Kollmorgen KSM31R Installation Manual

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Installation Manual
Installation Manual
for
KSM31R
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Installation Manual
The German version is the original version of the installation manual Status: 09/2015 Valid from FW release 2.0.2.31
Subject to change without prior notification The contents of this documentation has been collated with greatest care and corresponds with our present status of information. However, we would like to point out, that this document cannot always be updated at the same time as the technical further development of the products. Information and specifications can be changed at any time. Please keep yourself informed about the current version under www.kollmorgen.com.
Devices of the Kollmorgen Europe GmbH
Pempelfurtstraße 1 DE-40880 Ratingen
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Table of Contents
1 IMPORTANT NOTES .......................................................................................... 4
1.1 Definitions ........................................................................................................................................... 4
1.2 Co-valid documents ............................................................................................................................. 4
1.3 Abbreviations used .............................................................................................................................. 5
2 SAFETY REGULATIONS .................................................................................... 6
2.1 Operation and service ......................................................................................................................... 6
2.2 Transportation / storage ..................................................................................................................... 6
3 DEVICE TYPES ................................................................................................... 7
3.1 Characteristic data of device ................................................................................................................ 7
3.2 Identification ....................................................................................................................................... 8
3.3 Scope of delivery ................................................................................................................................. 8
4 CONNECTION AND INSTALLATION ................................................................. 9
4.1 General notes on installation ............................................................................................................... 9
4.2 Installation and assembly of the KSM module ................................................................................... 10
4.3 Installation of backplane bus system ................................................................................................. 10
4.4 Assembling the modules .................................................................................................................... 11
4.4.1 Assembly on C-rail............................................................................................................. 11
4.4.2 Assembly on backplane bus .............................................................................................. 12
4.5 Terminal assignment ......................................................................................................................... 14
5 SAFETY RELATED WIRING OF OUTPUTS ..................................................... 16
5.1 General specifications for wiring and testing ..................................................................................... 16
5.2 Wiring of the relay outputs ................................................................................................................ 17
5.2.1 Single-pole switching relay output without testing ............................................................. 17
5.2.2 Single-pole switching relay with external switching amplifier and testing ......................... 18
5.2.3 Dual-channel switching relay output with external monitoring group feedback ................ 19
5.2.4 Two-channel relay output – external control circuit with monitoring .................................. 20
5.2.5 Dual-channel relay output with external control circuit in PL e .......................................... 21
6 CONFIGURING THE KSM31R .......................................................................... 22
6.1.1 Basic configuration ............................................................................................................ 22
6.1.2 Step 2 ................................................................................................................................ 23
6.1.3 Step 3 ................................................................................................................................ 23
6.1.4 Step 4 ................................................................................................................................ 24
7 MAINTENANCE ................................................................................................ 25
7.1 Modification / handling changes to the device .................................................................................. 25
7.2 Exchanging a module ......................................................................................................................... 25
7.3 Maintenance intervals ....................................................................................................................... 25
8 TECHNICAL DATA ........................................................................................... 26
8.1 Environmental conditions .................................................................................................................. 26
8.2 Load carrying capacity of outputs ...................................................................................................... 26
8.3 Technical data of switching relay ....................................................................................................... 26
8.4 Safety-related characteristic data ...................................................................................................... 27
8.4.1 Single-channel use of the relay output according to 5.2.2 ................................................ 27
8.4.2 Dual-channel use of the relay output according to 5.2.3, 5.2.4 or 5.2.5............................ 27
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Description
Reference
Installation manual for KSM module series KSM10/11/12
HB-37350-810-01-xxF-DE KSM Installation manual
Acceptance test
TÜV certificate for product modules KSM31R

1 Important notes

Definition of individual target groups Project engineers for secure drive systems:
Engineers and technicians Assembly, electric installation, maintenance and replacement of devices
Maintenance electricians and service technicians Commissioning, operation and configuration:
Technicians and engineers

1.1 Definitions

The designation KSM is used as generic term for all derivatives from the KSM product range. Wherever this description refers to a certain derivative, the complete designation is used.
The term “safe” used in the following text in any case refers to the classification as a safe function for application up to Pl e acc. to EN ISO 13849-1 or SIL3 acc. to EN 61508.
The system software “SafePLC” serves the purpose of configuring and programming KSM modules.
The modules of the KSM series are internally built up of two independent processing units. In the following these are referred to as system A and system B.

1.2 Co-valid documents

Note:
Thoroughly read the manuals before you start the installation and the commissioning of the KSM module.
Paying attention to the documentation is a prerequisite for trouble-free operation and fulfilment of possible warranty claims.
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Abbreviation
Meaning
AC
Alternating voltage
IL
Instruction list
ELIA
Employer's liability insurance association
CLK
Clock (cycle)
CPU
Central Processing Unit
DC
Direct voltage
DI1..DI14
Digital Input
DIN
Deutsches Institut für Normung (German Institute for Standardization)
DO
Digital Output
EMU
Emergency Monitoring Unit
EMC
Electromagnetic compatibility
ELC
Emergency Limit Control
EN
European Standard
HISIDE
Output with 24 VDC nominal level switching to plus
IP20
Degree of protection for housing
ISO
International Organisation for Standardisation
LED
Light Emitting Diode
LOSIDE
Output switching to reference potential
OLC
Operational Limit Control
PIA
Process image of outputs
PII
Process image of inputs
P1,P2
Pulse outputs
PLC
Programmable Logic Controller
POR
Power on Reset
PSC
Position Supervision Control
SELV
Safety Extra Low Voltage
SSI
Synchronous Serial Interface
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik e. V. technology)

1.3 Abbreviations used

(association for electrical engineering, electronics and information
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2 Safety regulations

Intended use You can only operate the KSM31R module with a basic module. This means that the same
safety regulations apply as for the KSM10/11/12 modules.

2.1 Operation and service

The module must always be de-energized before installation and removal, or before disconnecting signal lines.
When installing or removing the module appropriate measures must be applied to prevent electrostatic discharge to the externally arranged terminal and plug connections.

2.2 Transportation / storage

Information concerning transport, storage and proper handling must be strictly followed. The climate related specifications in chapter “Technical data” must be complied with.
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Type designation
Device design
Design of module with the following periphery:

3 Device types

3.1 Characteristic data of device

12 digital inputs (DI 1-4 and DI8-12 OSSD) 2 I/Os optionally configurable as input or output
4 secure relay outputs 2 pulse outputs 2 signal outputs
12 status LEDs for inputs 10 status LEDs for I/O/relay output 1 backplane bus interface
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3.2 Identification

The type plate is located on the left side wall of the module and contains the following information:
Type designation Part number Serial number Identification of hardware release Identification of software release Safety categ ory Input characteristics Output characteristics
Type plate KSM31R (image enlarged)

3.3 Scope of delivery

The scope of delivery contains:
KSM31R module:
A plug for all the signal terminals
A backplane bus connector
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4 Connection and install a t ion

4.1 General notes on installation

Strictly follow the safety regulations when installing! Type of protection IP20
Route all signal lines for the interfacing of digital inputs and contact monitoring separately. In any case isolate 230 VAC voltages from low voltage lines, if these voltages are used in connection with the application.
The cable lengths for digital inputs and outputs must not exceed 30 m. Measures concerning the electromagnetic compatibility (EMC) The KSM module is intended for use in the drive environment and meets the
EMC-requirements mentioned above. It is also assumed that the electromagnetic compatibility of the overall system is ensured by application of appropriate measures.
Safety note: Electric power supply lines of the KSM and “discontinuous-action lines” of the power converter must be isolated from each other. Signal lines and power lines of the power converter must be routed through separate cable ducts. The distance between the cable ducts should be minimum 10 mm. Only shielded cables must be used to connect the position and speed sensors. The signal transmission cable must be RS-485-standard compliant (lines twisted in pairs). Care must be taken to ensure that the shielding is correctly connected in the 9-pin SUB-D plugs of the position and speed sensors. Only metal or metal coated plugs are permitted. The shielding on the sensor side must comply with appropriate methods. EMC-compliant installation of the power converter technology in the environment of th e KSM module must be assured. Special attention must be paid to the routing of cables, the shielding of motor cables and the connection of the braking resistor. Strict compliance with the installation instructions of the power converter manufacturer is mandatory. All contactors in the environment of the power converter must be equipped with appropriate suppressor circuits. Suitable measures to protect against overvoltages must be applied.
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KSM5x
KSM31R
KSM11

4.2 Installation and assembly of the KSM module

The module is solely to be installed in control cabinets, with a degree of protection of at least IP54.
The modules must be vertically fastened on a top hat rail The ventilation slots must be kept unobstructed, to ensure adequate air circulation inside
the module.

4.3 Installation of backplane bus system

The KSM31R module is connected to the base unit via the backplane bus. Example: KSM11 + KSM31R + KSM5x
(Base unit + KSM31R + communication module)
The KSM31R module is supplied with power via the backplane bus from the base unit. The digital outputs are supplied with power via plug connector X11 on the KSM31R module.
Note:
A maximum of 2 extension modules can be connected to a base unit. (Excl. bus module)
You must not connect several base units with extension modules to one backplane bus connection.
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4.4 Assembling the modules

The modules are mounted on C-standard rails by means of snap-on latches.

4.4.1 Assembly on C-rail

The devices are inserted into the rail under an oblique angle and then snapped on downwards. For disassembling use a screwdriver, insert it into the slot of the downwards pointing latch and then move it up.
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4.4.2 Assembly on backplane bus

After assembling the backplane bus, you can install the device. For this purpose insert the module from above into the plug connection under a oblique angle and snap it onto the C-rail.
Insert the module from above under an oblique angle.
Snap-on downwards on to the C-rail.
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The backplane plug connection can later be extended. The system configuration can thus be extended by additional modules.
Snap the backplane bus element into the C-rail and insert it into the counter-piece by sliding it sideways.
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Terminal
Designation
Function
X07:1
K1/11
Readback contact relay 1
X08:1
K3/11
Readback contact relay 3
X09:1
K5/11
Readback contact relay 5
X10:1
K7/11
Readback contact relay 7
X11:1
U24 external
IO voltage supply device +24 VDC
X12:1
IO01
I/O extension 1 (EAEx.1 / EAAx.1)
X13:1
Not used
X14:1
Digital IN01
Digital input 01 (Ex.1)
X17:1
K1.1
Relay output 1
X18:1
K3.1
Relay output 3

4.5 Terminal assignment

X07:2 X07:3 X07:4
X08:2 X08:3 X08:4
X09:2 X09:3 X09:4
X10:2 X10:3 X10:4
X11:2 X11:3 X11;4
K1/12 K2/11 K2/12
K3/12 K4/11 K4/12
K5/12 K6/11 K6/12
K7/12 K8/11 K8/12
U24 external GND external GND external
Readback contact relay 1 Readback contact relay 2 Readback contact relay 2
Readback contact relay 3 Readback contact relay 4 Readback contact relay 4
Readback contact relay 5 Readback contact relay 6 Readback contact relay 6
Readback contact relay 7 Readback contact relay 8 Readback contact relay 8
IO voltage supply device +24 VDC IO voltage supply device 0 VDC IO voltage supply device 0 VDC
X12:2 X12:3 X12:4
X13:2 X13:3 X13:4
X14:2 X14:3 X14:4
X17:2 X17:3 X17:4
X18:2 X18:3 X18:4
IO02 P1 P2
Ax.1 Ax.2
Digital IN02 Digital IN03 Digital IN04
K1.2 K2.1 K2.2
K3.2 K4.1 K4.2
I/O extension 2 (EAEx.2 / EAAx.2) Pulse output P1 Pulse output P2
Not used Semi-conductor output Ax.1 (not a safety output) Semi-conductor output Ax.2 (not a safety output)
Digital input 02 (Ex.2) Digital input 03 (Ex.3) Digital input 04 (Ex.4)
Relay output 1 Relay output 2 Relay output 2
Relay output 3 Relay output 4 Relay output 4
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X19:1
K5.1
Relay output 5
X20:1
K7.1
Relay output 7
X21:1
Not used
X22:1
Not used
X23:1
Digital IN05
Digital input 05 (Ex.5)
X24:1
Digital IN09
Digital input 09 (Ex.9) (OSSD)
X19:2 X19:3 X19:4
X20:2 X20:3 X20:4
X21:2 X21:3 X21:4
X22:2 X22:3 X22:4
X23:2 X23:3 X23:4
K5.2 K6.1 K6.2
K7.2 K8.1 K8.2
Digital IN06 Digital IN07 Digital IN08
Relay output 5 Relay output 6 Relay output 6
Relay output 7 Relay output 8 Relay output 8
Not used Not used Not used
Not used Not used Not used
Digital input 06 (Ex.6) Digital input 07 (Ex.7) Digital input 08 (Ex.8)
X24:2 X24:3 X24:4
Digital IN10 Digital IN11 Digital IN12
Note) X: 1-> KSM31R device 1 2-> KSM31R device 2
Digital input 10 (Ex.10) (OSSD) Digital input 11 (Ex.11) (OSSD) Digital input 12 (Ex.12) (OSSD)
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X14
DI1 DI2 DI3 DI4
EA1 EA2
P1 P2
X12
K1/11 K1/12 K2/11 K2/12
X07

5 Safety related wiring of out put s

5.1 General specifications for wiring and testing

The wiring suggestions below show both the options for functional use of the relay outputs and the wiring that is necessary for diagnostics in each case. Diagnosis must always be carried out in the case of any safety-relevant use of the relay outputs. Apart from the wiring, diagnostics requires integration into the application program of the monitoring function for secure outputs “EMU” – For more details on this topic, refer to the programming manual.
Safety note:
When using the relay outputs for safety-relevant functions, you must observe the information below, in particular the specifications on wiring diagnostics.
The diagnostics for achieving the respective Pl and SIL in accordance with the wiring suggestions below, require you to integrate an associated diagnostics function into the application program – For more details on this topic, refer to the programming manual.
For applications with frequent safety shut-down requests, these tests should be performed more frequently, e.g. at the beginning of the shift, 1 × per week. However, a test should at least be carried out cyclically 1 × year.
You must parameterize the HISIDE outputs of the KSM31R module as safety outputs (see configuration of KSM31R)
Wiring example relay with feedback:
Fig.: Feedback of AK1
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K1
K2
L+
L-
X17
X17.1
X17.2
X17.3
X17.4

5.2 Wiring of the relay outputs

5.2.1 Single-pole switching relay output without testing

For a single-pole connection without external testing, bear in mind that the KSM31R module will not recognize bonding of the internal relay or of one or more external contacts. The following circuit example is only suitable for safety applications on a limited basis; at a maximum, Pl b according to EN 13849-1 can be achieved!
Fig.: Single-pole switching relay output.
Safety note:
Not recommended for safety applications! In this context see also the notes in EN 13849-1 concerning the application and the required fault exclusions.
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X17
X14
K1
K2
IO01 IO02
P1 P2
X12
DI01 DI02
DI03 DI04
L + L -
X17.1
X17.2
X17.3 X17.4
X14.1 X14.2
X14.3 X14.4
X12.1 X12.2
X12.3 X12.4
X7
K1/11 K1/12 K2/11 K2/12
X7.1 X7.2
X7.3 X7.4

5.2.2 Single-pole switching relay with external switching amplifier and testing

If you are using only one relay output, you will need a set-up to test the complete chain, i.e. including all the downstream electro-mechanical, pneumatic or hydraulic components as well as a message / warning device if faults are detected to achieve PL c or above. You need positively guided auxiliary contacts for downstream electro-mechanical devices or failsafe alarm contacts for the valve position for the hydraulic or pneumatic components. The me ssage / warning device must ensure that the operator recognizes the dangerous situation immediately. The achievable PI mainly depends on the test rate, PI d acc. to EM 13849-1 can be achieved at a maximum.
Fig.: Single-pole relay output with testing
Safety note:
Only conditionally recommended for safety applications! In this context see also the notes in EN 13849-1 concerning the application and the required fault exclusions.
For PL c or above, a test rate > 100 * request rate is necessary. For Pl d, you must
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carry out testing at least once a year. For PL c and above, a message / warning feature is required that informs the
operator immediately about a dangerous situation.
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X17
X14
K1
K2
IO01 IO02
P1 P2
X12
DI01 DI02
DI03 DI04
L + L -
X17.1
X17.2
X17.3 X17.4
X14.1 X14.2
X14.3 X14.4
X12.1 X12.2
X12.3 X12.4
X7
K1/11 K1/12 K2/11 K2/12
X7.1 X7.2
X7.3 X7.4

5.2.3 Dual-channel switching relay output with external monitoring group feedback

For safety-related applications from Pl d onwards according to EN ISO 13849-1, two relays on the KSM31R module and two external power contactors are used.
Fig.: Two-channel switching relay output with external monitoring – group feedback The two external monitoring contacts are switched in series, supplied by clock signal P1 and
read-in from DI01 (configured as an EMU input). In the case of higher requirements, you must consider that at least one switching process must take place every 24 hours.
Safety note:
To achieve PI d and above according to EN ISO 13849-1, a sufficiently high testing rate is required.
For applications with frequent safety shut-down requests, these tests should be performed more frequently, e.g. at the beginning of the shift, 1 × per week. For Pl d, you must carry out a cyclical test at least once a year; to achieve Pl e this
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test is needed at least once per month.
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X17
X14
K1
K2
IO01 IO02
P1 P2
X12
DI01 DI02 DI03 DI04
L + L -
X17.1 X17.2
X17.3 X17.4
X14.1
X14.2 X14.3 X14.4
X12.1 X12.2
X12.3 X12.4
X7
K1/11 K1/12 K2/11
K2/12
X7.1 X7.2
X7.3 X7.4
P N
Abschaltkanal 1
Abschaltkanal 2
Shut-down circuit 1
Shut-down circuit 2

5.2.4 Two-channel relay output – external control circuit with monitoring

For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via two relay outputs. Each of the two external cutout paths is monitored. For PL e acc. to EN ISO 13849-1 a sufficiently high testing rate (see the remarks) and MTTF
= high is required for the external circuit.
D
Safety note:
To achieve PI d and above according to EN ISO 13849-1, a sufficiently high testing rate is required.
For applications with frequent safety shut-down requests, these tests should be
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performed more frequently, e.g. at the beginning of the shift, 1 × per week. For Pl d, you must carry out a cyclical test at least once a year; to achieve Pl e this test is needed at least once per month.
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X17
X14
K1
K2
IO01 IO02
P1 P2
X12
DI01 DI02
DI03 DI04
L + L -
X17.1
X17.2
X17.3 X17.4
X14.1 X14.2
X14.3 X14.4
X12.1 X12.2
X12.3 X12.4
X7
K1/11 K1/12 K2/11 K2/12
X7.1 X7.2
X7.3 X7.4
Ple
STO

5.2.5 Dual-channel relay output with external control circuit in PL e

For safety applications from PI d and higher acc. to EN ISO 13849-1. The external circuit is controlled in dual-channel mode via the relay outputs. For PL e according to EN ISO 13849-1, a sufficiently high testing rate (see the remarks) is required as well as PL e for the external circuit.
Safety note: For safety circuits, EN ISO 13849-1 yields the following requirements for the test interval: Cat 3 / PL d: Testing once per year
Cat 4 / PL e: Testing once per month.
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6 Configuring the KSM31R

6.1.1 Basic configuration

After starting the “Safe PLC” program you must first choose the basic unit, followed by the extension KSM31R.
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Inputs
Occupied
Free
Metering length

6.1.2 Step 2

On the KSM31R module, you must set the bus address using the address switch. This setting is made on the back of the module
Note:
The address range of the KSM31R module is from 1...15.
Address “0” is reserved for the basic device.

6.1.3 Step 3

In the main menu of the “Safe PLC” program one can open the configuration dialog for the KSM31R module by “double-clicking” on the basic device.
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6.1.4 Step 4

The following settings must be made in the KSM31R configuration dialog:
Logical address of KSM31R device x: Setting the address switch of the KSM31R module.
Group1 EAAx.1-EAAx.6 or group1 EAAx.7-EAAx.10: When using these outputs one can
choose between safety and standard outputs.
Attention:
You should always configure group EAAx.1-EAAx.6 or group 1 EAAx.7-EAAx.10 as safety outputs to be able to use them in a safety application.
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Module replacement
See technical data
Function test
See chapter “Start-up”

7 Maintenance

7.1 Modification / handling changes to the device

Repair Repair work on the device can only be performed in the factory.
Warranty By opening the module without permission the warranty will become null and void.
Note:
By modifying the module the safety approval will become null and void!

7.2 Exchanging a module

When replacing an KSM31R module, you must observe the following points: Switch off the electric power supply for all the KSM modules and disconnect them.
Remove all the plug-in connections of the KSM31R module. Take the module off the top hat rail, make a note of the bus address and pack it in an EMC-compliant way. Set the bus address of the new module using the address switch and mount it on the top hat rail. Reconnect all connections. Switch on the electric power converter. Switch on the supply voltage.
Note:
Pluggable connections of the KSM module must generally not be disconnected or connected in live condition.

7.3 Maintenance intervals

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Class of protection
IP 20
Ambient temperature
0 °C* ... 50 °C
Climatic category
3 acc. to DIN 50 178
Lifetime
90000 h at 50 °C ambient
Output
Voltage
Current
Ax.1, Ax.2
24 VDC
100 mA
EAAx.1-2 *)
24 VDC
250 mA
K1-K8
24 VDC 230 VAC/2 A
2 A 2 A
Switching capacity min./max.
3 / 2000 (1 mVA / 7 VA)
Switching performance
At 0.1 Hz DC 13
24 V / 4 A
Electrical service life
50,000 switching cycles
Switching frequency
20 switching cycles / s
Mechanical service life
> 40 × 106 switching cycles

8 Technical data

8.1 Environmental conditions

8.2 Load carrying capacity of outputs

The outputs can be loaded as follows:
48 VDC
2 A
Note:*) See th e KSM installation m anual

8.3 Technical data of switching relay

According to IEC/EN 609 47-5-1 AC 15 According to IEC/EN 609 47-5-1 DC 13
250 V / 3 A 24 V / 1 A
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Max. achievable safety class
SIL 2 acc. to EN61508 EN ISO 13849-1
System structure
1-channel with diagnose (1001)
Category 2 acc. to EN 13849-1
Rating of operating mode
“high demand” acc. t o EN 61508
Probability of an endangering failure
KSM31R = 2,2 * 10
-9 /
KAT 4
Proof test interval (EN61508)
20 years; after this time, the module must be
Max. achievable safety class
SIL 3 acc. to EN61508 EN ISO 13849-1
System structure
2-channel with diagnose (1002)
Category 4 acc. to EN 13849-1
Rating of operating mode
“high demand” acc. t o EN 61508
Probability of an endangering failure
KSM31R = 2,2 * 10
-9 /
KAT 4
Proof test interval (EN61508)
20 years; after this time, the module must be

8.4 Safety-related characteristic data

8.4.1 Single-channel use of the relay output according to 5.2.2

Performance level d according to
(high demand rate)
per hour (PFH value)
+ 1-channel / relay 20 * 10
-9
max. 8
replaced

8.4.2 Dual-channel use of the relay output according to 5.2.3, 5.2.4 or 5.2.5

Performance level e acc. to
(high demand rate)
per hour (PFH value)
+ 2-channel / relay 1,0 * 10
replaced
-9
max. 4
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Installation Manual
North America
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About Kollmorgen
Kollmorgen is a leading provider of motion syste ms and com ponents for machine builders. Through world-class knowledge in motion, industry-leading quality and deep expertise in linking and integrating stan dar d and cu sto m products, Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability and ease­of-use, giving machine builders an irrefutable marketplace advantage.
For assistance with your app li cati on n eed s, visit www.kollmorgen.com
or contact us at:
Kollmorgen
203A West Rock Road Radford, VA 24141 USA
Web: www.kollmorgen.com Mail: support@kollmorgen.com Phone: 1-540-633-3545 Fax: 1-540-639-4162
Kollmorgen
Avenida Tamboré - 1077 Tamboré - Barueri ­SP Brasil CEP: 06460-000, Brazil
Web: www.kollmorgen.com Tel.: +55 11 4191-4771
Kollmorgen
Pempelfurtstraße 1 40880 Ratingen, Germany
Web: www.kollmorgen.com Mail: technik@kollmorgen.com Phone: + 49-2102-9394-0 Fax: + 49 -2102-9394-3155
Kollmorgen
Room 202, Building 3, Lane 168, Lin Hong Road, Changning District Shanghai, China
Web: www.kollmorgen.cn Mail: sales.china@kollmorgen.com Tel.: +86 - 400 661 2802
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