Normally that in case of a signal Öffner 2 closed 2 LD E.1...
Page 225 Switch types Type Graphic symbols Truth table Function LD E.1 Selector switch Clear linkage of Normally AND NOT E.2 permissible switch Öffner closed contact ST IE.X1 positions Normaly open LD NOT E.1 Schließer contact AND E.2 ST IE.X2 Output Ausgang eMode_1s1o LD E.1 Selector switch...
Page 226: Notes On Designing, Programming, Validating And Testing Safety Related Applications
Notes on designing, programming, validating and testing safety related applications 12 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 227 Notes on designing, programming, validating and testing safety related applications Risk assessment as per EN ISO 13849-1 S – Severe physical injury S1 = minor, reversible injury S2 = severe, irreversible injury F – Frequency and/or duration of exposure to danger F1= rarely, not cyclic F2 = frequently up to permanent and/or long...
Page 228: Required Technical Documents
Notes on designing, programming, validating and testing safety related applications For machines sold within the EU the minimum risks to be examined are specified in the EU machine directive 2006/42/EU or in the latest version of this directive. Further information concerning the risk assessment and the safe design of machines can be found in the standards ▪...
Page 229: Necessary Steps For Draft, Realization And Testing
Notes on designing, programming, validating and testing safety related applications 12.3 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.
Page 230: Phase Of The V-Model
Notes on designing, programming, validating and testing safety related applications 12.3.1 Phase of the V-model Designation Description Design phase Validation phase Specification and Specification of all safety measures Testing of all passive and active safety validation of all passive to be applied, such as covers, measures for correct implementation and active safety barriers, max.
Page 231: Specification Of Safety Requirements ( Structural Schematic)
Notes on designing, programming, validating and testing safety related applications 12.3.2 Specification of safety requirements ( structural schematic) The safety requirements must be individually analyzed on the basis of applicable standards, e.g. product standard. Source: General specification, excerpt from BGIA Report 2/2008 concerning EN ISO 13849-1 HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 231/264...
Page 232 Notes on designing, programming, validating and testing safety related applications Example for an automatic handling machine: Function description: 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 233 Notes on designing, programming, validating and testing safety related applications Risk assessment A risk reduction is required under due consideration of all operating conditions. Inherently (risk from the project) safe design Movement of the cabin in direction x and y within the working area cannot be avoided. In the processing area the cabin must be moved up/down ...
Page 234 Notes on designing, programming, validating and testing safety related applications HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 234/264...
Page 235: Specification Of The Functional Safety System
Notes on designing, programming, validating and testing safety related applications 12.3.3 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 236: Required Performance Level (Plr) (Additional Emergency Stop)
Notes on designing, programming, validating and testing safety related applications 12.3.3.2 Required performance level (PLr) (additional emergency stop) The required performance level must now be determined on basis of the safety functions SF1..recognized above. The example below shows the decision path. Example for SF1: Result PF = d (Source Sistema) HB-37352-810-02-61F-EN SMX Gen2 Installation Manual Page 236/264...
Page 237: Example - Specification Of Safety Functions In Form Of A Table
Notes on designing, programming, validating and testing safety related applications 12.3.3.3 Example – specification of safety functions in form of a table Cons.- Safety function Measuring Implementation of Nominal Input/activation Response/ from value software parameters output /sensor Limitation of 1 x WCS Monitoring by 550mm/s Permanently...
Page 238 Notes on designing, programming, validating and testing safety related applications 1.6.1 Monitoring of 1 x WCS Muting of Pos 1 SF 1.6.2 carriage sensor /SSI diagnoses for (7626 - 7850) system absolute both carriage encoder sensors by means Pos 2 * the two of tested SCA (11030-1263)
Page 239: Software Specification
Notes on designing, programming, validating and testing safety related applications 12.3.4 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 12.3.3.3).
Page 240 Notes on designing, programming, validating and testing safety related applications Example software specification Cons.- Safety function Measuring Solution new Input/ Response/ value/ activation output sensor Monitoring V_Rope to Digital Monitoring by Permanently Operation stop V_Nominal incremental means of Monitoring of encoder, tested function SF 1.3.1...
Page 241: Hardware Specification
Notes on designing, programming, validating and testing safety related applications 12.3.5 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 242: Example For Default Hw
Notes on designing, programming, validating and testing safety related applications 12.3.5.2 Example for default HW Safety function Safe reduced speed SF 2.2 Safe monitored limited speed with door open Type Designation Function Design. Characteristic data Note Architecture MTTFD B10d Source Source [years] [1/h]...
Page 243: Consideration Of Systematic Failures
Notes on designing, programming, validating and testing safety related applications 12.3.5.3 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.
Page 244: Hard And Software Design
Notes on designing, programming, validating and testing safety related applications Fault exclusions If fault exclusions are made for certain devices or system components, these must be individually nominated and specified. Fault exclusions may be e.g. mech. shaft breakage, sticking of switching contacts, short-circuits in cables and lines, etc.
Page 245: Testing Of Hardware Designs
Notes on designing, programming, validating and testing safety related applications 12.3.7 Testing of hardware designs After completing the planning the hardware design must be examined for compliance with the targets from the hardware specification. Furthermore, one must check the compliance with the specified safety level for each safety function by using suitable analyses.
Page 246 Notes on designing, programming, validating and testing safety related applications 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 Single channel partial system Dual-channel partial Eink.
Page 247 Notes on designing, programming, validating and testing safety related applications Calculation acc. to EN ISO 13849-1: Channel A – Shut-down via main contactor: Component MTTF [years] Door closer = 100000 = 99% Switch = 30/AT = 9270/year (309 AT/year) MTTF = 107,87 years 0,1 ∙...
Page 248 Notes on designing, programming, validating and testing safety related applications Channel B – Shut-down via STO/inverter: Component MTTF [years] Door closer = 100000 = 99% Switch (s.o.) = 30/AT = 9270/year (309 AT/year) MTTF = 107,87 years 0,1∙n SIN/COS-Encoder MTTF = 30 years = 99% Encoder...
Page 249 Notes on designing, programming, validating and testing safety related applications Resulting PL for both channels: Symmetry of both channels: MTTF MTTF + MTTF =16,00 years MTTF MTTF DC mean value ∑ MTTF = 97,2 % ∑ MTTF MTTF = 16,00 years (average) = 97,4 % (average) PL =“d“...
Page 250: Verification Software (Program) And Parameters
Notes on designing, programming, validating and testing safety related applications 12.3.8 Verification Software (program) and parameters Verification takes place in two steps: 1. Checking the FUP with respect to the specified functionality. 2. Checking the FUP against the AWL-listing of the validation report, or the default parameters against the one listed in the validation report.
Page 251 Notes on designing, programming, validating and testing safety related applications Safety function: Limitation of max. travel speed in carriage in the worker's area: Monitoring of the maximum speed to < 0.33 m/s Safe Speed OK (ID 2124) (is bridged by available gap): Safe Speed OK responds when the the safe speed SLS (ID 2090) is exceeded in the worker's area and during setup work.
Page 252 Notes on designing, programming, validating and testing safety related applications Hoisting gear Safety function Emergency stop switch inputs and shut-down outputs 1.1 Emergency stop head control Dual-channel emergency stop with pulse monitoring If an emergency stop is triggered at the imposed control, this emergency stop can be bridgedif the approval 'Bridge safety' has been issued.
Page 253: Validation Of Fup Against Awl [Il] And Parameters By Means Of Validation Report
Notes on designing, programming, validating and testing safety related applications 12.3.8.2 Validation of FUP against AWL [IL] and parameters by means of validation report The programing carried out in the FUP must be compared with the AWL [IL] listing of the validation report.
Page 254 Notes on designing, programming, validating and testing safety related applications After checking the program, the parameters must be checked against the requirements in the specification by comparison. Example SLS: Validation report Safe Limited Speed (SLS) Index Parameters Value validated SLS - 0 Chosen axis: Speed threshold: SLS - 1...
Page 255 Notes on designing, programming, validating and testing safety related applications Example encoder configuration: Validation report Axis configuration / sensor interface Axis 1 General parameters Measuring distance: Type: Rotatory Position processing: Active Maximum speed: 2000 Incremtental shut-down: 10000 Shut-down speed: Sensors Type: SSI-standard SSI-standard...
Page 256: Performance Of The Ystem Test / Fit (Fault Injection Test)
Notes on designing, programming, validating and testing safety related applications 12.3.9 Performance of the ystem 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.
Page 257: Appendix
Appendix 13 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 (Confirm Button) Switch type Comment Classification PL acc. Classification SIL acc.
Page 258 Appendix Door Control (Door monitoring) Switch type Comment Classification Classification SIL category 2 normally closed Door monitoring PL e SIL 3 higher requirements 2 normally closed Door monitoring PL e SIL 3 time monitored monitored 1 normally open Door monitoring PL e SIL 3 + 1 normally...
Page 259 Appendix Light curtain Switch type Comment Classification Classification SIL category 2 normally closed Light curtain higher PL e SIL 3 requirements 2 normally closed Light curtain PL e SIL 3 time monitored monitored 1 normally open Light curtain higher PL e SIL 3 + 1 normally requirements...
Page 260 Appendix Sensor Switch type Comment Classification Classification SIL category 1 normally closed Sensor input PL d SIL 2 standard 1 normally open Sensor input PL d SIL 2 standard 2 normally closed Sensor input higher PL e SIL 3 requirements 2 normally closed Sensor input PL e...
Page 261: Appendix B - Ec Declaration
Appendix B – EC declaration EG-Konformitätserklärung für Sicherheitsbauteile im Sinne der EG-Maschinenrichtlinie 2006/42/EG (Anhang IV) EC declaration of conformity for safety components according the EU Machinery Directive 2006/42/EG (Appendix IV) BBH Products GmbH Firma Manufacturer Anschrift Böttgerstrasse 40 Address 92637 Weiden...
Page 262 Appendix Produktname SMX100-1/2/x, SMX100-2/2/x, SMX100-4/2/x, Product name SMX111/2/D, SMX111-2/2/D, SMX112/2/D, SMX112A/2/D, SMX112-2/2/D, SMX112-2A/2/D, SMX121/2, SMX121-2/2, SMX122/2, SMX122A/2, SMX122-2/2, SMX122-2A/2, SMX131/2, SMX131R/2, SMX131R-4/2, SMX132-0/2/D, SMX132-0R/2/D, SMX132-1/2/D, SMX132-1R/2/D FW-Version SMX100-x: 04-00-00-01 SMX11x: 04-00-00-01 SMX12x: 04-00-00-01 SMX131x: 04-00-00-01 SMX132x: 01-00-00-01 HW-Version 11-11-07, 11-10-10-11-07, 11-10-10-10-10-11-07, 11-11-07, 11-11-04-07, 11-11-04-07, 11-11-04-07, 11-11-04-04-04-07, 11-11-04-04-04-07, 11, 11-04, 11-04, 11-04,...
Page 263 Appendix Das Produkt wurde entwickelt, konstruiert und gefertigt in Übereinstimmung der o.g. Richtlinie. The product was developed, designed and manufactured in accordance to the directive as named above Folgende Normen wurden angewendet: Following standards were applied: Standard Title Edition Norm / Titel / Ausgabe / Elektrische Leistungsantriebssysteme mit einstellbarer Drehzahl...
Page 264 Appendix Folgende Prüfstelle hat eine Baumusterprüfung des Produkts im Zusammenhang mit der EMV Richtlinie ausgeführt: The below listed test house has executed a type certification in relation to the Low Voltage and EMC Directive: EMC: TEMPTON Service Plus GmbH, Thurn- und Taxis-Str. 18, D-9011 Nürnberg Reg.-Nr.: DGA-PL-231/9-04 Doc.

BBH SMX Series Installation Manual

Contents

General Information

Identification

Important Information of Use

Warranty Claims

Liability Exclusion

Copyright

Definitions

Supplied Documents

Abbreviations Used

Safety Regulations

Intended Use

Use in Regions with UL/CSA Requierments

General Safety Information

Transport/Storage

Electrical Connection

ESD Information

Operation and Service

Device Types

Module Overview

Characteristic Data of Devices

Derating Outputs

Identification

Safety Related Characteristics

General Design, Safety Related Architecture & Characteristic Data

Safety Related Characteristic Data and Wiring for the Connected

Sensors

Safety Related Characteristic Data and Wiring of the Outputs

Connection and Installation

General Notes of Installation

Installation and Assembly

Mounting Backplane Bus System

Assembly of the Modules

Installation and Configuration from Master <-> Master (SMMC) and Master <-> Slave (SDDC)

Terminal Assignment

External 24 VDC - Voltage Supply

Connection of External Encoder Supply

Connection of Digital Inputs

Connection of Analog Inputs

Connection of Position and Speed Sensors

Configuration of Measuring Distances

Response Time of the SMX

Response Time in Standard Operation

Response Time for FAST_CHANNEL

Response Time for Fault Distance Monitoring

Response Time When Using Smx31X/2

Response Time When Using SCA Extended

Commissioning and Start

Procedure

Switch-On Sequence

Reset Function

LED Display

Parameterization

Function Test

Validation

Safety Related Examination

Maintenance

Modification / Handling Changes to the Device

Exchanging a Module

Maintenance Intervals

10.1 Environmental Conditions

Technical Data

Safety Related Characteristic Data

11 Switch Types

Notes on Designing, Programming, Validating and Testing Safety Related Applications

12.1 Risk Assessment

Required Technical Documents

Necessary Steps for Draft, Realization and Testing

Appendix

Appendix A - Classification of Switch Types

Appendix B - EC Declaration

Quick Links

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Questions and answers

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Summary of Contents for BBH SMX Series