Baumuller BM5-O-SAF-000, BM5-O-SAF-001 Operating Instructions Manual

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Operation Manual

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Translation Document No. 5.09013.07 Part No. 432449 Date Nov. 19, 2018

5.09013.07



BM5-O-SAF-000/-001

Safety Module for b maXX 5000



Read the Operating Instructions before beginning!

 Baumüller Nürnberg GmbH

Ostendstr. 80 - 90 90482 Nürnberg Germany

Tel. +49 9 11 54 32 - 0  Fax: +49 9 11 54 32 - 1 30

E-Mail: mail@baumueller.de Internet: www.baumueller.de

Table of Contents

1 Document history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Information on the Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Preliminary information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6 Further applicable documents from other manufacturers . . . . . . . . . . . . . . . . . . . . . . 12

2.7 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.8 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.9 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.10 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.11 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.12 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.12.1 Approvals, directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Use of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Contents of the operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Alterations and rebuilding of the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.4 Operator responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5 Protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.6 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.7 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.8 Special dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.9 Fire fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.10 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.10.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.12 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.13 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5 Functional safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1 Safety-related parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1.1 SAF-001-000-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.1.2 SAF-001-001-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6 Packaging and shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.1 Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.3 Disposing of the packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.4 To be observed when shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7 Description of the Default and Parameter Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2 Compatibility list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.3 Working principle parameter module (BM5-O-SAF-000-000-000). . . . . . . . . . . . . . . . 32

7.4 Setting of the switch-on behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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7.5 Structure of the SAF-000 Default- and Parameter module . . . . . . . . . . . . . . . . . . . . . 35

7.6 Identification of the SAF-000 Default- and Parameter module. . . . . . . . . . . . . . . . . . . 35

8 Description of the Safety Module (SAF-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8.1.1 Safety Module SAF-001-000-xxx and SAF-001-001-000 with safety function STO . 37

8.1.2 Safety Module SAF-001-001-001 with safety function SS1 (time controlled) . . . . . . 37

8.2 Compatibility list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.2.1 Compatibility list SAF-001-000-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.2.2 Compatibility list SAF-001-001-xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.2.3 Compatibility list SAF-001-000-002 with automatic restart . . . . . . . . . . . . . . . . . . . . 39

8.3 Safety notes on the STO (Safe Torque Off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.4 Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.4.1 SAF-001-000-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.4.2 SAF-001-001-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.5 Input circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8.5.1 SAF-001-000-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8.5.2 SAF-001-001-xxx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.6 Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.6.1 Structure of the Safety Module (SAF-001-000-xxx). . . . . . . . . . . . . . . . . . . . . . . . . . 48

8.6.2 Structure of the Safety Module (SAF-001-001-000) . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.6.3 Structure of the Safety Module (SAF-001-001-001) . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.7 Pin assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.7.1 Pin assignment of connector X1 (SAF-001-000-xxx). . . . . . . . . . . . . . . . . . . . . . . . . 50

8.7.2 Pin assignment of connector X1 (SAF-001-001-xxx). . . . . . . . . . . . . . . . . . . . . . . . . 51

8.7.3 Pin assignment of connector X1 (SAF-001-000-002 with automatic restart). . . . . . . 51

8.8 Switching thresholds for voltage and current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.9 Maximum response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.10 Properties of the parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.11 Operation and display elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.11.1 LEDs for indicating the operation statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.11.2 Button for verification purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.12 Restart inhibit (SAF-001-000-xxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.13 Automatic restart (SAF-001-000-002 and SAF-001-001-xxx) . . . . . . . . . . . . . . . . . . . 58

8.14 Marking of the Safety Module (SAF-001) - type code . . . . . . . . . . . . . . . . . . . . . . . . . 59

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9 Description of the Reset-Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.2 Compatibility list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.3 Operating mode of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . 61

9.4 Structure of the Reset-Module (BM5-O-SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.5 Identification of the Reset-Module (SAF-100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.6 Mode of operation module replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10 Resetting of the safety level by the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

10.2 Operation mode of the reset command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

11 Planning of a safety-oriented control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

11.1 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

11.2 Installation and wiring plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

11.3 Course of the planning phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

12 Assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

12.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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12.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 72

12.3 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

12.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

12.4.1 Requirements for the electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

12.4.2 Requirements on the connection cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

13 Commissioning and exchange of the module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

13.1 General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

13.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 78

13.3 Exchanging the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

14 System validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

14.1 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

15 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

16 Troubleshooting and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

16.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

16.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 87

16.3 Error diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

16.4 Detecting errors in the periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

16.5 Safe status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

18 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

19 Disassembly, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

19.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

19.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 94

19.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

19.4 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

19.5 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

20 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

20.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

20.2 Requirements on the personnel conducting the work . . . . . . . . . . . . . . . . . . . . . . . . . 95

20.3 Disposal instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

20.4 Recycling collection center/offices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Appendix B - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

B.1 Planning checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

B.2 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

B.3 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

B.4 Modification and retrofitting checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Appendix C - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

C.1 Connection values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

C.2 Operational conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

C.3 Pin assignment of Safety Module (SAF-001-000-xxx) connector X1 . . . . . . . . . . . . . 104

C.4 Pin assignment of Safety Module (SAF-001-001-xxx and SAF-001-000-002) connector X1 105

Appendix D - Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH

1DOCUMENT HISTORY

Revision

State Modifications

level

01 16.11.2010 Initial document

02 17.05.2011 SAF-000 Default- and Parameter module added

03 07.08.2012 Push button combination for push button S1 added;

04 27.05.2014 SAF-001-000-002 (automatic restart) added

05 08.11.2016 New declaration of conformity

06 20.09.2017 Safety Module SAF-001-001-xxx added

Chap. 8.12 times added Mode of operation SAF-000 and SAF-001 changed Type code SAF-000 and SAF-001 changed Chap. 8.11.1 LED display corrected Chap. 9 SAF-100 Reset module added Chap. 10 Resetting by the controller added Chap. 13.3 Exchanging the module changed

Chap. 8.3 Compatibility list SAF-001-000-002 new Chap. 8.9 Pin assignment SAF-001-000-002 new Chap. 8.15 Automatic restart SAF-001-000-002 new Chap. 8.16 Type code SAF-001-000-002 added Chap.8: SAF-001-000-001 removed

Chap. 8.3 Compatibility list SAF-001-001-xxx new Chap. 8.6.2 Working principle SAF-001-001-xxx new Chap. 8.7.2 Input circuitry SAF-001-001-xxx new Chap. 8.8.2 Structure Safety Module (SAF-001-001-xxx) added Chap. 8.9.2 Pin assignment of connector X1 ( Chap. 8.10 Switching thresholds SAF-001-001-xxx added Chap. 8.16 Type code SAF-001-001-xxx added Declaration of conformity SAF-001

-001-xxx added

SAF-001-001-xxx) added

07 19.11.2018 Safety Module SAF-001-001-001 (Safe Stop 1) added

Chap. 8.1.2 SAF-001-001-001 added Chap. 8.2.2 Compatibility list SAF-001-001-001 added Chap. 8.4.2 Working principle SAF-001-001-001 added Chap. 8.14 Type code SAF-001-001-001 added

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2.1 Information on the Operation Manual

This operation manual provides important information for the use of the device. Respect of the safety guidelines and instructions in this operation manual are prerequisites for the safe work.

Furthermore, the local accident prevention legislation and general safety regulations applying to the device's field of application must also complied with.

Read the operation manual completely, in particular the chapter on safety instructions, before beginning any work on the device. The operation manual is a component of the product and must be kept accessible in the immediate vicinity of the device at all times.

2GENERAL

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2.2

Legend

2.2 Legend

Warning notices

Warning notices are marked by symbols in th introduced by signal words which express the extent of the hazard.

Comply with the notices under all circumstances an accidents, personal injury and property damage.

DANGER!

is operation manual. The notices are

d act with caution in order to avoid

....notifies of an imminent dangerous s

injuries if not avoided.

WARNING!

....notifies of a potentially dangerous situation which can lead to death or serious

injuries if not avoided.

CAUTION!

....notifies of a potentially dangerous situation which can lead to minor or slight

injuries if not avoided.

CAUTION!

....notifies of a potentially dangerous situation which can lead to property damage if

not avoided.

ituation which will lead to death or serious

Recommendations

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NOTICE!

....draws attention to useful tips and recommendations as well as information for

efficient and trouble-free operation.

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2.3 Limitation of liability

All statements and instructions in this operation manual have been compiled in compliance with the applicable standards and legislation while taking the current level of technology and our long-term experience and findings into account.

The manufacturer assumes

m failure to observe the operation manual m application for purposes other than those intended m use by untrained personnel

The actual scope of materials described here in the event of custom designs, the use of additional ordering options or due to the most recent changes in technology.

The user assumes the responsibility accordance with the safety regulations of the applicable standards and all other relevant national or regional legislation relating to conductor dimensioning and protection, grounding, circuit breakers, overv olt ag e pr otection, etc.

The person who conducted the assembly or installation shall be accountable for damages

ring during assembly or connection.

occur

General

no liability for damages resulting from:

delivered can vary from the explanations and illustrations

of conducting maintenance and commissioning in

2.4 Preliminary information

CAUTION!

The following shall apply if the document you are reading is design ated as preliminary information: This version pertains to preliminary techn described devices and functions should receive ahead of time, in order to be able to adjust to potential changes and/or functional expansions.  This information is to be seen as the Baumüller internal review process. In particular, this information is still subject to changes, meaning that this preliminary information cannot be construed as legally binding. Baumüller assumes no liability for damages resulting from this potentially incorrect or incomplete version.  Should you detect or suspect content-related and/or serious formal errors in this

eliminary information, please contact the contact person at Baumüller assigned to

pr you and inform us of your findings and comments, so that they can be taken into account and potentially incorporated during the transition from the preliminary information to the final (reviewed by Baumüller) information.

ical information which the user of the

preliminary, since it has not yet been subjected to

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2.5

2.5 Copyright

Treat the operation manual as confidential. It is intended exclusively for those working with the device. It is not permissible to transfer the operation manual to third parties without the written approval of the manufacturer.

NOTICE!

The content-related statements, texts, diagrams, images and copyright protected and subject to industrial property rights. Any improper use is liable to prosecution.

2.6 Further applicable documents from other manufacturers

Components from other manufacturers are built into the device. Hazard evaluations for these bought-in parts have been conducted by the applicable manufacturers. The conformity of the designs with the applicable European and national legislation ha s been declared by the respective component manufacturers.

other illustrations are

2.7 Replacement parts

WARNING!

Improper or defective replacement parts can lead to damage, malfunctions or total failure as well as jeopardize safety.

Therefore:

m Only use original replacement parts from the manufacturer

Procure replacement parts from authorized de

2.8 Disposal

If no return or disposal agreement has been made, dism antled components can be taken for recycling after proper disassembly.

2.9 Warranty and liability

All the information in this operation manual is non-binding customer information; it is subject to ongoing further development and is updated on a continuous basis by the permanent change management system of Baumüller Nürnberg GmbH.

Claims of warranty or liability towards Baumüller Nürnberg GmbH are rejected, in particular if one or more of the reasons listed in chapter have been the cause of the damage/s.

The operation of the devices described here in accordance with the specified methods/ procedures/requirements is permissible. Everything else, even the operation of devices in installation positions not depicted here, for instance, is not permissible and must be clarified with the factor on a case-by-case basis. The warranty will be rendered null and void if the devices are operated differently than described here.

2.10 Customer service

Our customer service is available for technical support.

General

ZIntended use– on page 18 has/

2.11 Terms used

2.12 Certification

Information on the competent contact person can be found at any time via telephone, fax, E-mail or over the Internet.

A list of the abbreviations used can be found in ZAppendix A - Abbre viations– from page 97 onward.

The Safety Module (BM5-O-SAF-001-000) from Baumüller Nürnberg GmbH has been developed in accordance with the standards specified in by TÜV Rheinland.

EC Type Examination Certificate Number: 01/205/5031.01/16 Test report no.: 968/M 264.05/16 Notified Body: 0035

The Safety Module (BM5-O-SAF-001-001) from Baumüller Nürnberg GmbH has been developed in accordance with the standards specified in by TÜV Rheinland.

ZChapter 2.12.1– and certified

EC Type Examination Certificate Number: 01/205/5563.03/18 Test report no.: 968/FSP 1400.03/18 Notified Body: 0035

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2.12

2.12.1 Approvals, directives and standards

Certification

Safety engineering standards and directives

IEC 61508, Parts 1-7 Functional safety of safety-related

DIN EN ISO 13849-1 Safety-related components of control

IEC 62061 Functional safety of safety-related

Additional standards Area of application

DIN EN 61800-3 Adjustable speed electrical power

DIN EN 61800-5-1 Adjustable speed electrical power

Area of application Approvals

electric, electronic and programmable electronic systems

units

electric, electronic and programmable electronic systems

Fulfillment of increased stability

quirements in accordance with

re reference to EN

drive systems - Part 3: EMC requirements

drive systems - Part 5-1: Safety requirements - Electrical, thermal and energy

61326-3-1

up to SIL 3

up to performance level e up to category 4

DIN EN 61800-5-2 Adjustable speed electrical power

drive systems - Part 5-2: Safety requirements - Functional

EN 61131-2 Programmable controllers - Part 2:

Equipment requirements and tests

EN 60204-1 Electrical equipment of machines

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3USE OF THIS MANUAL

This safety manual contains information on the intended use of the Baumüller plug-in module.

Knowledge of the regulations and proper technical implementation of the safety instructions in this manual by qualified personnel are prerequisites for the safe installation, commissioning and safety during the operation and maintenance of the Baumüller plug-in module. Unqualified interference with the devices during shutdown or use of the safety functions or failure to comply with the instructions of this manual can lead to serious personal injury, property dam a ge or env iro nm e nt al ha rm , fo r wh ich Baumü ller assumes no liability.

Baumüller safety components and systems are developed, manufactured and tested in compliance with the applicable safety standards. They may only be used under the specified environmental conditions and only in connection with approved external devices.

The operation manual contains safety instructions, descriptions of the interfaces and information on the phases of the product's life cycle:

n Planning n Installation/Assembly n Commissioning n Validation n Operation n Modification/Retrofitting n Troubleshooting n Maintenance/Repair n Disassembly

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This chapter provides an overview of all important safety aspects for the optimum protection of the personnel as well as for safe and trouble-free operation.

4.1 Contents of the operation manual

All persons assigned to work on or with the device must have read and understood that operation manual before beginning work with the device. This also applies if the person concerned has already worked with such a device or a similar device or has been trained by the manufacturer.

4.2 Alterations and rebuilding of the device

In order to avoid hazards and ensure optimu m performance, neither alterations, additions nor rebuilding work may be conducted on the device unless explicitly authorized by the manufacturer.

4SAFETY

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4.3

Intended use

4.3 Intended use

The plug-in module is exclusively designed and constructed for the intended purpose of use described here.

You are using the device according to the terms, as soon as you regard all notes and in

formation in this operation manual.

WARNING! Danger due to use other than intended!

Any use of the device different from and/or intended use can lead to dangerous situations.

Therefore:

m Only use the plug-in module as intended. m Only use the plug-in module in combination with compatible converters (see

ZCompatibility list SAF-001-000-xxx– on page 38, ZCompatibility list SAF-001-

001-xxx– on page 38 and ZCompatibility list SAF-001-000-002 with automatic restart– on page 39).

m Follow all specifications of m Ensure that exclusively qualified personnel work on or with the plug-in module. m Take care in project plannin

its specifications.

m Ensure that the power supply meets the required specifications. m Only operate the plug-in module if it is in technically faultless condition. m Only use the plug-in module in comb

Baumüller Nürnberg GmbH.

this operation manual.

g to see that the plug-in module is always used within

exceeding beyond the scope of the

ination with components approved by

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4.4 Operator responsibility

The plug-in module is implemented in an industrial zone. The operator of the device is thus subject to the legal work safety obligations.

In addition to the work safety instructio ns in this operation manual, the safety, accident prevention and environmental protection regulations applicab le to the area of applica tion of this device must also be complied with. In doing so, the following applies in particular:

m The operator must inform himself of the applicable work safety regulations and

additionally ascertain hazards arise through the special work co nditions at the pla ce of use of the device in a risk assessment. The operator must implement this in the form of operation instructions for the operation of the device.

m This operation manual must be kept in the immediate vicinity of the device and be

accessible to persons working on and with the device at all times.

m The statements of the operation manual are to be fo llowed comp letely and absolu tely! m The device may only be operated in technically faultless condition and must be safe for

operation.

Safety

4.5 Protective equipment

When installed in the converter, the plug-in module complies with the protective category

IP20.

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4.6

Personnel training

4.6 Personnel training

WARNING! Risk of injury if operated by insufficiently qualified persons!

Improper handling can lead to severe personal injury and property damage. Therefore:

m Only allow certain activities to be conducted b

chapters of this operation manual.

y persons specified in the respective

The following qualifications for various areas of ope manual:

m Operating personnel

The drive system may only be operated by p and authorized to do so. Troubleshooting, repairs, cleaning, maintenance and exchange may only be conducted by trained or instructed personnel. These persons must be familiar with the operation manual and act according to it. Commissioning and instruction may only be conducted by qualified personnel.

m Qualified personnel

Electrical engineers and specialist electricians of authorized by Baumüller Nürnberg GmbH, trained and certified in the installation and commissioning of Baumüller drive systems and commissioning, grounding and designating electrical systems and devices in accordance with the safety engineering standards. Qualified personnel is educated or trained in the maintenance and use of suitable safety equipment in accordance with the respective local safety engine ering standards.

ration are specified in the operation

ersons who have been trained, instructed

the customer or a third party who are

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4.7 Personnel protective equipment

Wearing the appropriate personal protective equ ipment when working is required in order to minimize hazards to the health.

m Always wear the respective protective equipment r

working.

m Observe signs on personal safety in the work area!

Protective work clothes

consists of close-fitting workwear of low tea projecting parts. Intended mainly to protect the wearer from moving machine parts.

Do not wear any rings and necklaces.

Protective helmet

for protection from falling and flying

parts.

Safety

equired for the respective task when

r strength, without loose sleeves or

To be worn during

ecial work

Safety shoes

for protection from heavy

Safety gloves

to protect hands from friction, abrasions, pu as well as from contact with hot objects.

Protective glasses

to protect the eyes from flying parts and spraying liquids.

falling objects.

ncture, prick wounds or deeper injuries

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4.8

Special dangers

4.8 Special dangers

The residual risks arising as a result of the hazard analysis will be specified in the following section.

Observe the safety instructions described here chapters in order to reduce health hazards and avoid dangerous situations.

Moving parts

WARNING! Danger of injury due to moving parts!

Rotating and/or linear moving parts can cause severe injuries. Therefore:

m Do not interfere with moving parts during operation. m Do not open covers during operation. m The mechanical residual energy depends on the application. Pow

also keep rotating/moving for a certai n time after the power supply has been shut off. Make sure to provide suitable safety equipment.

and the warning notices in the following

ered parts will

4.9 Fire fighting

DANGER! Live-threatening danger from electrical current!

Electric shock can occur if a conductive fire Therefore:

m Use the following fire extinguishing medium:



ABC-Pulver / CO

2<Default Font>

extinguishing medium is used.

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4.10 Electric safety

The plug-in module is designed for contamination level 2 in accordance with DIN EN 61800-5-1. This means that only non-conductive contamination may appear du module is not in operation.

WARNING! Risk of injury from conductive contaminants!

Safety

ring operating time. Short-term conductivity from condensation is only permissible if the

No conductive contaminants may ap Therefore:

m Before installing the s

and ensure so by additional measures, if necessary.

4.10.1 Notice on power supply

WARNING! Risk of injury from electric current!

Only devices which have a safe disconnection to the 230 volt mains may be

nnected to the plug-in module.

co The power supply unit for generating the 24 Volt supply must meet the requirements

for PELV in accordance

pear during operating time.

ystem, check that contamination degree 2 is not exceeded,

with EN 60204-1.

4.11 Safety equipment

WARNING! Live-threatening danger from inoperable safety equipment!

Safety equipment provides a maximum of safety du equipment may make work processes more complicated, they may not be put out of operation under any circumstances. Safety is only ensured if the sa fety equipment is intact.

Therefore: m Check to make sure that the safety equipm

before beginning work.

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ring operation. Even if the safety

ent is functional and installed properly

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4.12

Conduct in the event of danger and accidents

4.12 Conduct in the event of danger and accidents

Preventive measures

In case of emerg properly

ency: Act

4.13 Signage

m Always be prepared for accidents or fire! m Keep first aid equipment (first-aid box, bla m Instruct personnel in accident reporting, fir

m Put the device out of operation immediately with the EMERGENCY STOP. m Introduce first aid measures. m Keep people out of the danger zone. m Inform the supervisors at the site. m Notify a doctor and/or fire department. m Clear access routes for rescue

The following symbols and notification signs are found in the work area. They relate to their immediate installation environment.

WARNING! Injury hazard due to il

In the course of time, stickers and symb otherwise illegible.

Therefore: m Keep all safety, warning and operation signs o

condition at all times.

legible symbols!

vehicles.

nkets, etc.) and fire extinguishers on hand!

st aid and rescue equipment.

ols on the device can become dirty or

n the device in easily legible

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Electric current

Only qualified personnel may work in work spaces with this marking. Unauthorized persons may not touch work equipment bearing this marking.

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This chapter describes parameters in relation to functional safety. First of all, in accordance with IEC 61508, safety means that a system is free of unwarranted risks. Functional safety is the part of the overall safety, which ensures that a safety system's response to its input conditions is free of errors. Internal safety-related device erro rs must be detected and brought into a safe condition in the process.

5.1 Safety-related parameters

The following table lists the sa fety-related parameters o f the Safety Module (BM5-O-SAF-

001) for an operation of 20 years. Safety-related parameters of local I/O terminals and centralized components can be found in the applicable documentation.

CAUTION!

If the user calculates his safety ap safety module will have to be decommissioned and sent back to the manufacturer within not more than 20 years. The user cannot perform a proof test.

5FUNCTIONAL SAFETY

plication with 20 years for the specified values, the

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5.1

Safety-related parameters

5.1.1 SAF-001-000-xxx

The values in the following table relate exclusively to the Safety Module (BM5-O-SAF001-000-xxx).

Parameters in accordance with IEC 61508 Safety Module

(SAF-001)

PFH

(Probability of Failure per Hour)

configuration

Single axis @ 40°C 7.21 * 10

-10

Double axis @ 40°C 1.18 * 10-9/h Single axis @ 55°C 1.20 * 10-9/h Double axis @ 55°C 2.11 * 10-9/h

Safety Module  (SAF-001) configuration

Single axis @ 40°C 6.32 * 10 Double axis @ 40°C 1.04 * 10 Single axis @ 55°C 1.05 * 10 Double axis @ 55°C 1.85 * 10

SFF according to

SIL

PFDAv (T=20 years)

(Probability of Failure on Demand = mean residual error probability of a dangerous error on demand)

-5

-4

Safe Failure Fraction = fraction of failures which lead to a safe status.

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Parameters in accordance with DIN EN ISO 13849-1 Safety Module 

(SAF-001)

MTTF

(Mean Time To Failure)

Classification

configuration

Single axis @ 40°C 1460 years HIGH Double axis @ 40°C 770 years HIGH Single axis @ 55°C 819 years HIGH Double axis @ 55°C 432 years HIGH

Safety Module  (SAF-001)

avg

Diagnostic Coverage

Classification

configuration

All configurations 97.7% HIGH

a. This values lies within the permissible toler

HIGH.

ance of 5% according to EN ISO 13849-1 for the classification

No proof test is necessary during the ex pe cte d life cycle of the device of up to 20 years.

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5.1.2 SAF-001-001-xxx

The values in the following table relate exclusively to the Safety Module (BM5-O-SAF001-001-xxx) per axis.

m Parameters in accordance with IEC 61508-1 to 7 and IEC 62061

(Data if the device is used as part of a safety function)

Note: If the PFH value is less than 1% of the allowed SIL level, the execution of a

m Parameters in accordance with EN ISO 13849-1

Functional safety

n SIL CL 3 n PFH: 3,6 x 10 n PFDav: 3,2 x 10 n Proof test interval 20 years

special proof test is not considered to be necessary within the oper ating time of the device.

n Performance Level PL e n Category: Kat 4 n MTTFD: HIGH (751 a) n Diagnostic Coverage DC: HIGH (99 %)

-10

1/h, according to 0,4 % of SIL 3

-5

according to 3,2 % of SIL 3

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5.1

Safety-related parameters

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6.1 Shipping

6PACKAGING AND SHIPPING

Before shipping, we package every Baumüller device in such a manner that damaging occurring during transport is very unlikely.

Modules are packaged at the factory according to the order.

h Avoid heavy shaking and concussions when shipping. h Avoid static discharges on the electronic components of the module.

6.2 Unpacking

h Only remove the module from the protective

Upon receiving the still-packaged module: h Check to see if any shipping damages can be found! If so: h Immediately file a complaint to the supplier. Confir

immediately contact the representative of Baumüller Nürnberg GmbH who is assigned to assist you.

CAUTION! Danger due to electrostatic discharge!

The plug-in module (specifically its electronic destroyed if exposed to electrostatic dis ch arge s by being touched by hand.

Therefore: m Follow the rules and instructions on handling

discharge when handling the plug-in module.

packaging immediately before assembly.

m the complaint in writing and

components) can be damaged or totally

components sensitive to electrostatic

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6.3

Disposing of the packaging

If no damage from shipping can be found:

h Open the packaging of the device. h Check the items included in the delivery against the bill of delivery.

The items included in the delivery are:

m Plug-in module for b maXX 5000 m This operation manual including certificate of conformity / declaration of manufacturer.

h If any shipping damages can be found or any items are missing from the delivery, file

a complaint to the Baumüller representativ e ass ign e d to yo u.

6.3 Disposing of the packaging

The packaging consists of cardboard and plastic. h Follow local regulations on disposal if you dispose of the packaging.

6.4 To be observed when shipping

The module has been packaged at the factory for the initial shipping. If you subsequently need to ship the module again, please observe the following:

h Use the original packaging or h use suitable packaging for the components groups which are sensitive to electrostatic

discharge.

Make sure that the shipping conditions (see ZAppendix C - Technical data– from page 103 onward) are consistently fulfilled throughout the entire shipping process.

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7.1 General

7DESCRIPTION OF THE DEFAULT

AND PARAMETER MODULE

This chapter describes the SAF-00 0 (Default and Para meter module) with it´ s functions and the type code applied to the module.

To operate the axis units of the b maXX 5000 device series, the slot A of the device has to be assembled with a module (see 5.09021, Manual b functions are required, the module SAF-000 can be used. There are two variants avail able:

m BM5-O-SAF-000-001-001-#00 Default module

n The module itself has no functionality and is used if no additional functions such as

parameter storage or safety functions, for example, are required.

m BM5-O-SAF-000-000-000-#00 Parameter module

n The module is provided with a user stor age for the functional paramete rs for the axis

unit. In case of service the module can be plugged in an exchange un it. Therefor e it is possible to transmit the parameters to the exchange unit in an easy way.

maXX 5000, too). If no safety

7.2 Compatibility list

The SAF-000 modules Default and Parameter can only be operated in combination with converters of the type b

If the converter was previously equipped with a module with a higher safety level (SAF-001/002/003), the parameter storage of the converter m ust be reset with the ResetModule.

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7.3

Working principle parameter module (BM5-O-SAF-000-000-000)

7.3 Working principle parameter module (BM5-O-SAF-000-000-000)

The adjusted parameters of the b maXX 5000 axis u nit can be stored on the SAF-000 parameter module. The parameter backup is carried out by the parameterization software

oDrive. The software provides this function with adequate butto ns at the page „Data set

Pr management“. By selecting these buttons parameter data can be written to or read from the SAF-000.

Figure 1: Data set management ProDrive

NOTICE!

The parameter data cannot be copied to the SAF-000 Parameter module, if a complete data set which was loaded before of that from the RAM with all th was loaded in the flash memory of the b maXX 5000 again.

e parameters, 

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Description of the Default and Parameter Module

7.4 Setting of the switch-on behavior

The switch-on behavior of the SAF-000 parameter module from a b maXX 5000 axis unit can be set by ProDrive at the page „Data set management“ by means of the checkbox „Load automatical“.

Two switch-on behaviors can be set:

„Load automatical“ Description

OFF The parameters are not loaded automatically.

ON The parameters are loaded from the parameter

module at every re-start (Default setting).

The setting „OFF“ is usually used during the commissio ten not necessary to backup the parameter data while changes happen. If the commissioning is done, the setting „ON“ can be done at the device.

In this setting the SAF-000 parameter module ch difference between the parameters of the axis unit and the saved data of the module. If the data differs, the parameters saved at th e SAF-000 paramete r module are transmitted to the axis unit automatically and stored to the flash of the axis unit. A t the next re-sta rt both parameter sets are equal, that means no new transmission has to be done.

This behavior assures, that the parameters are from the module to the axis unit.

ning of the axis unit. Here it is of-

ecks at every re-start whether there is a

only in the case of service written back

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Switch on

No error

Command processing

BM5-O-SAF-000 (Parameter module)

Automatic loading of SAF-module?

(P105.010 == 1)

YES

Functional parameters b maXX 5000

¹ functional parameters SAF-module

or no parameters on b maXX 5000

and SAF-module

YES

Data backup of SAF-module to

b maXX 5000, safe in flash and load

into the work memory (RAM)

Writing of module identifications

Module version (P200.001 := 2)

Firmware version module (P200.002)

Hardware version module (P200.003)

Serial number (P200.004)

Functional parameters

in b maXX 5000

available

YES

Functional parameters

in SAF-module

available

YES

Data backup

of b maXX 5000

to SAF-module

Switch on

b maXX 5000 (controller)

Set last module version

BM5-O-SAF-000

(P200.008 := 2)

Scan on BM5-O-SAF-000

(P200.001 == 2)

Scan for 5s,

display of

module version

meanwhile no

BM5-O-SAF-000

available

Command processing

Up-/Downgrade safety module

(P200.008 < P200.001)

(Downgrade)

Error message

(error number 2418)

Command processing

YES

(Up-/Evengrade)

Drive state

(P108.006 := 15)

Failure

7.4

Setting of the switch-on behavior

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Figure 2: Flow diagram switch-on behavior

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH

Description of the Default and Parameter Module

Parametermodul

BM5-O-SAF-000-000-000-#00-000-000

S310345678 00500204

123456678

7.5 Structure of the SAF-000 Default- and Parameter module

Figure 3: SAF-000 Default- and Parameter module

7.6 Identification of the SAF-000 Default- and Parameter module

The type plate of the SAF module with the appropriate type key is to be found on the righ t hand side of the module (see the following example).

Figure 4: Example type plate SAF-000 Modul

NOTICE!

The third and fourth digit of the serial number p rovid e information on the year of p ro duction. Example: Serial number „S310045208“ corresponds to production year

10.

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7.6

Identification of the SAF-000 Default- and Parameter module

NOTICE!

This type code applies exclusively to the Defaultules have their own type codes.

BM5 - O - SAF - 000 - xxx - xxx - #xx Generation of the device in which the module

can be used (BM5 =

BM5 - O - SAF - 000 - xxx - xxx - #xx Optional module BM5 - O - SAF - 000 - xxx - xxx - #xx Safety module BM5 - O - SAF - X0X - xxx - xxx - #xx Version of the safety module

000: Default parameter module

100: Reset module

BM5 - O - SAF - 000 - xxx - xxx - #xx Hardware version of the safety module BM5 - O - SAF - 000 - xxx - xxx - #xx Software version of the safety module

000: Parameter module

001: Default module

and Parameter module. Other mod-

BM5000).

BM5 - O - SAF - 000 - xxx - xxx - #xx Safety level (identification for the compatibility

between converter and safety module)

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8DESCRIPTION OF THE SAFETY

MODULE (SAF-001)

This chapter describes the Safety Module (SAF-001), the meaning of the display and operation elements and the type code applied to the module.

8.1 General

8.1.1 Safety Module SAF-001-000-xxx and SAF-001-001-000 with safety function STO

The Safety Module (SAF-001-000-xxx) is a pure hardware solution for realization of the safe shutdown of the optocouplers in the driver stage o f converters (the param eterization via software is not possible).

The safety module (SAF-001-001-xxx) enables th e safe shutdo wn of th e optocou plers in the driver of converters by means of the microcontroller. A software parameter izing is not possible.

The modules SAF-001-000-xxx and SAF-001-001-000 only perform the safety function „Safe Torque Off (STO)“ (according to EN drive is shut down by the safe pulse inhibitor.

61800-5-2). With the safety function STO, the

Safe Torque Off (STO):

m With the safety function STO, the actuation of the power output module is safely

interrupted. Thus, the motor can no longer generate a rotary field. The motor coasts down in an uncontrolled manner when this safety function is activated.

m The safety function STO corresponds to Stop Category 0 of EN 60204-1.

8.1.2 Safety Module SAF-001-001-001 with safety function SS1 (time controlled)

After expiry of a specified time the safety module (SAF-001-001-001) allows a safe switching off of the optocouplers in the driver stage of converters by means of microcontrollers. A parameterization via the software is not possible.

The module SAF-001-001-001 carries out the safety function "Safe Stop 1 (SS1)" (safe stop 1 with time control according to EN61800- 5-2), exclusively. After the expiry of the

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8.2

Compatibility list

fixed SS1 time of 200 ms the drive is switched off by a safe pulse inhibit. After that the module is in the STO state (safe torque off).

Safe Stop 1 (SS1) with time

m When using the safety function SS1 the control of the power output stage is safely

nterrupted after a delay time of 200 ms. The drive can be braked to a stands

i drive control within the SS1 time if ap propriate parameterizations were made in the controller (see Working Principle ZSAF-001-001-xxx– on page 40).

m The safety function SS1 corresponds to Stop Category 1 of EN 60204-1.

8.2 Compatibility list

8.2.1 Compatibility list SAF-001-000-xxx

The Safety Module (SAF-001-000-xxx) can only be operated in combination with converters of the type b maXX 5000 released by the company Baumüller Nürnberg GmbH.

If the converter was previously equipped with a module with a higher safety level

SAF-002/003), the parameter storage of the converter must be reset with the Reset-

( Module.

8.2.2 Compatibility list SAF-001-001-xxx

control:

till by the

The Safety Module (SAF-001-001-xxx) with automatic restart can only be operated in combination with converters of the type b maXX 5000 with firmware version V01.1 0.02 or

igher by the company Baumüller Nürnberg GmbH. A firmware version V01.14.00 or

h higher must be used for the Safety Module with SS1 function (SAF-001-001-001).

If the converter was previously equipped with a module with a higher safety level

SAF-001 without automatic restart, SAF-002 or SAF-003), the parameter storage of the

( converter must be reset with the Reset-Module or with the reset command (see

ration mode of the reset command– on page 65).

ZOpe

If the converter was previously equipped with a module which includes a STO function

SAF-001-000-xxx, SAF-001-001-000) and is equipped with the module STO 001-001-

( 001 (SS1 function), the safety level of the converter must be reset to zero by the Reset module or by the Reset command (see ZOpe page 65).

WARNING!

A converter b maXX 5000 with a firmware version V01.14 for the Safety Module with SS1 function (SAF-001-001-001).

ration mode of the reset command– on

.00 or higher must be used

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Description of the Safety Module (SAF-001)

8.2.3 Compatibility list SAF-001-000-002 with automatic restart

The Safety Module (SAF-001-xxx-002) with automatic restart can only be operated in combination with converters of the type b maXX 5000 with firmwar e version V01.07.02 or

her by the company Baumüller Nürnberg GmbH.

hig If the converter was previously equipped with

(SAF-001 without automatic restart, SAF-001-001-xxx, SAF-002 or SAF-003), the parameter storage of the converter must be reset with the Reset-Module or with the reset command.

8.3 Safety notes on the STO (Safe Torque Off)

WARNING!

m When STO is activated, the drive is no m The safety function Safe Torque Off (STO) is not sufficient as the only safety

unction for drives which are affected by a permanent moment, for example, in

case of suspended loads.

m Use the Safety Module (SAF-001) only in combination with co nverters released by

e company Baumüller Nürnberg GmbH (see the chapter ZCompatibility list SAF-

001-000-xxx– on page 38).

m The Safety Module (SAF-001) may only be operated in combination with

emergency st according to

op devices according to DIN EN ISO 13850 or safety sensors

EN 61496.

t disconnected from power supply.

a module with a higher safety level

WARNING!

In the unlikely event of a total failure of an internal driver (IGBT) or a co ntrol element, a temporary excitation of the drive can occur (also if STO is active). The angular movement covered depends on the rotor position and the number of pole pairs of the motor. The maximum is 180°/number of pole pairs.

DANGER! Danger due to moving engine parts!

The supply of the inputs by a connected safe ty co mp o nent (em e rg en cy st op dev ice ,

fety light curtain) leads to the immediate supply of the driver stage. A converter

sa failure may lead to an unexpected start-up. Ensure by the use of the external safety components that an unexpected start-up is prevented during commissioning.

Therefore: m Maintain an adequate distance from moving machine parts/line parts or from the

moving machine/line.

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8.4

Working principle

WARNING!

If a module with STO function is reset (su SS1 function (such as SAF-001-001-001) the user must consider the SS1 time. Not before the SS1 time has expired after the module was activated, the module changes into the safe state STO (safe torque off).

8.4 Working principle

8.4.1 SAF-001-000-xxx

The Safety Module (SAF-001-000-xxx) provides the power for the power stage of the converter. The voltage applied on the input side of the Safety Module (SAF-001-000-xxx) is conver converter of the module. Power can only be transferred to the seco nda ry side o f the DC/ DC converter, if the Safety Module (SAF-001-000-xxx) is supplied on the input side via

emergency stop device, an electromagnetic safety sensor (for example safety light

an curtain) or another safety device (for example output of a safety control).

In case of a failure or on request (by activating an emergency stop device, interrupting a

afety light curtain), the Safety Module (SAF-001-000-xxx) ensures that t

s of the converter in the power stage is shut down safely and the pulse inhibi tor is activated. Thus, the motor can no longer generate a rotating field. The mains supply is not disconnected from the motor when the shut down function is activated.

ch as SAF 001-001-000) by a module with

ted to an alternating signal and transferred to the secondary side by the DC/DC

he power supply

8.4.2 SAF-001-001-xxx

The Safety Module (SAF-001-001-xxx) provides the supply for the driver of the con verter. The voltage applied on the input side of the Safety Module (SAF-001-001-xxx) is evaluated by two microcontrollers monitoring each other. They enable the driver of the converter if the Safety Module (SAF-001-001-xxx) provides an emergency device, an electric safety sensor (such as a safety light array) or another safety device (such as a safety control output).

An internal short circuit detection is provided by the device: If the STO requirement is

ade by a single channel, only (STO_A or STO_B) then the device remains in the STO

m status and cannot be enabled anymore. If voltage is on both channels simultaneously then the axis can be enabled again after re-applying 24 V to both channels.

In case of a failure or on request (by activating an emergency stop device, interrupting a

afety light curtain), the Safety Module (SAF-001-001-xxx) ensures that t

After activating the module SAF-001-001-001 the SS1 time runs for the full pe riod before it cha

f the module again while the SS1 is running. The drive enable is only possible if there

o was no voltage at both channels at the same time after reaching STO and the 24 V are

pplied again.

he power supply

nges into the STO state even though 24 V are applied to b oth of the input chann els

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Description of the Safety Module (SAF-001)

m The module SAF-001-001-001 carries out the safety function "Safe Sto p 1 (SS1)" (safe

stop 1 including the time control according to EN 61800-5-2), only.

m The SS1 time of the Safety Module SAF-001

cannot be parameterized.

m The tolerance of the SS1 time of the SAF-001-001-001 mod ule is -6 ms to 1 ms due to

onent tolerances and tolerances in the STO reaction time. Therefore the reaction

comp time is 194 ms to 201 ms until the change of the input states to < 5 V.

m Once the fixed SS1 time of 200 ms has passed the drive is switched off by a safe pulse

ibit. The module returns to the STO state (safe torque off) after this.

inh

m The safety function SS1 corresponds to Stop Category 1 of EN 60204-1. m The start of activation can be reported to the

braking ramp of the drive or to send the information of the coming STO to a fieldbus master (refer to the following information):

Time controlled SS1 function

-001-001 is a fixed amount of 200 ms and

controller in order to initiate a steep

Figure 5: Time-controlled SS1-function with the option "Signal SS1 start to the controller"

The SS1-signaling can be evaluated via bit 1 from the controller FW V01.15 in the parameter 108.5 (status word 2 of the drive manager) .

As soon as the bit is set the SS1-time begins to run. This bit information can be used to enable a braking procedure at the ramp in the

oller (SS1-stop, stop at the current limit) or to map to a fieldbus parameter in order

contr to send the information to a higher-level fieldbus master (bit 1 = 0: not activated; bit 1 = 1: SS1-time is

For the required settings of a braking procedure in the controller refer to the current

rameter manual b maXX BM5000 ("SS1" sto

pa Besides the error reaction "SS1

parameterized as well (such as "stop at the current limit"). The module SAF-001-001-001 is also displayed in parameter 200.1 (SAF module

sion) from the controller FW V01.15 (value 28):

ver

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001

running).

p, "SS1 stop time" and error reaction).

stop" another available error reaction can be

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8.5

Input circuitry

8.5 Input circuitry

8.5.1 SAF-001-000-xxx

Depending on the input circuitry of the Safety Module (SAF-001-000-xxx), the module can be operated with different safety components (emergency stop device, electronic safety sensor). The examples in the following sections show the wiring of the Safety Module (SAF-001-000-xxx) for the operation with an emergency stop device, a safety

ght curtain and the Baumüller Safety I/O terminal SO4000.

WARNING!

The power supply unit for generating the 24 Volt electrical supply must meet the requirements

for PELV according to EN 60204-1.

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Description of the Safety Module (SAF-001)

STO_1A_GND (X1-01)

STO_1B_GND (X1-02)

FS_1_GND (X1-03) STO_2A_GND (X1-04) STO_2B_GND (X1-05)

FS_2_GND (X1-06)

STO_2A_24V (X1-07)

FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12)

FS_2_24V (X1-13)

STO_1A_24V (X1-08) STO_1B_24V (X1-09)

STO_1A_24V (X1-14)

24V DC0V

STO Module BM5-O-SAF-001

Emergency Stop

Internal

connections

Internal

connections

-000-xxx

8.5.1.1 Operation with emergency stop device

The following example for the wiring of an emergency stop device with the Safety Module (SAF-001-000-xxx) ensures that short circuits case of a short circuit on the input side, the converter always switches to the STO (Safe Torque Off) status.

on the input side are detected. In

Figure 6: Safety Module (SAF-001-000-xxx) with emergency stop device

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8.5

STO_1A_GND (X1-01)

STO_1B_GND (X1-02)

FS_1_GND (X1-03) STO_2A_GND (X1-04) STO_2B_GND (X1-05)

FS_2_GND (X1-06)

STO_2A_24V (X1-07)

STO_1A_24V (X1-08)

FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12)

FS_2_24V (X1-13)

STO_1B_24V (X1-09)

STO_1A_24V (X1-14)

GND

OSSD2

OSSD1

STO Module BM5-O-SAF-001

Switching device with OSSD outputs

Safety light curtain

Internal

connections

Internal

connections

-000-xxx

Input circuitry

8.5.1.2 Operation with safety light curtain

If the Safety Module (SAF-001-000-xxx) is operated with a safety light curtain or a safety control, the reference potential (0 V) is hard-wired on the inpu t side. The two-channel shut down is then performed by two safety outputs (monitored by the safety sensor) which provide the two-channel supply for the Safety Module (SAF-001-000-xxx).

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Figure 7: Safety Module (SAF-001-000-xxx) with safety light curtain

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH

Description of the Safety Module (SAF-001)

STO_1A_GND (X1-01)

STO_1B_GND (X1-02)

FS_1_GND (X1-03) STO_2A_GND (X1-04) STO_2B_GND (X1-05)

FS_2_GND (X1-06)

STO_2A_24V (X1-07)

FS_1_24V (X1-10) STO_2A_24V (X1-11) STO_2B_24V (X1-12)

FS_2_24V (X1-13)

STO_1A_24V (X1-08) STO_1B_24V (X1-09)

STO_1A_24V (X1-14)

Output 1

24V

Output 1

+24 V

STO Module BM5-O-SAF-001

Baumüller

Safety I/O Terminals

SO4000

Internal

connections

Internal

connections

-000-xxx

8.5.1.3 Operation with Baumüller Safety I/O terminal SO4000

The output terminal SO4000 shown in ZFigure 8– on page 45 provides bipolar safety outputs. For connection of the Safety Module (SAF-001-000-xxx), the 0 V switching

tput is wired with STO_1A_GND (for axis 1) and STO_2A_GND (for axis 2). The

responding 24 V switching output is wired with ter

cor STO_2A_24V (for axis 2). The inputs STO_1B_24V and STO_2B_24V are supplied by

n external wire strap.

a Short circuits of the outputs of the Baumüller Safety

potentials or between the outputs are detected by the output terminal and lead to th e shut down.

minal STO_1A_24V (for axis 1) and

output terminal SO4000 to supply

Figure 8: Safety Module (SAF-001-000-xxx) with SO4000

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8.5

STO_1A_24V (X1-14)

STO_2A_24V (X1-11)

STO_1B_24V (X1-09)

STO_2A_GND (X1-04)

STO_2A_24V (X1-07)

STO_1A_24V (X1-08)

STO_1A_GND (X1-01)

24V DC

STO_1B_GND (X1-02)

STO_2B_GND (X1-05)

STO_2B_24V (X1-12)

24V DC

STO module BM5-O-SAF-001-001

Internal connections

reserved (X1-03)

reserved (X1-06)

reserved (X1-10)

reserved (X1-13)

Emergency

Stop

-xxx

Input circuitry

8.5.2 SAF-001-001-xxx

Depending on the input circuitry of the Safety Module (SAF-001-001-xxx), the module can be operated with different safety components (emergency stop device, electronic safety sensor). The examples in the following sections show the wiring of the Safety Module (SAF-001-001-xxx) for the operation with an e mergency stop device and a safety

ght curtain.

WARNING!

The power supply unit for generating the 24 Volt electrical supply must meet the requirements

for PELV according to EN 60204-1.

8.5.2.1 Operation with emergency stop device

The following example for the wiring of an emergency stop device with the Safety Module (SAF-001-001-xxx) ensures that short circuits on case of a short circuit on the input side, the converter always switches to the STO (Safe Torque Off) status.

the input side are detected. In

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Figure 9: Safety Module (SAF-001-001-xxx) with emergency stop device

Description of the Safety Module (SAF-001)

STO_1A_24V (X1-14)

STO_2A_24V (X1-11)

STO_1B_24V (X1-09)

STO_2A_GND (X1-04)

STO_2A_24V (X1-07)

STO_1A_24V (X1-08)

STO_1A_GND (X1-01) STO_1B_GND (X1-02)

STO_2B_GND (X1-05)

STO_2B_24V (X1-12)

GND

OSSD1

OSSD2

STO module BM5-O-SAF-001-001

Internal connections

reserved (X1-03)

reserved (X1-06)

reserved (X1-10)

reserved (X1-13)

Switching device with OSSD outputs

Safety

light curtain

-xxx

8.5.2.2 Operation with safety light curtain

If the Safety Module (SAF-001-001-xxx) is operated with a safety light curtain or a safety control, the reference potential (0 V) is hard-wired on the input side. The two-channel shut down is then performed by two safety outputs (monitored by the safety sensor) which provide the two-channel supply for the Safety Module (SAF-001-001-xxx).

Figure 10: Safety Module (SAF-001-001-xxx) with safety light curtain

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8.6

A = Button S1 B = LED H1 - green C = LED H2 - red D = Connector X1

Structure

8.6 Structure

8.6.1 Structure of the Safety Module (SAF-001-000-xxx)

Figure 11: Safety Module (SAF-001-000-xxx)

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Description of the Safety Module (SAF-001)

Connector X1

SS1

Time

200 ms

Connector X1

8.6.2 Structure of the Safety Module (SAF-001-001-000)

Figure 12: Safety Module (SAF-001-001-000)

8.6.3 Structure of the Safety Module (SAF-001-001-001)

Figure 13: Safety Module (SAF-001-001-001)

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8.7

Pin assignment

8.7 Pin assignment

8.7.1 Pin assignment of connector X1 (SAF-001-000-xxx)

The Safety Module (SAF-001-000-xxx) provides a 14-pin connector on the front with the following assignment.

Figure 14: Pin assignment of connector X1 (on front of Safety Module (SAF-001-000-xxx))

Pin Assignment Description

1 STO_1A_GND 0V safety device axis 1 / channel A 2 STO_1B_GND 0V safety device axis 1 / channel B 3 FS_1_GND 0V input restart axis 1 4 STO_2A_GND 0V safety device axis 2 / channel A 5 STO_2B_GND 0V safety device axis 2 / channel B 6 FS_2_GND 0V input restart axis 2 7 STO_2A_24V +24V safety device axis 2 / channel A 8 STO_1A_24V +24V safety device axis 1 / channel A 9 STO_1B_24V +24V safety device axis 1 / channel B 10 FS_1_24V +24V input restart axis 1 11 STO_2A_24V +24V safety device axis 2 / channel A 12 STO_2B_24V +24V safety device axis 2 / channel B 13 FS_2_24V +24V input restart axis 2

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14 STO_1A_24V +24V safety device axis 1 / channel A

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Description of the Safety Module (SAF-001)

8.7.2 Pin assignment of connector X1 (SAF-001-001-xxx)

Pin assignment see ZChapter 8.7.3 Pin assignment of connector X1 (SAF-001- 000-0 02 with automatic restart)

8.7.3 Pin assignment of connector X1 (SAF-001-000-002 with automa tic restart)

The Safety Module (SAF-001-000-002) provides a 14- pin conn ector on the front with th e following assignment.

Figure 15: Pin assignment of connector X1 (on front of Safety Module (SAF-001-000-002))

Pin Assignment Description

1 STO_1A_GND 0V safety device axis 1 / channel A 2 STO_1B_GND 0V safety device axis 1 / channel B 3 Reserved 4 STO_2A_GND 0V safety device axis 2 / channel A 5 STO_2B_GND 0V safety device axis 2 / channel B 6 Reserved 7 STO_2A_24V +24V safety device axis 2 / channel A 8 STO_1A_24V +24V safety device axis 1 / channel A 9 STO_1B_24V +24V safety device axis 1 / channel B 10 Reserved 11 STO_2A_24V +24V safety device axis 2 / channel A 12 STO_2B_24V +24V safety device axis 2 / channel B 13 Reserved 14 STO_1A_24V +24V safety device axis 1 / channel A

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8.8

Switching thresholds for voltage and current

8.8 Switching thresholds for voltage and current

NOTICE!

If electronic sensors such as safety light curtain these components can provide the input currents required for the supply of the Safety Module (SAF-001).

NOTICE!

If electronic sensors with OSSD outputs are used, it must be considered that the maximum test pulse width of 2 ms is not exceeded.

NOTICE!

If the STO connections are connected to the 24V supply system external safety devices against surge voltages are required .

Inputs STO_1A_24V, STO_1B_24V , ST O_ 2A _2 4 V and STO _ 2B_24V

Voltage and current switching thresholds (on STO_1B_24V, STO_2A_24V and STO_2B_24V:

s are used, it must be ensured that

input side) of the inputs STO_1A_24V,

Voltage / Current Switching threshold

SAF-001-000-xxx

U high max 30 V 30 V U high min 20 V 20 V U low max 5 V 5 V U low min -0.3 V -0.3 V I high max eff 135 mA (per axis at 20 V) approx.31 mA (per axis at 20 V) I high min eff 105 mA (per axis at 30 V) approx. 35 mA (per axis at 30 V) I low max eff 17 mA (per axis at 5 V) approx. 23 mA (per axis at 5 V) Input capacitance 47 µF (per input) 1 µF (per input)

Inputs FS_1_24V and FS_2_24V (restart axis 1 and 2)

The inputs FS_1_24V and FS_2_24V (restart axis 1 and 2) are in the normal range for

ital inputs according to type 1 (EN 61131-2).

dig

Switching threshold

SAF-001-001-xxx

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Description of the Safety Module (SAF-001)

8.9 Maximum response time

The maximum response time of the Safety Module (SAF-001-000-xxx) is tR  20 ms. The maximum response time of the Safety Module (SAF-001-001-xxx For the input voltage range specified in chapter ZSwitching thresh olds for voltage and

current– from page 52 onward, the voltage threshold on the output side of the

corresponding power module is underrun during this response ti me. Below this threshold

ulse inhibitor of the converter (see chapter ZCompatibility list SAF-001-000-xxx– on

the p page 38) is active.

8.10 Properties of the parameter memory

The default parameterization of the converter is stored in the parameter memory. If the converter should be exchanged, the parameter data are available and can be copied from the Safety Module (SAF-001) to the new converter.

) is tR  45 ms.

NOTICE!

The parameter data cannot be copied to the Safe ty Module (SAF-001), if a complete

ta set which was loaded before of that from the RAM with all the para meters, 

da was loaded in the flash memory of the b maXX 5000 again.

The Safety Module (SAF-001-001-xxx) has no parameter memory.

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8.11

H1 H2

SAF-001

LED H1 - green LED H2 - red

Type plate

Operation and display elements

8.11 Operation and display elements

8.11.1 LEDs for indicating the operation statuses

There are two LEDs (LED H1 - green, LED H2 - red) on the front of the Safety Module (SAF-001-000-xxx) that indicate the current operation status.

m LED H1 (green) - Indicates the trouble-free operation m LED H2 (red) - Indicates failures or incompatibility

with the converter

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Figure 16: LEDs on front of the Safety Module (SAF-001-000-xxx)

The following table lists the possible combinations of the status LEDs and the corresponding meaning:

LED

H1 (green) H2 (red) Meaning

Off Off No supply voltage. On Off Trouble-free operation. Off Flashes Device error or unallowed replacement of the module

(commissioning not possible).

Off On Firmware and parameter data of the Safety

Module (SAF-001) do not correspond with the data of

e converter. Th e parameter data of the converter has

The Safety Module (SAF-001-001-xxx) has

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001

to be copied to the Safety Module (SAF-001) by

essing the button S1 (long - short - short - long).

no LEDs.

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Description of the Safety Module (SAF-001)

H1 H2

SAF-001

Button S1

Type plate

8.11.2 Button for verification purposes

The button on the front of the Safety Module (SAF-001-000-xxx) is used to confirm the data transfer of the default parameter data of the converter to the parameter memory of the Safety Module (SAF-001-000-xxx). The button must be actuated as follows: Long –

t – short – long (long > 1000 ms, 500 ms < short < 1000 ms, see also the chapter

shor

ZExchanging the module– from page 79 onward).

Figure 17: Button S1 on the Safety Module (SAF-001-000-xxx)

The Safety Module (SAF-001-001-xxx) has no button.

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8.12

Control power supply

STO input

Restart switch

Output pulse inhibitor

Time

Restart inhibit (SAF-001-000-xxx)

8.12 Restart inhibit (SAF-001-000-xxx)

The Safety Module (SAF-001-000-xxx) prov ides an input for the connection of a restart switch or for the activation of a control. The diagram in ZFigure 18– on page 56 shows the recommended timing of the signal statuses to ac

1 Pow 2 Co

3 Sig

If this sequence is followed, the restar

er supply of the control switched on.

nnected safety device, for example, emergency stop device ena bled (note: function

STO inactive!)

nal change from „off“ to „on“ at the restart input.

tivate the safe approval of the pulse.

t inhibit is subsequently canceled.

Figure 18: Timing of signal statuses for restart inhibit

min max t1 0 ms t

t2 with t1 = 0 0 ms t

The controller is operational at once and the safety function STO is not active, when t

= 0.

and t

50 ms -

30 ms -

= 0

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Description of the Safety Module (SAF-001)

STO_1A_GND (X1-01) STO_1B_GND (X1-02)

STO_2A_GND (X1-04) STO_2B_GND (X1-05)

FS_2_GND (X1-06)

STO_2A_24V (X1-07)

STO_1A_24V (X1-08) STO_1B_24V (X1-09)

STO_2A_24V (X1-11) STO_2B_24V (X1-12)

FS_2_24V (X1-13)

STO_1A_24V (X1-14)

FS_1_GND (X1-03)

FS_1_24V (X1-10)

24 V DC

STO Module BM5-O-SAF-001

Restart inhibit

Internal

connections

Internal

connections

Wiring of the restart inputs

Figure 19: Wiring of restart inhibit inputs axis 1

NOTE!

The restart inputs of the Safety M odule (SAF-001) must remain activated after t he restart, i.e., after the activation of the driver supply. The cancellation of the activated status („on“) leads to the deactivation of the driver supply.

DANGER!

The restart inputs may in no case be used for the safety-related shut down of the driver supply. A safe activation of th e safety function STO is only permitted by t he STO inputs and the connected safety components.

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8.13

Automatic restart (SAF-001-000-002 and SAF-001-001-xxx)

DANGER!

The safety function STO is already canceled by resetting the safety component which

as triggered the function STO. From that point on, the machine can be restarted in

h case of a failure even if the restart input is deactivated.

8.13 Automatic restart (SAF-001-000-002 and SAF-001-001-xxx)

The safety module SAF-001 is available in the version SAF-001-000-002 and SAF-001-001-xxx with automatic restart. The connection of a restart switch is not necessary here.

The pulse inhibit for the drive is deactivated fr STO. The restart of the drive depends only on the oper ating state of the contro ller. Thus, the restart is no part of the safety function.

om the module immediately after reset of

NOTICE!

If a restart inhibit is necessary in the application, the SAF-001-000-000 module should be used. If the module version SAF-001-000-002 or SAF-001-001-xxx is used, the restart inhibit must be realized externally.

DANGER!

The safety function STO is already canceled by resetting the safety component which has triggered the function STO. From that point on, the machine can be restarted.

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Description of the Safety Module (SAF-001)

Safety Modul

BM5-O-SAF-001-000-000-#00-000-000

S310345678 00500204

123456678

8.14 Marking of the Safety Module (SAF-001) - type code

On the type plate of the Safety Module (SAF-001) (on the right of the module), you will find the type code of the module.

Figure 20: Type plate on the Safety Module (SAF-001)

NOTICE!

The third and fourth digit of the serial number provide information on the year of production. Example: Serial number „S310045208“ corresponds to production year

2010.

NOTICE!

This type code applies exclusively to the Safety Modules (BM5-O-SAF-xxx). O ther modules have their own type codes.

BM5 - O- SAF - 001 - xxx - xxx - #xx Generation of the device in which the module

can be used (BM5 =

BM5 - O - SAF - 001 - xxx - xxx - #xx Optional module BM5 - O - SAF - 001 - xxx - xxx - #xx Safety module BM5 - O - SAF - 001 - xxx - xxx - #xx Safety module ver sio n (0 01 = STO) BM5 - O - SAF - 001 - xxx - xxx - #xx Hardware version of the safety module

000: Standard

001: with short circuit detection

BM5 - O - SAF - 001 - xxx - xxx - #xx Software version of the safety module at

hardware version 000 (standard):

000: with parameter memory

002: with parameter memory and 

with automatic restart

at hardware version 001:

000: without parameter memory, with 

automatic restart

001: without parameter memory, with SS1 

function with fixed SS1 time (= 200

BM5000).

ms)

BM5 - O - SAF - 001 - xxx - xxx - #xx Safety level (identification for the compatibility

between converter and safety module)

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8.14

Marking of the Safety Module (SAF-001) - type code

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This chapter describes the BM5-O-SAF-100 (Reset-Module) with its function and explains the type code on the module.

9.1 General

In order to operate the axis unit of the series b maXX 5000 the slot A of the device must be equipped with a module (also see 5.09021, instruction handbook b case the device was previously equipped with a higher safety level, the parameter stor age of the converter must be reset with the Reset-Module (BM5- O-SAF-100) or with a re set command (see ZResetting of the safety level by the controller– on page 65).

9.2 Compatibility list

The Reset-Module (BM5-O-SAF-100) can only be used in the combination with converters of the type b maXX 5000, which where released by Baumüller Nürnberg GmbH.

9DESCRIPTION OF THE RESET-

MODULE

maXX 5000). In

9.3 Operating mode of the Reset-Module (BM5-O-SAF-100)

In order to reset the module ID of the converter the slot A of the device must be equipped with a Reset-Module. After switching on the voltage supply of the converter the ID of the previously equipped modules is deleted.

After 15 seconds the voltage supply can be switched off and the slot A can be equipped with the requested Safety Module.

An operation of the converter with the Reset-Module is not possible, because the module does not provide supply for the converter’s drivers.

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9.4

SAF-100

Reset-Modul

BM5-O-SAF-100-000-000-000-000

S310345678 00500204

123456678

Structure of the Reset-Module (BM5-O-SAF-100)

9.4 Structure of the Reset-Module (BM5-O-SAF-100)

Analog BM5-O-SAF-000, but another ID.

Figure 21: SAF-100 Reset-Module

9.5 Identification of the Reset-Module (SAF-100)

The type plate of the SAF module with its corresponding type code is found on the right side of the module (see the example below).

Figure 22: Example type code SAF-100 Reset-Module

NOTICE!

m The exchange of the module must only be performed by authorized and qualified

personnel.

ior to the exchange of the module, ensure that the Safety Module and the

m Pr

converter are compatible.

For a list of the converters compatible with the Safety Module refer to the chapter

ZCompatibility lis

t SAF-001-000-xxx– on page 38.

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Description of the Reset-Module

Switch on

BM5-O-SAF-100 (Reset-Module)

No error

Command processing

Deleting of safe parameter file and of protocol file

of b maXX 5000

Reset

last module version

(P200.008 := 0)

BM5-O-SAF-100

available

Command processing

Switch on

b maXX 5000 (Regler)

(P200.001 == 1)

an to BM5-O-SAF-100

odule version

an for 5 s, meanwhile display m

Error

(error number 2423)

message

(P108.006 = 15)

rive state:

Failure

Writing of module identifications:

Module version (P200.001 := 1)

Firmware version module (P200.002)

Hardware version module (P200.003)

Serial number (P200.004)

NOTE!

The third and fourth digit of the serial number p rovid e information on the year of p ro duction. Example: Serial number „S310045208“ corresponds to production year

10.

9.6 Mode of operation module replacement

Figure 23: Mode of operation module replacement BM5-O-SAF-100

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9.6

Mode of operation module replacement

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10RESETTING OF THE SAFETY LEVEL

10.1 General

For the operation of an axis unit of the series b maXX 5000, the slot A of the device must be equipped with a module (also see 5.09021, Instruction handbook b case the device was already equipped with a module of a higher safety level, the safety level of the converter can be reset without a Reset-Module with a controller command also.

10.2 Operation mode of the reset command

The safety level of the converter is reset to the value zero by the command. The parameter files remain in the converter.

The following mode of operation for resetting must be followed:

1 Writing of the value 4096 into parameter 139.023.0.0 (system command) 2 On the 7-segment-display a four-digit code is displayed after the prefix „C“ 3 This code must be written in parameter 200.020.0.0 (reset code). 4 After 15 seconds the voltage supply can be switched off and slot A can be equipped

with the required module.

BY THE CONTROLLER

maXX 5000). In

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10.2

Operation mode of the reset command

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11PLANNING OF A SAFETY-ORIENTED

CONTROL SYSTEM

The entire process of defining the safety system is carried out in the planning phase. In addition to risk assessment, the planning contains the detailed definition of all system components, the definition of the system parameters and the detailed installation and wiring of the components.

DANGER!

Conducting the planning thoroughly aids in avoid oriented machines can lead to permanent injuries and death.

CAUTION!

The „Planning checklist“ reproduced in the appendix is to be used in the planning phase.

11.1 Risk assessment

The risk assessment establishes which dangers a machine can present and which plant parts will have to be equipped with safety technology devices. The residual risk is reduced to a justifiable level by means of safety technology measures.

CAUTION!

As machine manufacturer, the applicable machine guidelines obligate you to conduct a risk assessment in order to establish the dangers associated with the machine an d reduce the residual risk to a justifiable minimum.

ing failures. Failures in safety-

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11.1

Risk assessment

CAUTION!

It is absolutely necessary to conduct the r and before conducting retrofitting work.

The risk assessment should be conducted according to the procedure described in the following.

isk assessment during the planning phase

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Figure 24: Risk assessment procedure in accordance with DIN EN ISO 12100-1 and EN ISO 14121

Delineation of the system: Determination of the limits of the system's boundaries

and the intended use

Hazard analysis:

Risk estimation: Risk assessment:

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001 Document no.: 5.09013.07 Baumüller Nürnberg GmbH

Identification of hazards and the related hazardous situations

Estimation of the risks for each hazard identified Assessment of the risks and establishment of risk

reduction measures

Planning of a safety-oriented control system

The determination of the required safety class (SIL, performance level) is carried out in the scope of risk assessment. The course of action for the determination of the Performance Level is described in DIN EN ISO 13849-1. Annex A of IEC 62061 contains

informative part for the determination of the required SIL.

11.2 Installation and wiring plan

An installation and wiring plan for the entire safety system is to be developed in the planning phase. It contains all system components and their wiring.

CAUTION!

The applicable standards and guidelines on laying electrical lines are to be observed

en developing the wiring plan.

11.3 Course of the planning phase

The system is planned according to the respective requirements of the plant or the machine. The components available for the automation of the available components are described in the Automation catalog of the company Baumüller Nürnberg GmbH. There, you can find information on concepts, PLCs, fieldbuses, motion control, technology blocks, HMIs, IPCs and I/Os.

Prior to commissioning of the Safety Module (SAF-001), the following ha s to be checke d

d guaranteed:

m Compatibility of the Safety Module (SAF-001) with the converter (see chapter

ZCompatibility list SAF-001-000-xxx– on page 38, ZCompatibility list SAF-001-001-

xxx– on page 38 and ZCompatibility list SAF-001-000-002 with automatic restart– on

page 39).

m Adequate supply of the converter by the connected power supply unit or safety

onents.

comp

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11.3

Course of the planning phase

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12ASSEMBLY AND INSTALLATION

This chapter describes the mechanical assembly and electrical installation of the plug-in module.

The assembly and installation proce

1 Asse 2 Conn

3 Check th

mble the plug-in module.

ect the plug-in module to the safety components (for example, emergency stop

device, electromechanical safety component, ...).

e assembly and installation by means of the „Installation checklist“ listed in

Appendix ZB.2– on page 101.

12.1 General safety regulations

CAUTION!

The „Installation checklist“ reproduced in Appendix ZB.2– on page 101 should be used during the assembly and installation phase.

m Make sure that the installation process is carried out entirely in accordance with

the installation and

m Conduct a visual inspection and check all system components for visib le damage. m Check the system for wiring errors. m Inspect the tightening torque and make sure tha

interrupted by insulation material.

m Inspect the tensile-load capacity of m Make sure that the installation and cable r

applicable standards and guidelines.

m Make sure that the system's environment

ZC.2.1– on page 103 are not exceeded.

m Make sure that the design of the system's t m Make sure that the safety system is not

area surrounding the installed safety components. m Make sure that the system components do not come int

substances (such as acids, bases, transmission oil).

ss consists of the following steps:

wiring plan.

t the electrical connection is not

the electrical terminal and screw connections.

outing are carried out in accordance with

al properties specified in Appendix

ype of protection is sufficient.

damaged by moving parts or work in the

o contact with aggressive

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12.2

Requirements on the personnel conducting the work

h Follow the information in the chapter ZSafety– from page 17 onward.

12.2 Requirements on the personnel conducting the work

DANGER! Live-threatening danger from electrical current!

The device and surrounding area in the electr voltages.

Therefore: m Make sure that power to the device and surrounding area is shut off before

eginning work.

m Follow the applicable safety regulations when handling devices carrying high

es.

voltag

m Ensure that this module is assembled and

personnel.

ical cabinet can carry life-threatening

installed exclusively by qualified

Qualified personnel refers to persons who have b of the plant safety to conduct the necessary activities applicable and are able to detect and avail potential dangers due to their training, experience, instruction and knowledge of the relevant standards and provisions, accident prevention regulations and operating conditions. Example of the qualifications required for work with the unit include:

m Training or instruction in accordance with the

maintenance and use of suitable safety equ ipm e nt .

12.3 Assembly instructions

The assembly of the converter is described in the operation manual for the conve rter.

DANGER! Live-threatening danger from electrical current!

The device and surrounding area in the electr voltages.

Therefore: m Make sure that power to the device and surrounding area is shut off before

eginning work.

m Follow the applicable safety regulations when handling devices carrying high

es.

voltag

een authorized by the parties in charge

safety technology standards in the

ical cabinet can carry life-threatening

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Assembly and installation

The following tools will be needed:

m Torx screwdriver (size TX8) for fastening the plug-in module in the converter. h Ensure that the suitable convert

001-000-xxx– on page 38).

Perform the assembly as follows:

1 Plug 2 Secure the module against unintentional

the plug-in module into the mounting opening of the frequency converter.

er is available (see chapter ZCompatibility list SAF-

falling out with the torx screw.

Figure 25: Assembly of plug-in module

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12.4

Pin assignment connector X1

Pin Assignment

1 STO_1A_GND 2 STO_1B_GND 3 FS_1_GND 4 STO_2A_GND 5 STO_2B_GND 6 FS_2_GND 7 STO_2A_24V 8 STO_1A_24V 9 STO_1B_24V 10 FS_1_24V 11 STO_2A_24V 12 STO_2B_24V 13 FS_2_24V 14 STO_1A_24V

H1 H2

SAF-001

Connector X1

Installation

12.4 Installation

Wire the Safety Module (SAF-001) in accordance with the following connection diagram. See also chapter ZInput circuitry– from page 42 onward.

Figure 26: Connection diagram of the Safety Module (SAF-001)

12.4.1 Requirements for the electrical connection

CAUTION! Danger due to faulty wiring!

The module can be damaged or destroyed if the requirements for the electrical

nection of the module are not met.

con Therefore:

m Make sure that the connection values specified in technical data are met and that

connections are carried out according to the specifications.

the

m Prevent a short circuit between inputs and ou

and outputs can destroy the plug-in module.

tputs. A short circuit between inputs

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In order to be able to fulfill the EN 60204-1 standard (electrical equipment of machines), you will have to use the cables it recommends. The connection plugs must not be able to fall out - otherwise, the danger of short circuits, external voltage, etc. will arise.

h Make sure that the connection cable is routed in an EMC-compatible manner.

12.4.2 Requirements on the connection cable

The connection cable must be selected in accordance with the EN 60204-1 standard.

Assembly and installation

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12.4

Installation

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13COMMISSIONING AND EXCHANGE

OF THE MODULE

This chapter describes the commissioning process of the Safety Module. The process of commissioning ensures that the Safety Module functions properly. In addition, the chapter describes how the module is exchanged.

Before beginning the commissioning process, make have been fulfilled:

e Safety Module is installed correctly.

1 Th 2 No

people or parts are in the danger zone.

3 Th

e converter is ready for use.

CAUTION!

The commissioning of the S afety Mo dule is o module.

sure that the following prerequisites

nly allowed after the acclimation of the

Please take note of ZTro during the commissioning process.

13.1 General safety regulations

h Follow the chapter ZSafety– from page 17 .

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13.2

Requirements on the personnel conducting the work

DANGER! Danger of injury due to moving parts!

Machine parts/line parts or the entire machin e/line ca n move during co mmiss ioning .

e „Planning checklist“ reproduced in the appendix ZCommis

checklist– fr

Therefore:

aintain an adequate distance from moving machine parts/line parts or from the

m M

moving machine/line.

m Note

additional modules connected to the Safety Module.

tivate the safety devices in any case prior to switching on the system.

m Ac m Make m M

ake sure that there are no people in the danger zone during the initial commissioning. Always anticipate that a machine, system or safety device may not behave as it is intended to.

m If ch

effects on the behavior of the system will have to be inspected. To do this, it will be necessary to process the checklists for the planning and installation phase again.

om page 102 is to be used in the commissioning phase.

that the machine parts/line parts or machine/line can be set in motion via

sure that the system is commissioned exclusively by qualified personnel.

anges or expansions are conducted during the commissioning process, the

sioning and validation

13.2 Requirements on the personnel conducting the work

The commissioning work may only be conducted by professionally trained personnel, in particular personnel which understands the safety regulations and can follow them.

DANGER! Danger from mechanical action!

The machine/line or parts of the machine or line can be started during the

mmissioning of the Safety Module.

co Therefore:

aintain an adequate distance from moving machine parts/line parts or from the

m M

moving machine/line.

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Commissioning and exchange of the module

13.3 Exchanging the module

DANGER!

If a defect in the Safety Module immediately and the Safety Module must be exchanged.

CAUTION!

m The exchange of the module must only be performed by authorized and qualified

personnel.

further changes in the configuration of the system may be made during the

m No

exchange of the module.

r to the exchange of the module, ensure that the safety module and the

m Prio

converter are compatible. For a list of the converters co m pa tib le wit h th e Saf et y M o du le re fe r to t he c ha pter

ZCompatibility list SAF-001-000-xxx– on page 38.

is detected, the converter must be put out of operation

Course of the exchanging process

After insertion of the Safety Module (SAF-001) into the converter and switching on the

nverter, the following processes are performed in the converter and Safety

co Module (SAF-001) (see also ZFigu

1 Scan of the automatic parameter adjustment by the Safety Module (SAF-001).

If, the checkbox „Load automatic“ is set in ProDr management“, the parameters are automatically loaded from the safety module into the converter.

If there is no data set in the Safety Module, the data of the conve rter is loaded in to th e Safety Module.

2 Check, if the converter was equipped with a higher level Safety Module before

le replacement (SAF-002/003).

modu

m Conve

m Th

3 Checking the parameters with Safety Module (SAF-001). 

If the data sets between the c different, this is displayed by a red LED H2 at the Safety Module, which always is on and the error message 2403 (different parameter data on the controller and the SAFModule) in parameter 100.010.0.0 (Safety Module state). By acceptance with button S1 (long-short-short-long) by the us er, the parameters are copied from the controller to the Safety Module.

rter was equipped with a Safety Module (downgrade) of higher level The converter indicates error 2418 (modu le change to lower safety level) . A release of the con (see ZD

e converter was not already equipped with a higher level Safety Module (see

step 3).

troller is only possible by resetting of the converter with a Reset-Module.

escription of the Reset-Module– from page 61 ).

re 27– on page 80).

ive on the page „Dataset

onverter and the Safety Module (SAF-001) still are

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Switch on

BM5-O-SAF-001 (STO-module)

Functional parameters b maXX 5000 ¹ functional parameters SAF-module

YES

Data backup of the functional

parameters of b maXX 5000

to SAF-module

Red LED is on

No error,

green LED is on

Command processing

Safety functions

Error message

(error number 2403)

Await confirmation

by button

Set last module version

on BM5-O-SAF-001

(P200.008 := 3)

BM5-O-SAF-001

available

Command processing

Up-/Downgrade safety module

(P200.008 < P200.001)

(Downgrade)

Error message

(error number 2418)

Command processing

YES

(Up-/Evengrade)

Switch on

b maXX 5000 (controller)

Scan on BM5-O-SAF-001

(P200.001 == 3)

Scan for 5s, meanwhile nodisplay of module version

Drive state

(P108.006 := 15)

Failure

Writing of module identifications:

Module version (P200.001 := 3) Firmware version module (P200.002) Hardware version module (P200.003)

Serial number (P200.004)

Automatic loading of SAF-module?

(P105.010 == 1)

YES

Functional parameters b maXX 5000 ¹ functional parameters SAF-module

or no parameters on b maXX 5000

and SAF-module

YES

Data backup of SAF-module to

b maXX 5000, save in flash and load

into the work memory (RAM)

Functional parameters

in b maXX 5000

available

YES

Functional parameters

in SAF-module

available

YES

Data backup of

b maXX 5000

to SAF-module

13.3

Exchanging the module

Figure 27: Course of the module exchange process

CAUTION!

Once the module has been exchanged, a complete function test for the system has to be conducted and documented accordingly.

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Commissioning and exchange of the module

CAUTION!

Ensure by the use of the external safety components (for example emergency stop

evice) that an unexpected start-up is prevented after the module has been

d exchanged.

CAUTION!

It is necessary to label defective components to indicate that they are defective. It is absolutely necessary to prevent defective components from being reused by taking measures in the scope of qualit y management on the user's side (s ee the chapter

ZRepa

ir– from page 91 ).

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13.3

Exchanging the module

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14SYSTEM VALIDATION

All safety functions as well as the trouble-free functioning of the installed system must be tested with the initial operation. The testing of the system must be documented.

WARNING! Danger during commissioning!

The Safety Module may only be put into opera a technical expert.

Therefore: m Conduct a complete function test. In doing so, check the correct allocation of the

nnected safety components.

m A checklist for the commissioning and validation

Appendix ZB.3 Commissioning and validation checklist– from page 102 onward. Conduct the validation of the system in acc document the procedure accordingly.

m Make sure that operating personnel has been instructed in the handling of the

Safety Module.

tion after being tested successfully by

of the system is reproduced in

ordance with this checklist and

14.1 Function test

The function test is a major part of the validation of the entire system. The function test is used to determine the trouble-free allocation of the network safety components and the programmed logic of the system.

Depending on the complexity of the logic cir recommended to conduct the function tests in steps.

The following course of action is recommended when conducting the function tests:

1 On

2 Co

cuit of the respective project, it is

ly connect the actuators and drives to the safe output ter minals once no errors have

been detected in the inspection of the logic circuit.

nduct a complete function test with all s ensors (initiators) , switches, actuat ors and

drives. To conduct the function tests, trigger all safety fun

system's reaction. Check whether their action corresponds with the expected behavior .

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ctions sequentially and document the

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14.1

Function test

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15OPERATION

Instructions on the operation of the system components connected to the converter used can be found in the corresponding operation manuals and application manuals for these components.

DANGER!

It is not permitted to make any changes t operation of the Safety Module.

Therefore: m Before expanding the system and removing individual system components and

making from the power source and put into safe condition by technical trained personnel.

changes in the wiring, the safety module must as a rule be disconnected

o the system configuration during the

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16TROUBLESHOOTING AND

This chapter describes the error indications of the Safety Module (SAF-001).

16.1 Safety regulations

Observe the applicable safety regulations, see ZSafety ab Seite 17.

16.2 Requirements on the personnel conducting the work

Personnel working with the Safety Module (SAF-001) must be instructed in the saf ety regulations and the operation of the module and be familiar with the proper operation of the system. The reaction to error indications and statuses in particular requires special knowledge which the operator must ha ve .

16.3 Error diagnosis

RECTIFICATION

Fail-safe principle

The Safety Module (SAF-001) is based on the fail-safe principle. This means that each

ror automatically causes the module to switch into the safe status STO (Safe Torque

er Off).

The red LED on the front panel of the Safety Module (SAF-001) indicates the error status

see chapter ZLEDs

(

WARNING!

Do not put a defective safety-oriented system ba cause of the error is unknown to you or an error has not been rectified.

Operation Manual Safety Module for b maXX 5000 BM5-O-SAF-000/-001

for indicating the operation statuses ab Seite 54).

ck into operation as long as the

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16.4

Detecting errors in the periphery

16.4 Detecting errors in the periphery

m Electromechanical error detection is ensu red by the input circuitry (see the chapter

ZInput circuitry ab Seite 42).

m Electronic sensors must have an own error detection regarding short circuits on the

output.

16.5 Safe status

In the safe status, the Safety Module (SAF-001) safely shuts off the driver supply of the converter. Thus, the actuation of the power output module of the converter is already interrupted.

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17MAINTENANCE

If you are complying with the mandatory environmental conditions, see ZAppendix C -

Technical data– from page 103 onward, then the plug-in module is maintenance-free. If

you detect or suspect a defect in the plug-in module, contact Baumüller Nürnberg GmbH.

CAUTION!

Take organizational measures to make sure that the interval for the repeat testing of all syste page 25 onward) is complied with.

m components (proof test interval, see ZSafety-related parameters– from

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18REPAIR

You cannot repair a defective plug-in module. Ple ase contact Baumüller Nürnberg GmbH for a replacement.

CAUTION!

Defective components may only be repaired by the manufacturer.

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This chapter describes how to decommission the plug-in module and store it.

19.1 Safety regulations

h Follow the chapter ZSafety– from page 17 onward.

CAUTION! Damage through electrical destruction.

19DISASSEMBLY, STORAGE

The component assembly can be destroyed by power is turned on.

Therefore: m Make sure that the power to all electrical conn

prevent from being turned back on.

m Using suitable measuring equipment, check to make sure that none of the

nnections are carrying live current before beginning work on the electrical

co connections.

m Only disassemble the connections and remove the connection once you are

mpletely certain that the component assembly is not under power.

electricity if it is removed when the

ections is shut off and secured to

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19.2

Requirements on the personnel conducting the work

WARNING! Danger of injury due to uncontrollable behavior of the machine/line.

The behavior of the machine/line can change as a result of removing the component

ssembly with the power source connected.

a Therefore:

m Make sure that the power to all electrical connections is shut off and secured to

event from being turned back on.

m Using suitable measuring equipment, check to m

connections are carrying live current before beginning work on the electrical connections.

m Only disassemble the connections and remove the connection once you are

pletely certain that the component assembly is not under power.

com

19.2 Requirements on the personnel conducting the work

ake sure that none of the

The personnel you assign to carry out the disassembly must have the knowledge and training necessary to perform this work properly. The personnel should be selected so that it will be able to understand and use the safety instructions attached to the device and its components as well as the connections.

19.3 Disassembly

The personnel carrying out the disassembly must meet the requirements above. Carry out the disassembly process in the following order:

ake sure that the power has been disconnected and cannot be turned back on

1 M

accidentally.

2 Disassemb

ZAssembly and installation– from page 71 onward).

cument the disassembly (or exchange) of the plug-in module.

3 Do Document the disassembly (or exchange) of Document the disassembly (or exchange) of the additional system components, if

plicable.

19.4 Storage conditions

le the plug-in module in the reverse order of the assembly (see chapter

the converter, if applicable.

Store the plug-in module in a suitable package under the storage conditions specified in the ZTechnical data– from page 103 onward.

19.5 Recommissioning

If you want to put the plug-in module back into operation, observe the spe cifications under „Storage conditions“. Then conduct the ZCommissioning and exchange of the module– from page 77 onward again.

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This chapter describes the proper and safe disposal of the Safety Module (STO). For the most part, it can be classified as electronic scrap.

m Prerequisite: The disassembly process has already been carried out, see

ZDisassembly, storage– from page 93 onward.

20.1 Safety regulations

The disposal may only be conducted in compliance with the safety regulations. Observe special local regulations as well, if applicable. If you are not able to conduct the disposal yourself, hire a suitable waste removal company to do so.

20.2 Requirements on the personnel conducting the work

The personnel you assign to carry out the disposal/disassembly must have the knowledge and training necessary to perform this work properly. The personnel should be selected so that it will be able to understand and use the safety instructions attached to the converter and its components.

20DISPOSAL

20.3 Disposal instructions

Prerequisites Safety Module (STO) has already been disassembled properly.

Sheet steel Parts of the module are made of galvanized sheet steel. Sheet steel must be put into the

cycle of potential recyclables for ferrous metals.

Electronic scrap Electronic scrap (circuit boards), which cannot be disassembled further must be disposed

of as special waste. Observe the applicable regulations in doing so.

Plastic The housing is made of plastic. Plastic must be put into the cycle of pote ntial recyclables

for plastics.

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20.4

Recycling collection center/offices

20.4 Recycling collection center/offices

Make sure that the disposal is carried out in compliance with your company's disposal guidelines as well as those of the competen t recycling collection centers and offices. In the event of uncertainty, contact the industrial inspectorate responsible for your company or the environmental agency.

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APPENDIX A - ABBREVIATIONS

DC Diagnostic Coverage EMC Electromagnetic compatibility EN European standard ESD Electrostatic sensitive device EXT, ext External I/O Input/Output ISO International Organization for

Standardization

LED Light-emitting diode MTTFdMean Time To Failure PFD Probability of Failure on Demand

PFH Probability of Failure per Hour SAF Safety module SIL Safety Integrity Level SFF Safe Failure Fraction (fraction of

STO Safe Torque Off

(mean residual error probability of a dangerous error on demand)

failures which lead to safe status)

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The use of checklists serves documentation purposes and guides in the implementation of a safety system. The checklists reproduced in this chapter serve to prevent errors and must be processed carefully for every proje ct. It is also required to make copies of the printed checklists.

No claim is made that the checklists are complete. There may be a dditional requirements depending on the specific plant.

B.1 Planning checklist

APPENDIX B - CHECKLISTS

Serial no.

1 Planning

1.1 Has a risk assessment been carried out

1.2 Are power supplies according to PELV

1.3 Is the line routing carried out in accord ance

1.4 Is the electrical supply for the local I/O

1.5 Do all safety-oriented system components



Requirement

and have the required SIL and performance levels in accordance with DIN EN ISO 13849-1 or IEC 62061 been determined?

specifications being used exclusively?

with the applicable standards and guidelines?

terminals and field bus components properly dimensioned?

meet the requirements of the established SIL (IEC 61508), performance levels and safety category (DIN EN ISO 13849-1)?

Fulfilled  Yes No

Remarks

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B.1

Planning checklist

Serial no.Requirement

1.6 Does the wiring of the safety components meet the requirements of the previously determined safety classification? (Example: Dual-channel wiring of an emergency stop for SIL 2 application)

1.7 Do the components meet the environmental conditions prevailing in the application?

1.8 Does the system fulfill the required type of protection?

1.9 Is degree of pollution 2 complied with?

1.10 Has the maximum permissible reaction time of the safety functions been established by means of a risk analysis?

1.11 Is the maximum permissible reaction time reached? Has computational evidence been provided?

1.12 Is the system protected from mechanical overloading?

Fulfilled  Yes No

Remarks

1.13 Is the system protected from corrosive substances?

Date Name Signature

100

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Baumuller BM5-O-SAF-000, BM5-O-SAF-001 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

2.1 Information on the Operation Manual

2.2 Legend

2.3 Limitation of liability

2.4 Preliminary information

2.5 Copyright

2.6 Further applicable documents from other manufacturers

2.7 Replacement parts

2.8 Disposal

2.9 Warranty and liability

2.10 Customer service

2.11 Terms used

2.12 Certification

2.12.1 Approvals, directives and standards

4.1 Contents of the operation manual

4.2 Alterations and rebuilding of the device

4.3 Intended use

4.4 Operator responsibility

4.5 Protective equipment

4.6 Personnel training

4.7 Personnel protective equipment

4.8 Special dangers

4.9 Fire fighting

4.10 Electric safety

4.10.1 Notice on power supply

4.11 Safety equipment

4.12 Conduct in the event of danger and accidents

4.13 Signage

5.1 Safety-related parameters

5.1.1 SAF-001-000-xxx

5.1.2 SAF-001-001-xxx

6.1 Shipping

6.2 Unpacking

6.3 Disposing of the packaging

6.4 To be observed when shipping

7.1 General

7.2 Compatibility list

7.3 Working principle parameter module (BM5-O-SAF-000-000-000)

7.4 Setting of the switch-on behavior

7.5 Structure of the SAF-000 Default- and Parameter module

7.6 Identification of the SAF-000 Default- and Parameter module

8.1 General

8.1.1 Safety Module SAF-001-000-xxx and SAF-001-001-000 with safety function STO

8.1.2 Safety Module SAF-001-001-001 with safety function SS1 (time controlled)

8.2 Compatibility list

8.2.1 Compatibility list SAF-001-000-xxx

8.2.2 Compatibility list SAF-001-001-xxx

8.2.3 Compatibility list SAF-001-000-002 with automatic restart

8.3 Safety notes on the STO (Safe Torque Off)

8.4 Working principle

8.4.1 SAF-001-000-xxx

8.4.2 SAF-001-001-xxx

8.5 Input circuitry

8.5.1 SAF-001-000-xxx

8.5.2 SAF-001-001-xxx

8.6 Structure

8.6.1 Structure of the Safety Module (SAF-001-000-xxx)

8.6.2 Structure of the Safety Module (SAF-001-001-000)

8.6.3 Structure of the Safety Module (SAF-001-001-001)

8.7 Pin assignment

8.7.1 Pin assignment of connector X1 (SAF-001-000-xxx)

8.7.2 Pin assignment of connector X1 (SAF-001-001-xxx)

8.7.3 Pin assignment of connector X1 (SAF-001-000-002 with automa tic restart)

8.8 Switching thresholds for voltage and current

8.9 Maximum response time

8.10 Properties of the parameter memory

8.11 Operation and display elements

8.11.1 LEDs for indicating the operation statuses

8.11.2 Button for verification purposes

8.12 Restart inhibit (SAF-001-000-xxx)

8.13 Automatic restart (SAF-001-000-002 and SAF-001-001-xxx)

8.14 Marking of the Safety Module (SAF-001) - type code

9.1 General

9.2 Compatibility list

9.3 Operating mode of the Reset-Module (BM5-O-SAF-100)

9.4 Structure of the Reset-Module (BM5-O-SAF-100)

9.5 Identification of the Reset-Module (SAF-100)