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Installation Manual

for

Series PSCBR-C-

Installation instructions for basic devices PSCBR-C-100-1 , PSCBR-C-100-2, PSCBR-C-100-4 series PSCBR-C-100 and the associated extension modules PSCBR-E-131-12DI-10DIO

Note: The German version if the original version of the installation manual

Status: 06/

Valid from FW release 2.0.2.

Subject to change without prior notification The contents of this documentation has been collated with greatest care and corresponds with our present status of information. However, we would like to point out, that this document cannot always be updated at the same time as the technical further development of the products. Information and specifications can be changed at any time. Please keep yourself informed about the current version under www.schmersal.com.br

Devices of the

ACE Schmersal Eletroeletrônica Industrial Ltda. Rodovia Boituva - Porto Feliz, Km 12 Jd. Esplanada CEP 18550- Boituva - SP - Brasil

• 1 IMPORTANT NOTES
• 1.1 Definitions
• 1.2 Co-valid documents
• 1.3 Abbreviations used
• 2 SAFETY REGULATIONS
• 2.1 Intended use...........................................................................................................................................
• 2.2 General safety regulations
• 2.3 Operation and service
• 2.4 Transport/storage
• 3 DEVICE TYPES
• 3.1 Characteristic data of device.................................................................................................................
  • 3.1.1 Basic modules
    • 3.1.1.1 System module PSCBR-C-
  • 3.1.2 Extension modules
    • 3.1.2.1 Extension group PSCBR-E- 131 - 12DI-10DIO
• 4 SAFETY RELATED CHARACTERISTICS
• 4.1 General design, safety related architecture and characteristic data
• 4.2 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 digital safety inputs
    • 4.2.1.4 Exemplary connections of digital sensors/input elements
    • 4.2.1.5 Overview of achievable PI for digital safety inputs
  • 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
    • 4.2.2.2 General diagnostic measures for encoder interface.........................................................
    • 4.2.2.3 Encoder types and their combination, diagnostic data
    • 4.2.2.4 Specific diagnostic measures with regard to the encoder type used
    • 4.2.2.5 Safety relevant cut-off thresholds encoder systems for position and speed detection
    • 4.2.2.6 Safety related assessment of encoder types or there combination
  • 4.2.3 Analog sensors
    • 4.2.3.1 Exemplary connection of analog sensors
• 4.3 Safety related characteristic data and wiring of the outputs
  • 4.3.1 Characteristic of the output elements
  • 4.3.2 Diagnoses in the cut-off circuit
    • 4.3.2.1 Diagnostic Functions
    • 4.3.2.2 Overview DC with respect to the chosen diagnostics functions
  • 4.3.3 Basic outputs
    • 4.3.3.1 Characteristic data of the basic outputs
    • 4.3.3.2 Wiring examples basic outputs
  • 4.3.4 Configurable I/O as outputs
    • 4.3.4.1 Classification of the I/O when used as output
    • 4.3.4.2 Wiring example for outputs of extension module
    • 4.3.4.3 Overview of achievable PI for digital safety outputs
• 5 CONNECTION AND INSTALLATION
• 5.1 General notes on installation
• 5.2 Installation and assembly of the PSCBR-C-100 module
• 5.3 Installation of backplane bus system
• 5.4 Assembling the modules
  • 5.4.1 Assembly on C-rail................................................................................................................
  • 5.4.2 Assembly on backplane bus
• 5.5 Installation and configuration I/O-extension PSCBR-E- 131 - 12DI-10DIO
  • 5.5.1 Log on PSCBR-E- 131 - 12DI-10DIO to basic group
  • 5.5.2 Physical address configuration PSCBR-E- 131 - 12DI-10DIO
  • 5.5.3 Configuration of the I/O-assignment PSCBR-E- 131 - 12DI-10DIO
  • 5.5.4 Logic address configuration PSCBR-E- 131 - 12DI-10DIO
• 5.6 Terminal assignment
  • 5.6.1 Terminal assignment PSCBR-C- 100 -
  • 5.6.2 Terminal assignment PSCBR-E- 131 - 12DI-10DIO
• 5.7 External 24 VDC – power supply
• 5.8 Connection of digital inputs
• 5.9 Connection of position and speed sensors
  • 5.9.1 General notes
• 6 RESPONSE TIMES OF THE PSCBR...................................................................
• 6.1 Response times in standard operation
• 6.2 Response time for FAST_CHANNEL
• 6.3 Response times for fault distance monitoring
• 6.4 Response times when using digital inputs and outputs on the extension groups
• 7 START-UP
• 7.1 Procedure
• 7.2 Making sequences
• 7.3 LED display
• 7.4 Parameterization
• 7.5 Function test.......................................................................................................................................
• 7.6 Validation
• 8 SAFETY RELATED EXAMINATION
• 9 MAINTENANCE
• 9.1 Modification / handling changes to the device
• 9.2 Exchanging a module
• 9.3 Maintenance intervals
• 10 TECHNICAL DATA
• 10.1 Environmental conditions
• 10.2 Safety related characteristic data
• 11 FAULT TYPES PSCBR
• 11.1 Fault indication
  • 11.1.1 PSCBR-C- 100 - x without extension modules
  • 11.1.2 PSCBR-C-100 with expansion modules
• 11.2 Alarm List PSCBR-C-
• 11.3 Fatal Fault list PSCBR-C-
• 12 ENCODER TYPES
• 13 SWITCH TYPES
• SAFETY RELATED APPLICATIONS 14 NOTES ON DESIGNING, PROGRAMMING, VALIDATING AND TESTING
• 14.1 Risk assessment
• 14.2 Required technical documents
• 14.3 Necessary steps for draft, realization and testing
  • 14.3.1 Specification of safety requirements (structural schematic)
  • 14.3.2 Specification of the functional safety system
    • 14.3.2.1 Definition of safety functions
    • 14.3.2.2 Required performance level (PLr) (additional emergency stop)
    • 14.3.2.3 Example – Specification of safety functions in form of a table
  • 14.3.3 Software specification
  • 14.3.4 Hardware specification
    • 14.3.4.1 Selection of SRP/CS and operating means
    • 14.3.4.2 Example for hardware specification............................................................................
    • 14.3.4.3 Consideration of systematic failures
  • 14.3.5 Hard and software design
  • 14.3.6 Testing of the hardware design
    • 14.3.6.1 Iterative testing of the achieved safety level
  • 14.3.7 Verification software(program) and parameters
    • 14.3.7.1 Checking FUP.............................................................................................................
    • 14.3.7.2 Validation of FUP against AWL and parameters by means of validation report.
  • 14.3.8 Performance of the system test / FIT (fault injection test)
• APPENDIX
• Appendix A – Classification of switch types

1.2 Co-valid documents

Description Reference

Configuration of the PSCBR module

for stand-alone applications without

field-bus interfacing with the program

“SafePLC”

SafePLC programming manual

(System CD)

Validation report for implemented

parameterization and PLC-program

Safety inspection with acceptance

protocol

Acceptance test for general safety

related applications

Certificate for type approval test for fail-

safe control system acc. to machine

directive 2006/42/EC for the product

groups

PSCBR-C-100-

PSCBR-C-100-

PSCBR-C-100-

Note:

 Thoroughly read the manuals before you start the installation and the commissioning of

the PSCBR-C-100 module.

 Paying attention to the documentation is a prerequisite for trouble-free operation and

fulfilment of possible warranty claims.

1.3 Abbreviations used

Abbreviation Meaning

AC Alternating voltage

IL Instruction list

ELIA Employer's liability insurance association

CLK Clock (cycle)

CPU Central Processing Unit

DC Direct voltage

DI1..DI14 Digital Input

Abbreviation Meaning

DIN Deutsches Institut für Normung (German Institute for Standardization)

DO Digital Output

EMU Emergency Monitoring Unit

EMC Electromagnetic compatibility

ELC Emergency Limit Control

EN European Standard

HISIDE Output with 24VDC nominal level switching to plus

IP20 Degree of protection for housing

ISO International Organisation for Standardisation

LED Light Emitting Diode

LOSIDE Output switching to reference potential

OLC Operational Limit Control

PIA Process image of outputs

PII Process image of inputs

P1,P2 Pulse outputs

PLC Programmable Logic Controller

POR Power on Reset

PSC Position Supervision Control

SDDC Safe Device To Device Communication

SELV Safety Extra Low Voltage

SSI Synchronous Serial Interface

VDE Verband der Elektrotechnik, Elektronik und Informationstechnik e. V.

(association for electrical engineering, electronics and information

technology)

 The use of the device must be strictly limited to the intended use as specified in the

following list. The values of data listed under section “3.2 Characteristic device data”

must also be observed.

 The contents of this installation manual is restricted to the basic function of the device

or its installation. The “Programming instructions PSCBR-C-100” contains a more

detailed description of the programming and re-parameterization of the devices. Exact

knowledge and understanding of these instructions is mandatory for a new installation

or modification of device functions or device parameters.

 Commissioning (i.e. starting up the intended operation) is only permitted in strict

compliance with the EMC-directive. The EMC-testing regulations EN55011:2007 +

A2:2007 and EN 61000-6-2:2005 are used as basis.

 Compliance with the conditions acc. to EN 60068-2-6 related to the values specified

under “Technical characteristics” is mandatory for storage and transport.

 The wiring and connecting instructions in chapter “Installation” must be strictly followed.

 The applicable VDE-regulations and other special safety regulations of relevance for

the application must be strictly followed.

 Evidence of the configured monitoring functions as well as their parameters and links

must be issued by means of a validation report.

 The implementation of the module must be coordinated with the demands of the

responsible acceptance testing authority (e.g. TÜV or ELIA).

 Do not install or operate damaged products. Report damages immediately to the

responsible forwarding agent.

 Never open the housing and/or make unauthorized conversions.

 Inputs and outputs for standard functions or digital and analog data transmitted via

communication modules must not be used for safety relevant applications.

WARNING:

Using our devices contrary to the rules and conditions specified hereunder can lead to

injuries or fatalities as well as damage to connected devices and machines!

This will also cause the loss of all warranty and compensation claims against

SCHMERSAL.

2.3 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

When installing or removing the module appropriate measures must be applied to prevent

electrostatic discharge to the externally arranged terminal and plug connections. Contact with

such terminals should be reduced to a minimum and earthing should by means of e.g. an

earthing strap should take place before and during these procedures.

2.4 Transport/storage

Information concerning transport, storage and proper handling must be strictly followed.

The climate related specifications in chapter “Technical data” must be complied with.

(Class B) (Class B) (Class B) (Class B) (Class B) (Class B)

(Relay)

Connection example with separated I/O supply! (when connecting I/O's with high current consumption

Connection example with common I/O supply! (when connecting I/O's with low current consumption

(Relay)

3.1 Characteristic data of device

3.1.1 Basic modules

3.1.1.1 System module PSCBR-C-

Type designation Device design

Design of module with the following periphery:

20 secure digital I/O

14 digital inputs

2 pulse generator outputs

1 digital output relay

2 digital outputs LOSIDE

2 digital outputs HISIDE

6 signal outputs

Characteristics of the module:

 20 secure I/O – configurable as input or output, 14 secure inputs, 3 shut-down

channels, 1 of these a secure relay output and 6 signal outputs provided by the basic

device

 Extendable to max. 130 secure I/O and/or 12 secure axes by means of integrated

backplane bus (connectors to snap on top-hat rail)

 Logic diagram oriented programming by means of SafePLC-SW

 Extensive library for pre-configured safety sensors and operator controls

 Complete speed and position related safety functions for drive monitoring in

accordance with DIN EN 61800 integrated in firmware

 Three-dimensional functions for secure speed and area monitoring possible

 Parameter management for extension modules in the basic device

 Cross-shorting monitoring

 Possibility of contact multiplication or contact amplification by means of external

contactors in connection with integrated monitoring

 Extensive diagnostics functions integrated in FW

 Encoded status display via 7-segment display and status LEDs in front panel

 Quit-/Start-/Reset buttons operable in front panel

3.1.2 Extension modules

3.1.2.1 Extension group PSCBR-E-131-12DI-10DIO

Type designation Device design

Design of module with the following periphery:

12 digital inputs

10 I/O optionally configurable as input or output

2 pulse outputs

2 signal outputs

12 status LEDs for inputs

10 status LEDs for I/O

1 backplane bus interface

Characteristics of the module:

 12 secure inputs; 8 of these OSSD compatible

 10 secure I/O optionally configurable as input or output,

 Cross-shorting monitoring

 Possibility of contact multiplication or contact amplification by means of external

contactors in connection with integrated monitoring

 Extensive diagnostics functions integrated in FW

 Power supply via basic module

 Assembly on top hat rail

Technical characteristic data:

Safety related characteristic data

Pl acc. to EN 13849 Pl e

PFH / architecture Typical: 1.1 * 10-9 1)^ / Class 4

SIL acc. to EN 61508 SIL 3

Proof test interval 20 years = max. utilization period

General data

Secure digital I 12 incl. 8 OSSD

Secure digital I/O 10

Secure digital Out -

Secure analog In -

Secure relay outputs -

Signal outputs 2

Pulse outputs 2

Type of connection Clamp-type terminals

Electrical data

Power consumption Max. 3.8 W

Ratings digital I 24 VDC; 20 mA, Type1 acc. to EN61131-

Ratings digital O 24VDC; 250 mA

Pulse outputs Max. 250 mA

Environmental data

Temperature 0° to 50° operating temp.;

-10° to +70 ° storage temp.

Class of protection IP 52

Climatic category 3 acc. to DIN 50 178

EMC In accordance with EN 55011 and

EN 61000-6-

Mechanical data

Dimensions (HxDxW [mm]) 100x115x

Weight 300 g

Fastening To snap on standard rail

Max. conductor size 1.5 mm²

In detail one must differentiate between the following cases:

a) Axis modules with safety functions related to one axis or use of secure inputs on an

extension module and shut-down channel via outputs on the basic module

IA LA OA

IB LB OB

m

mi

i c

im

im Basisbaugruppe Aktuator

IA LA

IB LB

c

im

im Erweiterungsbaugruppe

SDDC Kommunikation

SMX100-System

Sensor

PFHPSCBR-C-100 = PFHPSCBR-C-100-X + PFHPSCBR1XX_IN + PFHSDDC

b) 1..N axis modules with safety functions for inter axes functionality (e.g. X/Y range

protection) or use of secure inputs on several extension modules with effect on one

individual safety function and shut-down channel via outputs on the basic module

IA LA OA

IB LB OB

m

mi

i c

im

im Basisbaugruppe Aktuator

IA LA

IB LB

c

im

im Erweiterungsbaugruppe N

SDDC Kommunikation

SMX100-System

Sensor N

IA LA

IB LB

c

im

im Erweiterungsbaugruppe 1

SDDC Sensor 1 Kommunikation

PFHPSCBR-C-100 = PFHPSCBR-C-100-X + N * PFHPSCBR1XX_IN + N * PFHSDDC

c) Inputs on basic group and shut-down channel via outputs on an extension module

Sensor 1 Extension module 1 Communication

Sensor N Extension module N Communication Base module Actuator

Sensor (^) Communication Extension module Basic module Actuator

IA LA OA

IB LB OB

m

mi

i c

im

im Basisbaugruppe Aktuator SMX100-System

Sensor N

SDDC Kommunikation

LA OA

LB OB

m

mi

i c

Erweiterungsbaugruppe

PFHPSCBR-C-100 = PFHPSCBR-C-100-X + PFHPSCBR1XX_OUT + PFHSDDC

d) Axis module with safety functions related to one axis or use of secure inputs on an

extension module and shut-down channel via outputs on the basic module

IA LA OA

IB LB OB

m

mi

i c

im

im Basisbaugruppe Aktuator

IA LA

IB LB

c

im

im Erweiterungsbaugruppe

SDDC Kommunikation

SMX100-System

SDDC Kommunikation

LA OA

LB OB

m

mi

i c

Erweiterungsbaugruppe

PFHPSCBR-C-100 = PFHPSCBR-C-100-X + PFHPSCBR1XX_IN + PFHPSCBR1XX_OUT + 2 * PFHSDDC

e) 1..N axis modules with safety functions for inter axes functionality (e.g. X/Y range

protection) or use of secure inputs on several extension modules with effect on one

individual safety function and shut-down channel via outputs on one extension module

IA LA OA

IB LB OB

m

mi

i c

im

im Basisbaugruppe Aktuator

IA LA

IB LB

c

im

im Erweiterungsbaugruppe N

SDDC Kommunikation

SMX100-System

Sensor N

SDDC Kommunikation

LA OA

LB OB

m

mi

i c

Erweiterungsbaugruppe

IA LA

IB LB

c

im

im Erweiterungsbaugruppe 1

SDDC Sensor 1 Kommunikation

PFHPSCBR-C-100 = PFHPSCBR-C-100-X + N * PFHPSCBR1XX_IN + PFHPSCBR1XX_OUT + (N+1) *

PFHSDDC

The characteristic data from chapter 3 must be used for the partial systems PFHPSCBR-C-

100 -X, PFHPSCBR1XX_IN, PFHPSCBR1XX_OUT and PFHSDDC to determine the PFHPSCBR-C-100 for the

PSCBR-C-100 system.

Sensor N Communication Base module (^) Extension module Actuator

Sensor N

Extension module Communication Base module^ Communication Extension module Actuator

Extension module 1 Communication

Base module (^) Extension module Actuator Communication^ Communication Extension module N

Sensor