Baumuller SI4000, SO4000 Operating Instructions Manual

Download

Operating Instructions

Language English

Translation Document-No. 5.08009.05 Part No. 422585 Status 11.03.2015

5.08009.05

 

b maXX

Safety I/O Terminals



SI4000 / SO4000

Read the Operating Instructions before beginning

Systems

 Baumüller Nürnberg GmbH

Ostendstr. 80 - 90  90482 Nürnberg Germany

Tel. +49 9 11 5432 - 0  Fax: +49 9 11 54 32 - 1 30

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

Table of Contents

1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Information on the Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Preliminary information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.6 Further applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.7 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.9 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.10 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.11 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.12 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.12.1 Approvals, directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Use of this handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Contents of the Operation Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Alterations and rebuilding of the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4 Operator responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.6 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.7 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.8 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.9 Firefighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.10 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.10.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.12 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.13 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4 Functional Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Safety-related parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.3 Using of the terminals with b maXX safe PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5 Description of the Safety I/O Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.1 SI4000 4-channel safety digital input terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.2 SO4000 4-channel safety digital output terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4.1 SI4000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4.2 SO4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6 Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

Inhaltsverzeichnis

6.2 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.3 Installation of Bus Terminals on C mounting rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.3.1 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.3.2 Mounting rail installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.4 Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.4.1 Connections within a bus terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.4.2 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.5 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1.2 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1.3 Mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.1.5 SI4000 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.1.6 SO4000 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.1.7 Address settings on the safety terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.1.8 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.2 Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.2.1 Diagnostic LEDs SI4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.2.2 Diagnostic LEDs SO4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.4.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.4.2 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8 System validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.1 Function test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9 Dismantling, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.2 Requirements of the personnel carrying out work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Appendix B - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

B.1 List of all accessory items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Appendix C - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

C.1 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

C.2 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix D - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

D.1 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

D.2 Connection values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

D.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

of 82

Appendix E - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

E.1 What is an EC directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

E.2 What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

Inhaltsverzeichnis

E.3 Definition of the term Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

E.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

1.1 Information on the Operation Manual

This Operation Manual provides important information on handling the device. Compliance with all safety instructions operation instructions specified is a prerequisite for work safety.

Furthermore, it is also necessary to comply with the local accident prevention legislation and general safety regulations applying to the device’s field of application.

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 to personnel in the immediate vicinity of the device at all times.

1PREFACE

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

1.2

Legend

1.2 Legend

Warning notices

Warning notices are indicated by symbols in this Op troduced 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!

eration Manual. The notices are in-

d act with caution in order to avoid

....notifies of an imminent dangerous

juries if not avoided.

WARNING!

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

juries if not avoided.

CAUTION!

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

ries if not avoided.

NOTE!

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

not avoided.

situation which will lead to death or serious in-

Recommendations

of 82

NOTICE!

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

cient and trouble-free operation.

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

1.3 Limitation of liability

All statements and instructions in this Operation Manual have been compiled in compliance with the applicable standards and legislation w nology and our long-term experience an

The manufacturer assumes

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

hile taking the current level of tech-

d findings into account.

no liability for damages resulting from:

Preface

The actual scope of materials delivered may v described here in cases involving custom designs or the use of additional ordering options, or as a result of 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, ove

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

ring during assembly or connection.

occur

1.4 Preliminary information

CAUTION!

The following shall apply if the document you are reading is designated as preliminary information: This version pertains to preliminary technic scribed devices and functions should receive ahead of time, in order to be able to adjust to potential changes and/or This information is to be considered preliminary since it has not yet been subjected

the Baumüller internal review process. In particular, this information is still subject

to 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 preliminary information, please contact the contact person assigned to you and inform us of your tially incorporated during the transition from (reviewed by Baumüller) information. The obligations specified in the following section under “Obligations” do not apply to preliminary information.

findings and comments, so that they can be taken into account and poten-

ary from the explanations and illustrations

of conducting maintenance and commissioning in

rvoltage protection, etc.

al information which the user of the de-

functional expansions.

the preliminary information to the final

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

1.5

1.5 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.

b maXX

is a registered trademark of Baumüller Nürnberg GmbH

1.6 Further applicable documents

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 Eur clared by the respective comp

1.7 Replacement parts

WARNING!

Improper or defective replacement parts can failure as well as jeopardize safety.

Therefore:

m Only use original replacement parts from the manufacturer

other illustrations are

opean and national legislation has been de-

onent manufacturers.

lead to damage, malfunctions or total

1.8 Disposal

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Procure replacement parts from authorized dealers or directly from the manufacturer. See also ZAppendix

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

1.9 Warranty conditions

The warranty conditions can be found as a separate document in the sales documentation.

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.

1.10 Customer service

Our customer service is available for technical support. Information on the contact person responsible can be found at any time via telephone,

fax, E-mail or over the internet (www.baumueller.de).

1.11 Terms used

Preface

1.12 Certification

The terms “SI4000” (for input terminal) or “SO4000” (for output terminal) are also used for the product “Safety I/O Terminals.”

A list of the abbreviations used can be found in ZAppendix A - Abbreviations– from page 63 onward.

The safety I/O Terminals are a component part of a system composed of b maXX safe PLC, power supply and other system modules.

The safety I/O Terminals have been developed in accordance with the standards specified in ZChapter 1.12.1– and certified by TÜV Süd.

SI4000: Approval no. Z10 15 03 75013 001 Test report: BV82168T

SO4000: Approval no. Z10 15 03 75013 003 Test report: BV82168T

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

1.12

1.12.1 Approvals, directives and standards

Certification

Safety engineering standards and directives

EN 61508, Parts 1-3 Functional safety of security-

DIN EN ISO 13849-1 Safety-related components of

Additional standards Area of application

2006/42/EC machinery directive

DIN EN 81-1 to the extent to which

EN 13243 to the extent to which

DIN EN 61000-6-2

DIN EN 61000-6-4

Area of application Approvals

up to SIL 3 related electric, electronic and programmable electronic systems

up to performance control units

e (category 4)

level

they may be applica-

ble

they may be applica-

ble

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

2USE OF THIS HANDBOOK

This safety handbook contains information on the intended use of the Baumüller safety I/O terminals.

Knowledge of regulations and proper technical implementation of the safety instructions in this handbook by qualified personnel are prerequisites for the safe installation, commis sioning and safety during the operation and maintenance of the Baumüller safety I/O terminals. Unqualified interventions in the devices, during shutdown or use of the safety functions or failure to comply with the instructions of this handbook can lead to serious personal injury, property damage or environmental harm, for which Baumüller assumes no liability.

Baumüller control devices are developed, manufactured and tested in compliance with the applicable safety standards. They may only be used under the specified environmen tal conductions 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 Installation/Assembly n Commissioning n Operation n Troubleshooting n Maintenance/repair n Disassembly

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

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

3.1 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 similar device or has been trained by the manufacturer.

3.2 Alterations and rebuilding of the device

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

3SAFETY

3.3 Appropriate use

WARNING! Caution - Risk of injury

Safety terminals may only be used for the purposes described below!

The safety terminals expand the application range of Baumüller bus terminals with functions that enable them to be used for machine safety applications. The safety terminals

e designed for machine safety functions and directly associated industrial automation

ar tasks. They are therefore only approved for applications with a defined fail-safe state.This safe state is the wattless state. Fail-safety according to the relevant standards is required.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

3.3

Appropriate use

The safety terminals enable connection of:

m 24 V

emergency stop push buttons, pu switches, safety mats, light curtains, light barriers, laser scanners etc.

m 24 V

contactors, protection door switches with tumble

NOTICE! Test pulses

When selecting actuators please ensure that the SO4000 test pulses do not lead to

tuator switching or diagnostic message from the SO4000. The test pulses of the

ac SO4000 terminal outputs are not configurable and cannot be switched off.

sensors (SI4000) such as

actuators (SO4000) such as

ll cord switches, position switches, two-hand

r, signal lamps, servo drives etc.

The following modules were developed f

m The SI4000 terminal is an input module with digital inputs. m The SO4000 terminal is an output module with digital outputs.

These modules are suitable for operation with

m Baumüller b maXX safe PLC m Baumüller ECK000 series bus coupler

Your use of the device is considered to be comp all instructions and information in this Operation Manual.

WARNING! Follow the machinery directive

The safety terminals may only be used in machines according to the Machinery Directive.

WARNING! Ensure traceability

The buyer has to ensure the traceability

or these tasks:

liant with its intended use if you have read

of the device via the serial number.

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

WARNING! Danger due to use other than intended!

Safety

Any use of the device different from and/o ed use can lead to dangerous situations.

Therefore:

m Only use the device as intended. m Follow all specifications of this m Ensure that exclusively qualified per m Take care in project planning to see that the device i

ifications.

m The device and/or mounting rail is mounted on a w m Ensure that the power supply meets the m Only operate the device if it is in technically faultless condition. m Only use the device in combination with co

berg GmbH.

3.4 Operator responsibility

The device 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 in prevention and environmental protection regulations applicable to the area of application of this device must also be complied with. In doing so, the following applies in particular:

m The operator must inform himself of the applicab

tionally ascertain hazards arise through the special w 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

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

m The statements of the Operation Manual are to b m The device may only be operated in technically fau

operation.

r exceeding beyond the scope of the intend-

Operation Manual.

sonnel work on or with this device.

s always used within its spec-

all which is sufficiently sturdy.

required specifications.

mponents approved by Baumüller Nürn-

structions in this Operation Manual, the safety, accident

le work safety regulations and addi-

ork conditions at the place of use

immediate vicinity of the device and be ac-

e followed completely and absolutely!

ltless condition and must be safe for

3.5 Protective equipment

Protection category

All SI4000 and SO4000 devices with the couple stations (b maXX safe PLC or bus coupler) must be built into a suitable electrical cabinet in order to comply with the protective catego

ries (IP54) required in EN 60529.

SI4000 IP 20

SO4000 IP 20

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

3.6

Personnel training

DANGER! Life-threatening danger through electric current!

Immediate life-threatening danger is present if Therefore:

m Operate the device in an electrical cabinet which p

contact with the devices and meets at least the protective categories (IP54) of EN 60529.

3.6 Personnel training

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

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

contact with live parts is made.

rovides protection from direct

Therefore: m Only allow certain activities to be conducted b

chapters of this Operation Manual.

The following qualifications for various areas o Manual:

m Operating personnel

The drive system may only be operated by p and authorized to do so. Troubleshooting, repairs, cleaning, maintena ed by trained or instructed pers tion Manual and act according to it. Commissioning and instruction may only b

m Qualified personnel

Electrical engineers and specialist electricians of authorized by Baumüller Anlagen-Systemtechnik GmbH & Co. KG, trained and certified in the installation and commissioning of Baumüller drive systems and commissioning, grounding and designating electrical systems and devices in ac safety engineering standards. Qualified personnel is educated or trained in ty equipment in accordance with the respective

onnel. These persons must be familiar with the Opera-

y persons specified in the respective

f operation are specified in the Operation

ersons who have been trained, instructed

nce and exchange may only be conduct-

e conducted by qualified personnel.

the customer or a third party who are

cordance with the

the maintenance and use of suitable safe-

local safety engineering standards.

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

3.7 Personnel protective equipment

Wearing the appropriate personal protective equipment 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

denotes tight-fitting work clothing with low tea truding parts. It primarily serves in protecting from...

Do not wear any rings and necklaces.

Protective helmet

for protection from falling and flying

parts.

Safety

equired for the respective task when

r resistance, tight sleeves and no pro-

To be worn during

ecial work

Safety shoes

for protection from heavy

Safety gloves

to protect the hands from friction, abrasions, pr as from contact with hot objects.

Protective glasses

to protect the eyes from flying parts and spraying liquids

falling parts.

ick wounds or deeper injuries as well

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

3.8

Special dangers

3.8 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.

Electric current

DANGER! Live-threatening danger from electric current!

Immediate life-threatening danger is present age to the insulation or individual comp

Therefore:

m Shut down immediately if the insulation on the power supply is damaged. m Only allow the work to be co

nel.

m Turn the current off when conducting any work on the electrical system and secure

it befo

and the warning notices in the following

if contact with live parts is made. Dam-

onent can be life-threatening.

nducted on the electrical system by qualified person-

re turning it back on.

Dangers from residual energy

DANGER! Live-threatening danger from electric current!

After the device has been disconnected from nectors may only be touched once the cap charged.

Therefore: m Take the capacitors’ discharge time into account and do not touch live parts be-

forehand.

m Follow commensurate instructions on the device. m If you have connected additional capacitors to the

take considerably longer for the intermediate circuit to discharge. In such case, you will have to establish the necessary waiting period yourself or measure whether the device has been de-energized.

the mains, live parts such as line con-

acitors in the device have been dis-

intermediate circuit, it can also

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Moving parts

3.9 Firefighting

Safety

WARNING! Risk of energy from 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 applic

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

ation. Powered parts will

DANGER! Live-threatening danger from electric current!

Electric shock can occur if a conductive Therefore:

m Use the following fire extinguishing medium:



ABC powder/CO2

fire extinguishing medium is used.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

3.10

Electric safety

3.10 Electric safety

The safety control is designed for contamination level 2 in accordance with EN 50178. This means that only non-conductive contamination may appear during operating time. Short-term conductivity from condensation is only permissible if the control is not in operation.

WARNING! Risk of injury from conductive contaminants!

No conductive contaminants may appear during operating time. Therefore:

m Before installing the system, check that contamination degree 2 is not exceeded,

nd ensure so by additional measures, if necessary.

3.10.1 Notice on power supply

WARNING! Risk of injury from electric current!

Only devices which have a safe disconnection ed to the control.

The power supply for generation the 24-volt su PELV in accordance with EN 50178.

3.11 Safety equipment

WARNING! Live-threatening danger from inoperable safety equipment!

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

to the 230 volt mains may be connect-

pply must meet the requirements for

uring operation. Even if the safety

of 82

Therefore: m Check to make sure that the safety equipment is functional and installed properly

efore beginning work.

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

3.12 Conduct in the event of danger and accidents

Safety

Preventative measures

In case of emergency: Act properly

m Always be prepared for accidents or fire! m Keep first aid equipment (first aid kits, blankets, etc.) and fire extinguishers readily

available.

m Instruct personnel in accident reporting, first aid and rescue equipment.

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 vehicles.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

3.13

Signage

3.13 Signage

The following symbols and notification signs are found in the work area. They relate to the immediate environment in which they are placed.

WARNING! Live-threatening danger from electric current!

In the course of time, stickers and symbols on the device can become dirty or otherwise illegible.

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

tion at all times.

the device in easily legible condi-

Electric current

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

DANGER! Live-threatening danger from electric current!

Discharge time > 1 minute Saved electric charge. Therefore:

m Keep the discharge time of the capacitors in min

forehand.

m Follow the commensurate instructions on the device. m If you have connected additional capacitors to the

take considerably longer for the intermediate circuit to discharge. In such case, you will have to establish the necessary waiting period yourself or measure whether the device has been de-energized.

d and do not touch live parts be-

intermediate circuit, it can also

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

This chapter describes parameters in relation to functional safety. First of all, in accordance with IEC 61508, safety means that a syste al safety is the part of the o to its input conditions is free of errors. Internal safety-related device errors must be detected and brought into a safe condition in the process.

4.1 Safety-related parameters

The safety-related parameters of the safety I/O Terminals will be described in the following Safety-related parameters of b maXX safe PLC and decentral components can be

d in the applicable documentation. The values specified here relate exclusively to the

foun safety I/O Terminals.

4FUNCTIONAL SAFETY

m is free of unwarranted risks. Function-

verall safety, which ensures that a safety system’s response

Parameters in accordance with

Meaning

IEC 61508

PFH = 2.30 * 10-9/h for SI4000

-9

PFH = 1.73 * 10

PFD

= 1.81 * 10-4 for SI4000

avg

/h for SO4000

Probability of Failure per Hour

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

PFD

= 1.42 * 10-4 for SO4000

avg

error on demand

Lifetime [a] = 20 years

Safety Integrity Level = SIL 3

Classification element *) type A

HFT 1 Hardware Failure Tolerance

*) Classification according to IEC 61508-2:2010 (see chapter 7.4.4.1.2 and 

7.4.4.1.3 in IEC 61508-2)

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

4.2

Lifetime

4.2 Lifetime

Parameters in accordance with DIN EN ISO 13849

MTTFd > 100 years Mean Time To Failure

DC > 99% (high) Diagnostic Coverage

Performance level = e

Category = 4

The interval for the repeat test (proof test interval) is set for 20 years. The repeat test serves to detect failures which could not be detected by the diagnostic coverage during the operating time. It is necessary to detect all dangerous failures so that the repeat test will be fully effective and “like new” condition can be established for the system.

CAUTION!

To ensure the safety-related to be decommissioned and sent back to the manufacturer within not more than 20 years.

parameters specified above, the safety control will have

Meaning

The safety terminal are designed for a service life of 20 years. Due to the high diagnostic coverage within the

quired. The terminals have a date code which corresponds to the following glossary: Date code: WW YY SW HW

WW calendar week of production YY year of production SW software version (hex) HW hardware version (hex)

Example: Date code: 17 11 05 00

calendar week of production 17 year of production 2011 software version 05 hardware version 00

Additionally the terminals have a unique serial number.

lifecycle no special proof tests are re-

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

NOTICE! Declaration of the version

All changes both of the hardware and of the firmware lead to a change of the version. All cha this manual.

nges which impact security-relevant properties of the terminals are denoted in

4.3 Using of the terminals with b maXX safe PLC

The tests of the b maXX safe PLC are carried out with the following terminal versions.

Functional Safety

Test Version input

termial SI4000

Module test FSoE 1701 1404

Module test Motion Control 1701 1404

Environmental test 1701 1404

EMC test 1701 1404

System test 1701 1405 / 1406

The results only apply for the current terminal hard tests were carried out in a laboratory environment.

Version output terminal SO4000

ware version at the time of testing. The

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

4.3

Using of the terminals with b maXX safe PLC

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

5DESCRIPTION OF THE SAFETY I/O

This chapter describes the safety I/O Terminals and the type code applied to the module.

5.1 General description

5.1.1 SI4000 4-channel safety digital input terminal

The SI4000 is a digital input terminal for sensors with floating contacts for 24 VDC. The bus terminal has 4 fail-safe inputs.

With two-channel connection, the SI4000 meets the requirements of IEC 61508:2010 SIL3, DIN

The bus terminal has the standard design of a Baumueller Bus Terminal.

EN ISO 13849-1:2008 (Cat 4, PL e) and UL 508.

TERMINALS

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

5.1

General description

Figure 1: SI4000 safety input terminal

5.1.2 SO4000 4-channel safety digital output terminal

The SO4000 is a safe output terminal with digital outputs for connecting actuators (contactors, relays, etc.) with a maximum current 0.5 A (24 V safe outputs.

The SO4000 meets the requirements of IEC 61508:2010 SIL3,  DIN EN ISO 13849-1:2008 (Cat 4, PL e) and UL 508.

The bus terminal has the standard design of a Baumueller Bus Terminal.

). The bus terminal has 4 fail-

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Description of the Safety I/O Terminals

Figure 2: SO4000 safety output terminal

5.2 Appropriate use

DANGER!

The safety I/O terminals may only be used for the purposes described in

ZAppr

5.3 Technical data

See ZAppendix D - Technical Data– from page 71 onward.

opriate use – from page 15 onward.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

5.4

Dimensions

5.4 Dimensions

5.4.1 SI4000

Figure 3: Dimensions of SI4000

Width: 12 mm (side-by-side installation) Height: 100 mm Depth: 68 mm

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

5.4.2 SO4000

Description of the Safety I/O Terminals

Figure 4: Dimensions of SO4000

Width: 24 mm (side-by-side installation) Height 100 mm Depth 68 mm

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

5.4

Dimensions

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

6.1 Safety instructions

Before installing and commissioning the safety I/O terminals please read the chapter

ZSafety

– from page 15 onward.

CAUTION!

The "Installation checklist" reproduced in Appendix ZC.1– o 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 visible 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 environmental pr

ZD.3.1– on pa

m Make sure that the design of the system’s type 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).

6ASSEMBLY AND INSTALLATION

n page 67 should be

wiring plan.

t the electrical connection is not

the electrical terminal and screw connections.

outing are carried out in accordance with

operties specified in Appendix

ge 74 are not exceeded.

of protection is sufficient.

damaged by moving parts or work in the

o contact with aggressive

6.2 Transport and storage

Use the original packaging for transporting or storing the digital safety I/O terminals.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

6.3

Installation of Bus Terminals on C mounting rails

CAUTION! Note the specified environmental conditions

Please ensure that the digital safety I/O terminals are only transported and stored under the specified environmenta page 71 onward).

l conditions (see ZAppendix D - Technical Data– from

6.3 Installation of Bus Terminals on C mounting rails

DANGER! Danger from electricity

Set the bus system into a safe, powered down state assembly or wiring of th

6.3.1 Control cabinet

The safety I/O terminals must be installed in a control cabinet or terminal box with IP54 protection class according to IEC 60529 as a minimum.

6.3.2 Mounting rail installation

The Bus Coupler and Bus Terminals are attached to commercially available 35 mm C mounting rails (according to EN 50022) by applying slight pressure:

before starting installation, dis-

e Bus Terminals!

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Assembly and Installation

Figure 5: Assembly of the terminals

1 First attach the Fieldbus Coupler to the mounting rail. 2 Th

e Bus Terminals are now attached on the right-hand side of the Fieldbus Coupler. Join the components with slot and key and push the terminals against the mounting rail, until the lock clicks onto the mounting rail.  If the Terminals are clipped onto the mounting rail first and then pushed together without slot and key, the c significant gap should be visible between the housings.

During the installation of the Bus Terminals, the lo not come into conflict with the fixing bolts of the mounting rail.

onnection will not be operational! When correctly assembled, no

6.4 Electrical installation

6.4.1 Connections within a bus terminal block

The electric connections between the Bus Coupler and the Bus Terminals are automatically realised by joining the components:

m The six spring contacts of the I/O-Bus deal with the transfer of the data and the supply

e Bus Terminal electronics.

of th

cking mechanism of the terminals must

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

6.4

Electrical installation

NOTICE! Note the maximum I/O bus current!

Observe the maximum current that your Bus Coupler can supply to the I/O bus!

m The power contacts deal with the supply for the field electronics and thus represent a

supply rail within the bus terminal block. The power contacts are supplied via terminals on the Bus Coupler.

NOTICE! Note the pin assignment of the power contacts!

During the design of a bus terminal block, the pin assignment of the individual Bus

rminals must be taken account of, since some types (e.g. analog Bus Terminals or

Te digital 4-channel Bus Terminals) do not or not fully loop through the power contacts.

Power Feed Terminals (ES0000) interrupt the power contacts and thus represent the

t of a new supply rail.

star

PE power contact

The power contact labeled PE can be used as a protective earth. For safety reasons this

ntact mates first when plugging together, and can ground short-circuit currents of up to

co 125 A.

CAUTION! Danger from damage of the terminal

Note that, for reasons of elec tatively coupled to the mounting rail. This may tion testing or to damage on the terminal (e.g. disruptive discharge to the PE line

uring insulation testing of a consumer with a nominal voltage of 230 V).

d Therefore:

m For insulation testing, disconnect the PE supply line at the Bus Coupler or the Pow-

er Feed Terminal! In order to decouple further feed points for testing, these Power

eed Terminals can be released and pulled at least 10 mm from the group of ter-

F minals.

tromagnetic compatibility, the PE contacts are capaci-

lead to incorrect results during insula-

of 82

DANGER! Serious risk of injury!

The PE power contact must not be used for other potentials!

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

6.4.2 Wiring

Assembly and Installation

Figure 6: Wiring

Up to eight connections enable the connection of solid or finely stranded cables to the Bus Terminals. The terminals are implemented in spring force technology. Connect the cables as follows:

1 Op

2 T 3 Th

Wire cross-section 0.08 bis 2.5 mm² Strip length 8 mm

6.5 Power supply

The supply connections Vk for the module electronics (I/O bus) and supply connections for the field devices (power contacts) of a terminal block are galvanically separated from each other and can be supplied via separate 24 V lation is required between I/O bus and field d devices can be supplied from a single voltage source.

en a spring-loaded terminal by slightly pushing with a screwdriver or a rod into the

square opening above the terminal.

he wire can now be inserted into the round terminal opening without any force.

e terminal closes automatically when the pressure is released, holding the wire securely and permanently.

voltage sources. If no electrical iso-

evices, the module electronics and the field

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

6.5

Power supply

NOTICE!

For the trouble-free operation of an I/O bus extension system, the ground connection of each other via a low-impedance connection (see Figure). This also includes the ground connection of the I/O bus power supply of the higher-level Fieldbus Coupler!

the I/O bus power supplies (V

0 V) of all terminal blocks must be connected with

of 82

Figure 7: Power supply of the terminal blocks

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

7COMMISSIONING

Please ensure that the safety I/O terminals are only transported, stored and operated under the specified conditions (see ZAp

CAUTION!

The ZCommis Appendix should be used during the commissioning phase.

Therefore:

m Make sure that the system is commissio m Make sure that there are no people in the danger zone during the initial commis-

sioning. Always anticipate that a machine, system or safety device may not behave as it is

m Never leave the system unsupervised during

variables in debug mode (forcing). The important safety functions may not be active in this form of operation. Make sure that no one enters the danger zone.

m If changes or expansions are conducted dur

fects on the behavior of the sy necessary to process the checklists for the planning and installation phase again.

sioning and validation checklist – on page 69 reproduced in the

intended to.

pendix D - Technical Data– from page 71 onward).

ned exclusively by qualified personnel.

commissioning with manually set

ing the commissioning process, the ef-

stem will have to be inspected. To do this, it will be

DANGER! Risk of injury! The safety I/O terminals must not be used

m under the influence of ionising radiation m in corrosive environments m in an environment that leads to unacce

Operation Manual Safety I/O Terminals SI4000 / SO4000

under the following operating conditions:

ptable soiling of the bus terminal

Document no.: 5.08009.05

of 82

7.1

Installation

7.1 Installation

7.1.1 Safety instructions

Before installing and commissioning the safety I/O terminals please read the chapter

fety– from page 15 onward.

ZSa

7.1.2 Transport and storage

Use the original packaging for transporting or storing the digital safety I/O terminals.

CAUTION! Note the specified environmental conditions

Please ensure that the digital safety I/O terminals are only transported and stored under the specified environmenta page 71 onward).

l conditions (see ZAppendix D - Technical Data– from

7.1.3 Mechanical installation

DANGER! Danger from electricity

Set the bus system into a safe, powered down state assembly or wiring of th

7.1.3.1 Control cabinet

The safety I/O terminals must be installed in a control cabinet or terminal box with IP54 protection class according to IEC 60529 as a minimum.

7.1.3.2 Installation of Bus Terminals on C mounting rails

See ZMounting rail installation– from page 36 onward.

7.1.4 Electrical installation

See ZElectrical installation– from page 37 onward.

e Bus Terminals!

before starting installation, dis-

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

7.1.5 SI4000 pin assignment

Commissioning

Figure 8: SI4000

Clamping point Input Signal

1 1 Input 1+

2 Input 1-

3 3 Input 3+

4 Input 3-

5 2 Input 2+

6 Input 2-

7 4 Input 4+

8 Input 4-

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

7.1

Installation

NOTICE! Configurable inputs

The inputs 1 to 4 can be occupied as you wan sponding analysis is carried out in the b maXX safe PLC.

7.1.5.1 Tested devices

The following list contains devices that were tested together with the SI4000 terminal. The results only apply for the current device hardware version at the time of testing. The tests were carried out in a laboratory environment. Modifications of these products cannot be considered here. If you are unsure please test the hardware together with the safety terminal.

Manufacturer Type Comment

SICK C4000 Safety light curtain

Wenglor SG2-141S045C1 Safety light grids

Leuze lumiflex ROBUST 42/43/44 Safety light barriers

Schmersal BNS250-11ZG Safety switch

ifm GM701S Inductive safety sensor

t with N/C or N/O contacts. The corre-

The tests were carried out as function tests o tive manufaturer documentation remains valid.

nly. The information provided in the respec-

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

7.1.6 SO4000 pin assignment

Commissioning

Figure 9: SO4000

Clamping point Input Signal

1 not used, no function

2 positive power contact

3 negative power contact

4 not used, no function

5 not used, no function

6 positive power contact

7 negative power contact

8 not used, no function

1’ 1 Output 1+

2’ Output 1-

3’ 3 Output 3+

4’ Output 3-

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

7.1

Installation

Clamping point Input Signal

5’ 2 Output 2+

6’ Output 2-

7’ 4 Output 4+

8’ Output 4-

NOTICE! Test pulses

When selecting actuators please ensure that the SO4000 test pulses do not lead to

ctuator switching or diagnostic message from the SO4000.

a The test pulses of the SO4000 terminal outputs are not configurable and cannot be

ed off.

switch

7.1.6.1 Tested devices

The following list contains devices that were tested together with the SO4000 terminal. The results only apply for the current device hardware version at the time of testing. The tests were carried out in a laboratory environment. Modifications of these products cannot be considered here. If you are unsure please test the hardware together with the safety terminal.

Manufacturer Type Comment

Beckhoff AX5801 TwinSAFE Drive option card: safe restart lock

Beckhoff AX2000 AS option Safe restart lock

Beckhoff KL2964 Three-channel contact extension with feedback

Siemens SIRIUS series S00

Telemecanique LP1K09 Contactor

Dold LG5929.54/100 Extension module with floating contacts

The tests were carried out as function tests o tive manufaturer documentation remains valid.

Contactor

3RT1016-1BB42

nly. The information provided in the respec-

of 82

NOTICE! Recommended protective circuits

We recommend R/C or diode-based protective circuits for these devices. Varistor-

sed protective circuits should not be used.

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

7.1.7 Address setting s on th e sa fe t y te rminals

Commissioning

Figure 10: Address setting

The address of the terminal is set via the 10-way Dip switch on the left-hand side of the safety terminal. Addresses between 1 and 1023 are available.

Dip switch  1 2 3 4 5 6 7 8 9 10

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0 ON OFF OFF OFF OFF OFF OFF OFF OFF OFF 1 OFF ON OFF OFF OFF OFF OFF OFF OFF OFF 2 ON ON OFF OFF OFF OFF OFF OFF OFF OFF 3 OFF OFF ON OFF OFF OFF OFF OFF OFF OFF 4 ON OFF ON OFF OFF OFF OFF OFF OFF OFF 5 OFF ON ON OFF OFF OFF OFF OFF OFF OFF 6

Address

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

7.1

Installation

Dip switch  1 2 3 4 5 6 7 8 9 10 ON ON ON OFF OFF OFF OFF OFF OFF OFF 7

... ... ... ... ... ... ... ... ... ... ...

ON ON ON ON ON ON ON ON ON ON 1023

WARNING! Unique safety address

Each address may only be used once within a network!

Address

7.1.8 Parameterization

7.1.8.1 SI4000 parameter overview

PrmName Meaning Values

S_Address Dip switch address 1 to 1023

Channel 1 Activation of channel 1 active/not active

Channel 2 Activation of channel 2 active/not active

Channel 3 Activation of channel 3 active/not active

Channel 4 Activation of channel 4 active/not active

Sensor test channel 1

Sensor test channel 2

Sensor test channel 3

Sensor test channel 4

The clock signal for connection Input1+ is checked at connection Input1-

The clock signal for connection Input2+ is checked at connection Input2-

The clock signal for connection Input3+ is checked at connection Input3-

The clock signal for connection Input4+ is checked at connection Input4-

active/not active

of 82

Channel 1 and 2For two-channel evaluation, inputs 1 and 2

must have the same signal states

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

single-channel evaluation/two-channel evaluation

Commissioning

PrmName Meaning Values

Channel 3 and 4For two-channel evaluation, inputs 3 and 4

must have the same signal states

Ambivalence channel 1 and 2

Ambivalence channel 3 and 4

7.1.8.2 SI4000 configuration for light barriers, light grids, light curtains etc.

The SI4000 also supports direct connection of contact-free protective eqipment with two self-testing outputs such as light barriers, light grids, light curtains, laser scanner etc.

CAUTION! Sensors with self-testing outputs

Only sensors with self-testing outputs and a 350 µs may be connected to the SI4000.

If active, inputs 1 and 2 must have different signal states

If active, inputs 3 and 4 must have different signal states

maximum sensor self-test duration of

single-channel evaluation/two-channel evaluation

not active/active

Parameter

To connect these sensors please set the follo ProMaster:

m Connect the two sensor signals either to channels 1 and 2 or channels 3 and 4 and

te the two-channel evaluation for the two inputs used.

activa m Set the SI4000 sensor test for the two inputs used to not

Operation Manual Safety I/O Terminals SI4000 / SO4000

wing parameters for the SI4000 in

active.

Document no.: 5.08009.05

of 82

7.1

Installation

CAUTION! No simultaneous sensor self-test

The sensor self-test must not set the two ch simultaneously.

with two-channel evaluation

annels for two-channel evaluation to LOW

7.1.8.3 SO4000 parameter overview

PrmName Meaning Values

S_Address Dip switch address 1 to 1023

Channel 1 Activation of channel 1 active/not active

Channel 2 Activation of channel 2 active/not active

Channel 3 Activation of channel 3 active/not active

Channel 4 Activation of channel 4 active/not active

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

7.1.8.4 Configuration of the safety SI4000 Parameter in ProSafety

Commissioning

Figure 11: ProSafety

h Switch to „Bus Configuration“ with the mouse

and mark the „Local I/O module / SI4000“.

=> The field „Safety parameter“ will be opened.

Here you can configure the SI40 such as „Watchdog time“, „Activation test pulse“, and so on.

Operation Manual Safety I/O Terminals SI4000 / SO4000

00 specific safety parameter

Document no.: 5.08009.05

of 82

7.1

7.1.8.5 Configuration of the safety SO4000 Parameter in ProSafety

Installation

Figure 12: ProSafety

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

h Switch to „Bus Configuration“ with the mouse

and mark the „Local I/O module / SO4000“.

=> The field „Safety parameter“ will

Here you can configure the SO4000 specific safety parameter „Watchdog time“.

be opened.

7.1.8.6 Meaning of the SI4000 and SO4000 diagnostic variables

Variable Value / Bit Meaning

w_LM*_SDx_Diag_01 Bit 0 0: Configuration data of the safety device is

invalid 1: Configuration data of the safety device is valid

Bit 1 0: Safety communication has not yet started

running to the safety device 1: Safety communication has started running to the safety device (display saved)

Bit 2 0: An error has not occurred

1: An error related to the safety device has occurred (saved display)

Bit 3 0: An error has not occurred

1: An error related to the safety device has occurred (current display)

Commissioning

Bit 4 0: Safe parameter download to the safety

device not active 1: Safe parameter download to the safety device active

Bit 5 0: Safety communication in another status

1: Safety communication running to the safety device in “FailSafeData” status

Bit 6 0: Safety communication in another status

1: Safety communication is running t device in “ProcessData” status (normal operation status)

Bit 7 0: No error reported by safety device

1: Safety device is reporting an error (FailSafeData)

Bit 8 – 15 Reserved

x stands for I with the input module and for O with the output module

o the safety

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

7.2

Diagnostic

7.2 Diagnostic

7.2.1 Diagnostic LEDs SI4000

Figure 13: Diagnostic LEDs SI4000

7.2.1.1 Diag 1 (green)

The Diag 1 LED indicates the state of the FSoE interface.

Flashing Code Meaning

LED illuminated continuously normal operation:

FSoE communication OK

rapid flickering, alternating with 1 flash pulse

rapid flickering, alternating with 2 flash pulses

rapid flickering, alternating with 3 flash pulses

rapid flickering, alternating with 4 flash pulses

rapid flickering, alternating with 5 flash pulses

rapid flickering, alternating with 6 flash pulses

rapid flickering, alternating with 7 flash pulses

rapid flickering, alternating with 8 flash pulses

Error in S parameter (Failsafe parameter

Error in I parameter (Individual parameter

Waiting for S and I parameter

S- and I-parameter correct: Waiting for first host message

Watchdog error

CRC error

Sequence number error

Intermediate state in a sensor

7.2.1.2 Diag 2 (red)

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

The Diag 2 LED illuminates red if the terminal detects an external supply or cross-circuit. Once the error has been rectified the LED goes out.

7.2.1.3 Diag 3 (red) and Dia g 4 (red)

The Diag 3 and Diag 4 LEDs indicate internal terminal errors.

NOTICE! Returning the terminal

These errors lead to shutdown of the termin mueller Anlagen-Systemtechnik GmbH

Diag 3 LED (red) Diag 4 LED (red) Source of error

Commissioning

al. The terminal must be checked by Bau-

& Co. KG.

Lit flashes (see below for

flashing codes)

Lit off µC2

In the event of a fault the Diag 4 LED indicates the The flashing codes are structured as follows:

Flashing sequence Meaning

Rapid flickering Start of flashing code

First slow sequence Error code

Second slow sequence Error code argument

Figure 14: Blinking sequence

µC1

type of error through flashing codes.

Count the number of flash pulses after the rapid flickering sequence

m during the first slow sequence in order to ascertain the error code m during the second slow sequence in order to ascertain the error argument

The flashing code is repeated after the seco ing.

Operation Manual Safety I/O Terminals SI4000 / SO4000

nd slow sequence, followed by rapid flicker-

Document no.: 5.08009.05

of 82

7.2

7.2.2 Diagnostic LEDs SO4000

7.2.2.1 Diag 1 (green)

Diagnostic

Figure 15: LEDs SO4000

The Diag 1 LED indicates the state of the FSoE interface.

7.2.2.2 Diag 2 (red)

Flashing Code Meaning

LED illuminated continuously normal operation:

FSoE communication OK

rapid flickering, alternating with 1 flash pulse

rapid flickering, alternating with 3 flash pulses

The Diag 2 LED indicates the state of the digital outputs.

Flashing Code Meaning

rapid flickering, alternating with 1 flash pulse

rapid flickering, alternating with 2 flash pulses

Communication error: The connection is not in „Run“ State

Output 1: Open load or current below minimum value of 20 mA or current above

ximum value of 500

Output 2: Open load or current below minimum value of 20 mA or current above

ximum value of 500

of 82

rapid flickering, alternating with 3 flash pulses

rapid flickering, alternating with 4 flash pulses

rapid flickering, alternating with 5 flash pulses

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Output 3: Open load or current below minimum value of 20 mA or current above

ximum value of 500

Output 4: Open load or current below minimum value of 20 mA or current above

ximum value of 500

field potential too low

Flashing Code Meaning

Commissioning

rapid flickering, alternating with 6 flash pulses

rapid flickering, alternating with 7 flash pulses

rapid flickering, alternating with 8 flash pulses

rapid flickering, alternating with 9 flash pulses

rapid flickering, alternating with 10 flash pulses

These errors can only be reset by switching the power supply for the safety terminal off and back again.

7.2.2.3 Diag 3 (red) and Dia g 4 (red)

See ZDiag 3 (red) and Diag 4 (red)– from page 55 onward.

7.3 Troubleshooting

field potential too high

terminal temperature too low

terminal temperature too high

Temperature difference error

error in output circuit through Open Load, external supply or cross-circuit

m Check wiring, check 24 V supply m SO4000: Pay attention to minimum current of 20 mA m The SAF module for the b maXX 5000, which is directly controlled via SO4000 must

cope with this ("Separate Grounds" of the type: BM5-O-SAF-002-001-xxx-#01 or BM5-O-SAF-003-001-xxx-#01 and the adapter for the safety-I/O-terminal).

m FSoE communication problems:

n Checking the address setting on the safety terminals (may be assigned once only) n Check if EtherCAT bus is running synchronously

m The setting of the cycle time in the ring must be the same all over

m The user must activate the bus synchronization in all b maXX 5000 controllers

(there is no automatic setting, as the EtherCAT slave is permanently integrated in the controller. The device is delivered as single device without a configured bus connection)

m Check grounding at the machine

m Regard EtherCAT cabling sequence by starting from the EtherCat master (for ex-

ample, if b maXX 5000 controllers are integrated): Cable of EtherCAT master → Connection at (input) terminal “X3” (of the b maXX

5000), of (output) terminal “X4” → go to the next EtherCAT slave

n Incorrect mapping of the FSoE participants in the configuration software n Mapped participants are missing at the EtherCAT bus

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

7.4

Maintenance

7.4 Maintenance

The digital safety input terminal SI4000 and the digital safety output terminal SO4000 are maintenance free!

WARNING! Observe the specified environmental conditions!

Please ensure that the safety terminals are only stored and operated under the specified conditions (see ZAppendix

D - Technical Data– from page 71 onward).

7.4.1 Cleaning

7.4.2 Service life

If the terminal is operated outside the permitted temperature range it will sw fault state.

Protect the safety terminal from unacceptable soiling during operation and storage! If the safety terminals were subjected to unacc

erated!

WARNING! Have soiled terminals checked!

Cleaning of the safety terminal by the user Please send soiled terminals to the manufacturer for inspection and cleaning!

The safety terminals are designed for a service life of 20 years. Due to the high diagnostic coverage within the

quired.

eptable soiling they may no longer be op-

is not permitted!

lifecycle no special proof tests are re-

itch to global

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

8SYSTEM VALIDATION

All safety functions as well as the trouble-free functioning of the installed and programmed system must be tested with the initial o be documented.

WARNING! Danger during commissioning!

peration. The testing of the system must

8.1 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.

Use the project documentation printed out by ProSafety to conduct the function test. The instru handbook.

The control system may only be put into commission aft by 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 valida

pendix ZC.2 Commission validation of the system in accordance with this checklist and document the procedure accordingly.

m Make sure that operating personnel has been instru

trol system.

ctions on handling the project documentation can be found in the programming

ing and validation checklist– on page 69. Conduct the

tion of the system is reproduced in Ap-

er being tested successfully

cted in the handling of the con-

Depending on the complexity of the logic circuit of ed to conduct the function tests in steps.

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

the respective project, it is recommend-

of 82

8.1

Function test

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

1 Separate all actuators and drives from the output terminals electrically. 2 Test the logic circuit by forcing variables in the ProSafety safe programming interface

3 Only connect the actuators and drives to the safe output terminals once no errors have

4 Conduct a complete function test with all sensors (initiators), switches, actuators and

(see chapter “FORCING AND OVERWRITING“ in the safe PLC function. Also check whether the evaluation of multi-channel safety components is con ducted in a multi-channel manner.

been detected in the inspection of the logic circuit.

drives.

To conduct the function tests, trigger all safety functions sequentially and document the system’s reaction. Check whether the reaction corresponds with the expected behav ior.

The function test must lead to the following results:

<). Check whether the behavior of the logic corresponds with the expected

n the logical allocation of all system components is correct n the allocation of all system components is complete

>Application Manual b maXX

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

9DISMANTLING, STORAGE

In this chapter, we will describe how you decommission the terminals store it. Observe the information in chapter ZSafety– from

page 15 onward.

9.1 Safety regulations

Bring the bus system into a safe, powered down state before starting disassembly of the Terminals! Only specially trained personnel are allowed to dismantle the terminals. The safety regulations for commissioning apply analogously to dismantling.

9.2 Requirements of the personnel carrying out work

The personnel that carries out dismantling must have the necessary knowledge and have been trained appropriately to carry out this work. Choose these persons such that they understand and can apply the safety instructions printed on the unit and parts of it and on the connections.

9.3 Decommissioning

DANGER! Serious risk of injury!

Set the bus system into a safe, de-energized state before starting disassembly of the

s terminals!

9.4 Disassembly

Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

9.5

Storage conditions

Figure 16:

1 Carefully pull the orange-colored lug approximately 1 cm out of the disassembled ter-

minal, until it protrudes loosely. The lock with the terminal, and the terminal can be pulled from the mounting rail without excessive force.

sp the released terminal with thumb and index finger simultaneous at the upper and

2 Gra

lower grooved housing surfaces and pull the terminal away from the mounting rail.

9.5 Storage conditions

Store the terminals in suitable packaging according to the storage conditions in

pendix D - Technical Data– from page 71 onward.

ZAp

9.6 Recommissioning

If you want to recommission the terminals, observe the information in "Storage Conditions" in ZAp

Then, carry out ZAss

9.7 Disposal

In order to dispose of the device, it must be removed and fully dismantled.

m Housing components (polycarbonate,

cycling.

m Metal parts can be sent for metal recycling. m Electronic parts such as disk drives and cir

dance with national electronics scrap regulations.

mounting rail is now released for this

pendix D - Technical Data– from page 71 onward.

embly and Installation– from page 35 onward again.

polyamide (PA6.6)) are suitable for plastic re-

cuit boards must be disposed of in accor-

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

APPENDIX A - ABBREVIATIONS

CPU Central Processing Unit DC Diagnostic Coverage Diag Diagnostic LED DIN Deutsches Institut für Normung

EMC Electromagnetic compatibility EN European standard FSoE Safety protocol „Safety over Ether-

HFT Hardware Failure Tolerance I/O Input/Output I/O bus Bus between b maXX safe PLC

LED Light-emitting diode MTTF PFD Probability of Failure on Demand PFH Probability of Failure per Hour PLC Process loop control, stored Pro-

RAM Random Access Memory ROM Read Only Memory SFF Safe Failure Fraction (Fraction of

SIL Safety Integrity Level SW Software

e.V.

CAT“

and the modules right of the PLC and/or power supply

Mean Time To Failure

gram Control, SPS

failures which lead to safe status)

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

This appendix lists all accessory items which are available from Baumüller Nürnberg GmbH for the safety I/O terminals.

If you have enquiries or suggestions on the accessory items, the Baumüller product management will be glad to assist you.

B.1 List of all accessory items

At the moment there are no accessories available for the I/O terminals.

APPENDIX B - ACCESSORIES

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

B.1

List of all accessory items

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

The use of checklists serves documentation purposes and guides in the implementation of a safety system. The checklists reproduced in Appendix C - Checklists serve to prevent errors and must be processed carefully for every project. It is also required to make cop ies of the printed checklists.

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

C.1 Installation checklist

APPENDIX C - CHECKLISTS

Serial no.

1 Installation

1.1 Has it been ensured that there are no short

1.2 Has it been ensured that the safety switch

1.3 Has a wiring inspection in accordance with

1.4 Are all connection plugs labelled according

1.5 Are the connection terminals loaded with

1.6 Has it been ensured that the insulation of

1.7 Has the reliability of all terminal connections

Requirement Fulfilled Remarks

circuits from the wiring of the input and out put terminals?

devices have not been bypassed as a result of wiring errors?

the installation plan been conducted

to their allocation?

the specified clamping torque?

the lines is not causing any faulty contacts?

been tested through mechanical tensile loading?

Yes No

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

C.1

Installation checklist

Serial no.

1.8 Has a visual inspection of the installed com-

1.9 Have the required installation spacings to

1.10 Do the components meet the environmental

1.11 Does the system fulfil the required type of

1.12 Is degree of pollution 2 complied with?

1.13 Is the system protected against corrosive

Date Name Signature

Requirement Fulfilled Remarks

Yes No

ponents been conducted?

other components been complied with?

conditions prevailing in the application?

protection?

substances?

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

C.2 Commissioning and validation checklist

Checklists

Serial no.

2 Commissioning

2.1 Has it been ensured that all safe communi-

2.2 Has a complete function test been con-

2.3 Has the operating personnel been

Date Name Signature

Requirement Fulfilled Remarks

Yes No

cation participants of a system have a

ique safe device address? This also

un applies to participants belonging to different safety controls, if the controls are connected to one another via gateways (such as ethernet).

ducted and documented?

instructed in the handling of the control system?

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

C.2

Commissioning and validation checklist

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

In this appendix, you will find the technical data for Baumüller Nürnberg GmbH's Safety I/O terminals.

D.1 Connection technology

Connection technology

Wiring Cage Clamp® spring-loaded system

Connection cross-section 0.08 mm² ... 2.5 mm², AWG 28-14, stranded wire, solid

Field bus connection depending on fieldbus

Power contacts up to 3 blade/spring contacts

Current load 10 A

Nominal voltage depends on bus terminal type

D.2 Connection values

APPENDIX D - TECHNICAL DATA

wire

Product name SI4000

Number of inputs 4

Number of outputs 0

Status display 4 (one green LED per output)

Response time (read input / write to I/O bus)

Fault response time < watch dog time (adjustable from 5 ms to 100 ms)

Cable length between sensor and terminal (unscreened line)

Cable length between sensor and terminal (screened line)

Operating Instructions Safety I/O Terminals SI4000 / SO4000

typical: 4 ms maximum: see fault response time

max. 100 m (at 0.75 mm² or 1 mm²)

Dokument-Nr.: 5.08009.05

of 82

D.2

Connection values

Product name SI4000

Input process image 6 bytes

Output process image 6 bytes

SI4000 supply voltage 24 VDC (-15% / +20%)

Current consumption of the modular electronics at 24 V (without current consumption of sensors)

Current consumption from I/O-bus 4 channel occupied: typically 47 mA

Power dissipation of the terminal typically 540 mW

Electrical isolation (between the channels)

Electrical isolation (between the channels and the I/O bus)

Insulation voltage (between the channels common operating conditions)

Permissible contamination level Contamination level 2

Unacceptable operating conditions Safety terminals must not used under the following

and the I/O bus, under

4 channel occupied: typically 12 mA 0 channel occupied: typically 1 mA

0 channel occupied: typically 33 mA

yes

isolation checked with 500 VDC

(see chapter ZCleaning– on page 58)

operating conditions:

m under the influence of ionising radiation m in corrosive environments m in an environment that leads to unacceptable soil-

ing of the bus terminal

Shocks 15 g with pulse duration 11 ms in all three axes

Protection class IP20

Permitted operating environment control cabinet or terminal box with minimum protec-

tion class IP54 according to IEC 60529

Permissable installation position any

Approvals CE

Product name SO4000

Number of inputs 0

Number of outputs 4

Status display 4 (one green LED per output)

Output current per channel max. 500 mA, min. 20 mA per channel

Cable length between sensor and terminal (unscreened line)

Fault response time < watch dog time

max. 100 m

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

Product name SO4000

Technical Data

Cable length between sensor and terminal (screened line)

Wire cross section min. 0.75 mm²

Input process image 6 bytes

Output process image 6 bytes

SO4000 supply voltage 24 VDC (-15% / +20%)

Current consumption from I/O-bus max. 250 mA

Power dissipation of the terminal typically 2 W

Electrical isolation (between the channels)

Electrical isolation (between the channels and the I/O bus)

Insulation voltage (between the channels and the I/O bus, under

mon operating conditions

com

Permissible contamination level Contamination level 2

Unacceptable operating conditions Safety terminals must not used under the following

)

max. 100 m

yes

insulation checked with 500 VDC

(see chapter ZCle

operating conditions:

er the influence of ionising radiation

m und m in co m in a

rrosive environments

n environment that leads to unacceptable soil-

ing of the bus terminal

aning– on page 58)

Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27

Shocks 15 g with pulse duration 11 ms in all three axes

Protection class IP20

Permitted operating environment control cabinet or terminal box with minimum protec-

tion class IP54 according to IEC

Permissable installation position horizontal

Approvals CE

WARNING!

The operating conditions specified in the ta time.

ble above may not be exceeded at any

60529

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

D.3

D.3 Operating conditions

D.3.1 Climatic properties

Operating conditions

Product SI4000

Permissible ambient temperature (operation)

Permissible ambient temperature (transport and storage)

Permissible relative air humidity 95 %, non-condensing

Climate class according to

60721-3-3

Permissable air pressure (operation, storage, transport)

Product SO4000

Permissible ambient temperature (operation)

Permissible ambient temperature (transport and storage)

Permissible relative air humidity 95 %, non-condensing

Climate class according to

60721-3-3

0°C ... +55°C

-25°C ... +70°C

3K3

750 hPa to 1100 hPa

0°C ... +55°C

-25°C ... +70°C

3K3

Permissable air pressure (operation, storage, transport)

D.3.2 Mechanical properties

Product SI4000

Material polycarbonate, polyamide (PA 6.6)

Dimensions (W x H x D) 12 mm x 100 mm x 68 mm

Mounting on 35 mm mounting rail (conforms to EN 50022) with

Attachable by double slot and key connection

Weight approx. 50 g

750 hPa to 1100 hPa

lock

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

Product SO4000

Material polycarbonate, polyamide (PA 6.6)

Dimensions (W x H x D) 24 mm x 100 mm x 68 mm

Mounting on 35 mm mounting rail (conforms to EN 50022) with

Attachable by double slot and key connection

Weight approx. 100 g

D.3.3 EMC properties

Product SI4000 and SO4000

EMC resistance burst conforms to EN 61000-6-2

ESD emission conforms to EN 61000-6-4

lock

Technical Data

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

D.3

Operating conditions

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

APPENDIX E - DECLARATION OF

In this section we provide general information about EC directives, the CE symbol and the Declaration of Conformity.

E.1 What is an EC directive?

EC directives specify requirements. The directives are written by the relevant bodies within the EU (which used to be called the EC, and the EEC before that, hence the now illogical term EC directive), and are implemented by all the member countries of the EU in national law. In this way the EC directives guarantee free trade within the EU.

An EC directive only contains essential minimum requirements. You will find detailed requirements in standards, to which references are made in the directive.

E.2 What the CE symbol indicates

a) The CE marking symbolizes conformity to all the obligations incumbent on manufacturers for the product by virtue of the Community directives providing for its affixing.

…

CONFORMITY

b) The CE marking affixed to industrial products symbolizes the fact that the natural or legal person having affixed or be en responsible for the affixing of the said marking has verified that the product conforms to all the Community total harmonization provisions which apply to it and has been the subject of the appropriate conformity evaluation pro cedures.

…

Council Decision 93/465/EEC, Annex I B. a) + c)

We affix the CE mark to the equipment and to the operating instructions as soon as we have established that we have satisfied the requirements of the relevant directives.

I/O terminals supplied by the Baumüller Nürnberg GmbH are not concerned of the Low Voltage Directive, because their operating voltage is less than 60 75

V AC. Therefore a declaration of conformity to 2006/95/EC (Low Voltage Directive)

cannot be issued.



Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

V DC or less than

of 82

Definition of the term Declaration of Conformity

The electrical safety and function of the I/O terminals will be checked with the harmonized standard EN

With specified application of this Baumüller equipment in your machinery, you can act on the assumption that the equipment satisfies the requirements of 2006/42/EG (machinery directive). Therefore the equipment is developed and constructed in such a way, that the requirements of the harmonized standard EN 60204-1 can be met by the electrical installation.

I/O terminals supplied by the Baumüller Nürnberg GmbH satisfy the requirements of 2014/30/EU (EMC Directive) by satisfying the requirements of the harmonized standard EN

61000-6-2 and EN 61000-6-4.

To enable you to market your machine within the EU, you must be in possession of the following:

m Conformity mark (CE mark) m Declaration(s) of Conformity regarding the directive(s) relevant to the machine

E.3 Definition of the term Declaration of Conformity

A Declaration of Conformity as defined by this operating instruction is a declaration that the electrical equipment brought into circulation conforms to all the relevant fundamental safety and health requirements.

61508, part 1-3.



By issuing the Declaration of Conformity in this section the Baumüller Nürnberg GmbH declares that the equipment conforms to the relevant fundamental safety and health re quirements resulting from the directives and standards which are listed in the Declaration of Conformity.

E.4 Declaration of Conformity

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Declaration of EC conformity Doc.-No.: 5.10067.01

Date: 2015-03-04

according to machinery directive 2006/42/EC

We the manufacturer: Baumüller Nürnberg GmbH 

Ostendstraße 80-90 

90482 Nürnberg, GERMANY declare that our product Name: Safety I/O Terminals 

Type: SI4000, SO4000 Date of manufacture: 2015-03-04

was developed, constructed and manufactured according to the machinery directive 2006/42/EC. Applied harmonized standards:

Authorized person for preserving relevant technical documents:  Name: Engelbert Meier, Baumüller Nürnberg GmbH Address: Ostendstraße 80-90, 90482 Nürnberg, Germany

Notified body which has provided the EC type-Examination Certificate in accordance with the machinery directive mentioned above:  Name: TÜV Süd Product Service GmbH  Address: Ridlerstr. 65, 80339 München / Germany  Notified body number: 0123  Registration number: Z10 15 03 75013 001 (SI4000) and Z10 15 03 75013 003 (S04000)

The safety instructions in the manual must be observed. This product is designed for integration in a machine. The commissioning is not allowed until the entire machine, in which this product is integrated, is complying with the directives mentioned above.

Nürnberg / 2015-03-04

Location / Date

subject to change of this declaration of EC conformity without notice. Actual valid edition on request

Standard Title

EN 61508-1:2010 Functional safety of security-related electric, electronic and programmable electronic systems - Part 1:

General requirements

EN 61508-2:2010 Functional safety of security-related electric, electronic and programmable electronic systems - Part 2:

Requirements for electrical/electronic/programmable electronic safety-related systems

EN 61508-3:2010 Functional safety of security-related electric, electronic and programmable electronic systems - Part 3:

Software requirements

EN ISO 13849-1:2008 Safety of machinery – Safety-related parts of control systems –

Part 1: General principles for design

DIN EN 81-1:2000 (to the extent to which they may be applicable)

Safety rules for the construction and installation of lifts - Part 1: Electric lifts

EN 13243:2004 (to the extent to which they may be applicable)

Safety requirements for cableway installations designed to carry persons - Electrical equipment other than for drive systems

DIN EN 61000-6-2:2006 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environ-

ments

DIN EN 61000-6-4:2007 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial

environments

Declaration of Conformity

Operation Manual Safety I/O Terminals SI4000 / SO4000

Document no.: 5.08009.05

of 82

Declaration of Conformity

of 82

Operation Manual Safety I/O Terminals SI4000 / SO4000 Document no.: 5.08009.05 Baumüller Nürnberg GmbH

Index

Numerics

2006/95/EC 77

Address setting 47 Appropriate use 15

C mounting rails 36 CE symbol 77 Certification 11 Checklists 67 Cleaning 58 Climatic properties 74 Configuration

SI4000 49

Conformity

Declaration 78 Connection technology 71 Control cabinet 36 Copyright 10

Declaration of Conformity 77 Decommissioning 61 Diagnostic Coverage (DC) 26 Diagnostic LEDs

SI4000 54

SO4000 56 Dimensions

SI4000 32

SO4000 33 Disassembly 61 Disposal 62

EC directive 77 EMC properties 75

Firefighting 21 Function test 59

Mean Time To Failure (MTTFd) 26 Mechanical properties 74

Operating personnel 18

Parameter overview

SI4000 48

SO4000 50 PE power contact 38 Personnel protective equipment 19 Pin assignment

SI4000 43

SO4000 45 Power supply 39 Preface 7 Probability of Failure on Demand (PFD) 25 Probability of Failure per Hour (PFH) 25 Protective equipment 17

Qualified personnel 18

Safety 15 Safety aspects 15 Safety-related parameters 25 Service life 58 SI4000 11 SO4000 11 SO4000 Test pulses 46

Technical Data 71 Terms

Definition 11 Test pulses 46

Unacceptable operating conditions 72

General description

SI4000 29 SO4000 30

Waranty conditions 11 Wiring 39

Hardware Failure Tolerance 25

Limitation of liability 9 Low Voltage Directive 77

Operating Instructions Safety I/O Terminals SI4000 / SO4000

Dokument-Nr.: 5.08009.05

of 82

Stichwortverzeichnis

of 82

Operating Instructions Safety I/O Terminals SI4000 / SO4000 Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH

Baumüller Nürnberg GmbH Ostendstraße 80-90 90482 Nuremberg Tel: +49(0)911-5432-0 Fax: +49(0)911-5432-130

All the information in these Operating Instructions is non-binding customer information; it is subject to ongoing further development and is updated on a continuous basis by our permanent change management system. Note that all the data/numbers/information that are quoted are current values at the time of printing. This information is not legally binding for dimensioning, calculation and costing. Before using the information listed in these Operating Instructions as the basis for your own calculations and/or applications, make sure that you have the latest most current information. This means that we accept no resonsibility for the accuracy of the information.

www.baumueller.de

Baumuller SI4000, SO4000 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 Information on the Operation Manual

1.2 Legend

1.3 Limitation of liability

1.4 Preliminary information

1.5 Copyright

1.6 Further applicable documents

1.7 Replacement parts

1.8 Disposal

1.9 Warranty conditions

1.10 Customer service

1.11 Terms used

1.12 Certification

1.12.1 Approvals, directives and standards

3.1 Contents of the Operation Manual

3.2 Alterations and rebuilding of the device

3.3 Appropriate use

3.4 Operator responsibility

3.5 Protective equipment

3.6 Personnel training

3.7 Personnel protective equipment

3.8 Special dangers

3.9 Firefighting

3.10 Electric safety

3.10.1 Notice on power supply

3.11 Safety equipment

3.12 Conduct in the event of danger and accidents

3.13 Signage

4.1 Safety-related parameters

4.2 Lifetime

4.3 Using of the terminals with b maXX safe PLC

5.1 General description

5.1.1 SI4000 4-channel safety digital input terminal

5.1.2 SO4000 4-channel safety digital output terminal

5.2 Appropriate use

5.3 Technical data

5.4 Dimensions

5.4.1 SI4000

5.4.2 SO4000

6.1 Safety instructions

6.2 Transport and storage

6.3 Installation of Bus Terminals on C mounting rails

6.3.1 Control cabinet

6.3.2 Mounting rail installation

6.4 Electrical installation

6.4.1 Connections within a bus terminal block

6.4.2 Wiring

6.5 Power supply

7.1 Installation

7.1.1 Safety instructions

7.1.2 Transport and storage

7.1.3 Mechanical installation

7.1.3.1 Control cabinet

7.1.3.2 Installation of Bus Terminals on C mounting rails

7.1.4 Electrical installation

7.1.5 SI4000 pin assignment

7.1.5.1 Tested devices

7.1.6 SO4000 pin assignment

7.1.6.1 Tested devices

7.1.7 Address setting s on th e sa fe t y te rminals

7.1.8 Parameterization

7.1.8.1 SI4000 parameter overview

7.1.8.2 SI4000 configuration for light barriers, light grids, light curtains etc.

7.1.8.3 SO4000 parameter overview

7.1.8.4 Configuration of the safety SI4000 Parameter in ProSafety

7.1.8.5 Configuration of the safety SO4000 Parameter in ProSafety

7.1.8.6 Meaning of the SI4000 and SO4000 diagnostic variables

7.2 Diagnostic

7.2.1 Diagnostic LEDs SI4000

7.2.1.1 Diag 1 (green)

7.2.1.2 Diag 2 (red)

7.2.1.3 Diag 3 (red) and Dia g 4 (red)

7.2.2 Diagnostic LEDs SO4000

7.2.2.1 Diag 1 (green)

7.2.2.2 Diag 2 (red)

7.2.2.3 Diag 3 (red) and Dia g 4 (red)

7.3 Troubleshooting