9.3 Field bus data FB variant.................................8
10 EU Declaration of conformity
1. About this document
1.1 Function
This operating instructions manual provides all the information you
need for the mounting, set-up and commissioning to ensure the safe
operation and disassembly of the safety switchgear. The operating
instructions must be available in a legible condition and a complete
version in the vicinity of the device.
1.2 Target group: authorised qualified personnel
All operations described in this operating instructions manual must
be carried out by trained specialist personnel, authorised by the plant
operator only.
Please make sure that you have read and understood these operating
instructions and that you know all applicable legislations regarding
occupational safety and accident prevention prior to installation and
putting the component into operation.
The machine builder must carefully select the harmonised standards
to be complied with as well as other technical specifications for the
selection, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional information.
Caution: Failure to comply with this warning notice could
lead to failures or malfunctions.
Warning:
lead to physical injury and/or damage to the machine.
1.4 Appropriate use
The products described in these operating instructions are developed
to execute safety-related functions as part of an entire plant or machine.
It is the responsibility of the manufacturer of a machine or plant to
ensure the correct functionality of the entire machine or plant.
The safety switchgear must be exclusively used in accordance with
the versions listed below or for the applications authorised by the
manufacturer. Detailed information regarding the range of applications
can be found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating
instructions manual, the country specific installation standards as well
as all prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal
catalogues or in the online catalogue on the Internet:
www.schmersal.net.
Failure to comply with this warning notice could
EN
1
Operating instructions
Control panel with emergency stop
BDF200-SD
BDF200-FB
The information contained in this operating instructions manual is
provided without liability and is subject to technical modifications.
There are no residual risks, provided that the safety instructions as well
as the instructions regarding mounting, commissioning, operation and
maintenance are observed.
1.6 Warning about misuse
In case of improper use or manipulation of the safety
switchgear, personal hazards or damages to machinery
or plant components cannot be excluded. The relevant
requirements of the standard ISO 13850 must be observed.
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from
defective mounting or failure to comply with this operating instructions
manual. The manufacturer shall accept no liability for damages
resulting from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary
repairs, conversions and modifications to the device are strictly
forbidden; the manufacturer shall accept no liability for damages
resulting from such invasive work, arbitrary repairs, conversions
and/or modifications to the device.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
Only if the information described in this operating instructions
manual are realised correctly, the safety function and therefore
the compliance with the Machinery Directive is maintained.
2.2 Special versions
For special versions, which are not listed in the order code below 2.1,
these specifications apply accordingly, provided that they correspond to
the standard version.
2.3 Comprehensive quality insurance to 2006/42/EC
Schmersal is a certified company to appendix X of the Machinery
Directive. As a result, Schmersal is entitled to autonomously conduct
the conformity assessment procedure for the products listed in
Appendix IV of the MD without involving a notified body. The prototype
test certificates are available upon request or can be downloaded from
the Internet at www.schmersal.com.
2.4 Purpose
The modular BDF200-SD/FB control panel is installed on the safety
guard of a machine or plant. It enables the operator to activate
functions such as, for instance, emergency stop, on/off and reset.
The emergency stop command device is used on machinery and plants
as a safe command device to generate a safe signal initiating the
shutdown of a hazardous movement when actuated.
The emergency stop command device may only be operated in
connection with a safety monitor.
The user must evaluate and design the safety chain in
accordance with the relevant standards and the required
safety level.
BDF200-➀-➁-➂-➃-➄-➅No. OptionDescription
SDVariant for SD interface
➀
FBVariant for safety field box SFB
Pos. 1Command device
➁
NHEmergency stop without protective collar
NHKEmergency stop with protective collar
LT. .Illuminated pushbutton
LM..Illuminated signal
DT..Pushbutton
PT..Mushroom push button
➅
G24Indicator lamp G24, top
2875Pushbutton caps for pushbuttons and
➆
➆
2 or 3 positions
2 or 3 positions
without indicator lamp
illuminated pushbuttons
included in the kit
The entire concept of the control system, in which the
safety component is integrated, must be validated to the
relevant standards.
Maintenance:
be triggered at least once a year to test the system!
Please observe that the safety function must
Pos. 1
Pos. 2
Pos. 3
Pos. 4
The unused positions 2 - 4 are labelled "B" and are sealed
with a blanking plug in factory.
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EN
Operating instructions
Control panel with emergency stop
BDF200-SD
BDF200-FB
2.5 Technical data
Standards:IEC 60947-5-1, IEC 60947-5-5, ISO 13850,
ISO 13849-1, IEC 61508, EN 62061
Material of the enclosure:glass-fibre reinforced thermoplastic,
self-extinguishing
Mechanical life:command devices: 1 million operations;
emergency stop: 100,000 operations
Connection: Connector plug M12, 8-pole, A-coded
Lamp socket:BA5S, LED: max. length 17 mm
LED change:from front
LED power consumption (operating elements):16 mA
Operating current G24 indicator lamp red/green:20 mA
Response time: ≤ 50 ms
Duration of risk: ≤ 100 ms
Device category SD variant:Hex: 41
Ambient conditions:
Ambient temperature: −25 °C … +65 °C
Storage and transport temperature: −25 °C … +85 °C
Climatic resistance:to EN 60068 part 2 - 30
Protection class: IP65
Protection class: III
Resistance to vibration:10 ... 150 Hz (0.35 mm / 5 g)
Resistance to shock:30 g / 11 ms
Insulation values to IEC 60664-1:
- Rated insulation voltage Ui:32 VDC
- Rated impulse withstand voltage U
- Rated insulation voltage: III
- Overvoltage category: 3
Electrical data:
Rated operating voltage Ue: 24 VDC −15% / +10%
Rated operating current Ie: 0.6 A
Required rated short-circuit current:100 A
No-load current Io: 35 mA
Safety inputs X1/X2:
Rated operating voltage Ue1:24 VDC −15% / +10%
Power consumption per input:5 mA
safety outputs Y1/Y2: p-type, short-circuit proof
Rated operating current Ie1:max. 0.25 A
Residual current Ir:< 0.5 mA
Utilisation category:DC-12 Ue/Ie 24 VDC / 0.25 A
Minimum operating current Im:0.5 mA
Voltage drop:Ue < 1 V
Serial diagnostic: short-circuit proof
Operating current:150 mA
Wiring capacitance:max. 50 nF
:800 V
imp
(PELV to IEC 60204-1)
(PELV unit)
DC-13 Ue/Ie 24 VDC / 0.25 A
3. Mounting
3.1 General mounting instructions
There are two mounting holes for M5 screws in the device for attachment
of the BDF200-SD/FB. Any mounting position.
The relevant requirements of the standard ISO 12100 must
be observed.
3.2 Dimensions
All measurements in mm.
30
13.5
39
22019
50
M12
40
5.5
M4
27
20
8
3.3 Mounting of the pushbutton and illuminated pushbutton caps
for option -2875
The caps for the pushbuttons and illuminated pushbuttons
are only suitable for a one-time mounting. Disassembly of the
caps could cause damages to the component.
The caps must be mounted immediately after unpacking the
control panel, in order to avoid soiling of the inner pushbutton
compartment by gross dirt particles / dust.
The caps for the pushbuttons and illuminated pushbuttons are mounted
in the following manner:
1. Take the pushbutton or illuminated pushbutton cap as well as the
rubber disk out of the kit
2. Take the control panel out of the protective packaging
3. Place the rubber disk on the pushbutton surface
4. Install the pushbutton or illuminated pushbutton cap onto that
5. Fix the cap
The cap "clicks" when it is engaged
209
For use in NFPA79, Industrial Machinery, only.
The power-source has to be an isolated secondary source
limited by a Listed fuse rated 4A min. 24VAC/DC.
Adapters providing field wiring means are available from
the manufacturer. Refer to manufacturer’s information.
2.6 Safety classification emergency stop
Standards:ISO 13849-1, IEC 61508, EN 62061
PL: e
Control Category: 4
PFH: ≤ 2.89 x 10
SIL:suitable for SIL 3 applications
Service life: 20 years
-10
/ h up to max. 5,000 switching cycles/year
6. Check the smooth actuation of the pushbutton
7. Repeat this procedure for all other pushbuttons
After the pushbutton or illuminated pushbutton cap is
mounted, the proper tting and the smooth actuation of
the pushbutton must be checked. The button must return
autonomously from the actuated to the non-actuated state and
the cap must be at the same height as the component edging.
EN
3
Operating instructions
ab
Control panel with emergency stop
BDF200-SD
BDF200-FB
3.4 Fixing
Remove the cover of the enclosure a and b (screws: Torx 10).
When opening the enclosure cover, please avoid damage to
the connecting cables.
Caution!
Do not touch electrostatically loaded elements.
Do not touch the printed circuit board.
Use 2 x M5 cylindral screws ISO 4762 (DIN 912) for the assembly.
After fitting, the cover screws must be tightened with a tightening torque
of 0.7 … 0.8 Nm.
When closing the enclosure cover, please observe that the
individual cables are not caught between the command
device and the contact element.
4. Electrical connection
4.1 General information for electrical connection
The electrical connection may only be carried out by
authorised personnel in a de-energised condition.
The safety outputs can be integrated into the safety circuit of the control
system. To meet the demands of ISO 13849-1 for PL e / category 4,
the safety outputs of the control panel and control panel chain must be
connected to a monitor of the same category.
Protection is not required when pilot wires are laid. The cables however
must be separated from the supply and energy cables. The max. fuse
rating of a device chain for protection of the cable depends on the
cross section of the cables used.
Requirements for the connected safety-monitoring module
• Dual-channel safety input, suitable for p-type devices
with normally-open function
Information for the selection of suitable safety-monitoring
modules can be found in the Schmersal catalogues or in the
online catalogue on the Internet: www.schmersal.net.
The control panel tests its safety outputs through cyclic deactivation.
The safety-monitoring module therefore does not need to be equipped
with a cross-wire short detection. The switch-off times must be tolerated
by the safety-monitoring module. The deactivation time of the control
panel is also extended depending on the cable length and the capacity
of the cable used. Typically, a switch-off time of 250 μs is reached with
a 30-m connecting cable.
When closing the enclosure cover, ensure that the
emergency stop module is ush with the bottom section and
that the cover screws are screwed in as far as they will go.
The emergency stop safety function must be checked by
an appointed safety technician / safety representative once
successfully installed.
3.5 Inscription plates
The marking on the inscription plates (included in delivery) is carried out
by colour change by laser. The effects of heat may change the colour of
the surface.
Configuration of the safety-monitoring module
If the control panel is connected to electronic safetymonitoring modules, we recommend a discrepancy time of
100 ms. The safety inputs of the safety-monitoring module
must be able blanking a test impulse of approx. 1 ms.
The safety-monitoring module does not need to have a
cross-wire short monitoring function, if necessary, the
cross-wire short monitoring function must be disabled.
4.2 Serial diagnostic SD interface
Cable design in case of serial diagnostics
When wiring SD devices, please observe the voltage drop
on the cables and the current carrying capacity of the
individual components.
The wiring capacitance of the connecting cable of the safety sensor
must not exceed 50 nF.
Depending on the strand structure, normal unshielded 200 m long
control cables LIYY 0.25 mm² to 1.5 mm² have a wiring capacitance of
approx. 20 - 50 nF.
Accessories SD interface
For ease of wiring and series-wiring of SD devices
considerable accessories are available.
Detailed information is available on the Internet,
www.schmersal.net.
It must be ensured that the top is inscribed.
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EN
Operating instructions
Control panel with emergency stop
• Position 1 NO contact Response bit 1 = 0
NC contact Response bit 2 = 0
• Position 0 NO contact: Response bit 1 = 0
0
2
1
NC contact Response bit 2 = 1
• Position 2 NO contact: Response bit 1 = 1
NC contact Response bit 2 = 1
Position 3:
Illuminated pushbutton, indicator lights, pushbutton and
mushroom pushbutton
LT.., LM.., DT.., PT..
• Pushbutton function NO contact Response bit 3 = 1
NC contactResponse bit 4 = 0
• Indicator lightsLEDQuery bit 4
5.2 Emergency stop function
The emergency stop impact button switches off the safety OSSDs.
Release details of the emergency stop impact button are transmitted to
the control system via the response byte in the SD/FB protocol.
The bit assignment in the SD/FB response byte is as follows:
Position 1: Emergency stop
• Unactuated Authorised operation: Response bit 0 = 1
• Actuated Switched off: Response bit 0 = 0
5.3 Mode of operation of the safety outputs
The safety outputs of the emergency stop function can be integrated
directly into the safety-relevant part of the user control system for circuit
connection. Actuation of the emergency stop impact button causes
immediate deactivation of the safety outputs.
Any error that does not immediately affect the functionality of
the emergency stop function (e.g. ambient temperature too high,
interference potential at safety output, short circuit) will lead to a
warning message and delayed shut-down of the safety outputs.
safety outputs are disabled if the error warning is active for 30 minutes.
Once the error has been rectified, it can be acknowledged by actuating
and disengaging the emergency stop impact button. The safety outputs
enable and allow a restart. Error acknowledgement can be carried out
by setting / deleting bit 7 in the SD/FB query telegram.
5.4 Function of the command and signalling devices
The non-safety signals of the command devices are transmitted to
the control system via the response byte in the SD/FB protocol. The
Illuminated signals are controlled by the control system via the query
byte in the SD/FB protocol.
• Position 1 NO contact Response bit 3 = 0
NC contact Response bit 4 = 0
• Position 0 NO contact Response bit 3 = 0
0
2
1
NC contact Response bit 4 = 1
• Position 2 NO contact Response bit 3 = 1
NC contact Response bit 1 = 1
Position 4:
Illuminated pushbutton, indicator lights, pushbutton and
mushroom pushbutton
LT.., LM.., DT.., PT..
• Pushbutton functionNO contactResponse bit 5 = 1
• Indicator lightsLEDQuery bit 5
5.5 Function of G24 indicator lamp
The G24 indicator lamp is controlled by the control system via the query
byte in the SD/FB protocol.
The bit assignment of the query byte is as follows:
• G24Red LEDQuery bit 1
• G24green LEDQuery bit 2
EN
5
Operating instructions
Control panel with emergency stop
BDF200-SD
BDF200-FB
6. Diagnostic functions
6.1 Diagnostic functions of SD interface
Safety switchgear devices with serial diagnostic cable have a serial
input and output instead of the conventional diagnostic output. If these
safety switchgear devices are wired in series, the safety channels as
well as the inputs and outputs of the diagnostic channels are wired in
series.
Up to 31 safety switchgear devices can be connected in series with
serial diagnostics. For the evaluation of the serial diagnostics line either
the PROFIBUS-Gateway SD-I-DP-V0-2 or the Universal-Gateway
SD-I-U-... are used. This SD-Gateway is integrated as a slave in an
existing field bus system. In this way, the diagnostic signals can be
evaluated by means of a PLC.
The necessary documentation for the integration of the SD-Gateway is
available for download at www.schmersal.com.
The query details for each safety sensor are transmitted to the device
via one output byte of the PLC respectively.
The request data for each safety sensor are transmitted to the device
through an output byte of the PLC.
Should a communication error occur between the SD Gateway and the
safety switchgear, the safety switchgear retains its switch status for the
safety outputs.
Table 1: Overview of status signals, warnings or error messages of SD variant
Communication directions: Request byte:From PLC to local safety switchgear
Response byte:From local safety switchgear to PLC
Warning/error byte:From local safety switchgear to PLC
Diagnostic error warning and error
If an error (warning) is signalled in the response byte, detailed fault
information can be read out.
Detailed information about the use of the serial diagnostics can be
found in the operating instructions of the PROFIBUS-Gateway
SD-I-DP-V0-2 and the Universal-Gateway SD-I-U-….
Error warning
A fault has occurred, which causes the safety outputs to be disabled
after 30 minutes. The safety outputs initially remain enabled.
This enables the shutdown of the process in a controlled manner.
An error warning is deleted when the cause of error is eliminated.
Error
A fault has occurred, which causes the safety outputs to be disabled.
The fault is reset, when the cause is eliminated and bit 7 of the query
byte changes from 1 to 0 or the emergency stop is pressed again.
Faults at the safety outputs are only deleted upon the next release,
as the fault rectification cannot be detected sooner.
On the FB variant of the BDF200-SD/FB, the two diagnosis
bytes 'Error warnings' and 'Error messages' are not
transferred.
Bit n° Request byteResponse byteDiagnostic
Error warningsError messages
Bit 0: —Safety output
emergency stop switched on
Bit 1: LED G24 redNO contact from pos. 2Error output Y2Error output Y2
Bit 2: LED G24 greenNC contact from pos. 2Cross-wire Y1/Y2Cross-wire Y1/Y2
Bit 3: LED illuminated push button pos. 2 NO contact from pos. 3Temperature too highTemperature too high
Bit 4: LED illuminated push button pos. 3 NC contact from pos. 3—Error emergency stop button
Bit 5: LED illuminated push button pos. 4 NO contact from pos. 4Internal device errorInternal device error
Bit 6: —Error warningCommunication error between field
Bit 7: Error resetError
(enabling path switched off)
7. Set-up and maintenance
7.1 Functional testing
The safety function of the safety components must be tested.
The following conditions must be checked and met:
• Correct fixing of the fitted component
• Check the integrity of the cables and connections
• Check the command and signalling devices for damage
• For the types with extension …-2875, the proper fitting and the
smooth operation of the pushbuttons must be checked after the
installation of the pushbutton and illuminated pushbutton caps
Error output Y1Error output Y1
—
bus Gateway and SD slave
Operating voltage limit—
In case of correct installation in accordance with the instructions
described above, the component requires little maintenance. Under
extreme conditions, we recommend routine maintenance as follows:
• Check the correct fixing of the control panel
• Remove particles of dust and soiling.
• Check the integrity of the cables and connections
• For the types with extension …-2875, the smooth operation of the
pushbuttons and the illuminated pushbuttons must be checked.
Damaged or defective components must be replaced.
7.2 Maintenance
The function of the emergency stop button must be tested in regular
intervals.
Maintenance:
be triggered at least once a year to test the system!
6
Please observe that the safety function must
8. Disassembly and disposal
8.1 Disassembly
The safety switchgear must be disassembled in a de-energised
condition only.
8.2 Disposal
The safety switchgear must be disposed of in an appropriate manner in
accordance with the national prescriptions and legislations.
Operating instructions
Control panel with emergency stop
9.3 Field bus data FB variant
PLC output data BDF200-FB (PLC → SFB → BDF200-FB)
- Device module: SFB module data_1
- Sub module: Diagnosis and FB interface
4 byte output
SlotPROFINETEtherNet/IP
Output dataOutput data
4Slot: 1 3
Byte: n
5Slot: 1 3
Byte: n + 1
6Slot: 1 3
Byte: n + 2
7Slot: 1 3
Byte: n + 3
Bit assignment output data
Bit n° Request byte
Bit 0:--Bit 1:LED G24 red
Bit 2:LED G24 green
Bit 3:LED illuminated push button pos. 2
Bit 4:LED illuminated push button pos. 3
Bit 5:LED illuminated push button pos. 4
Bit 6:--Bit 7:Error reset
Assembly 301
- Byte 2
Assembly 301
- Byte 3
Assembly 301
- Byte 4
Assembly 301
- Byte 5
BDF200-SD
BDF200-FB
PLC input data BDF200-FB (BDF200-FB → SFB → PLC)
- Device module: SFB module data_1
- Sub module: Diagnosis and FB interface
6 byte input
SlotPROFINETEtherNet/IP
Input dataInput data
4Slot: 1 3
Byte: n + 2
5Slot: 1 3
Byte: n + 3
6Slot: 1 3
Byte: n + 4
7Slot: 1 3
Byte: n + 5
Bit assignment input data
Bit n°Response byte
Bit 0:Safety output emergency stop switched on
Bit 1:NO contact from pos. 2
Bit 2:NC contact from pos. 2
Bit 3:NO contact from pos. 3
Bit 4:NC contact from pos. 3
Bit 5:NO contact from pos. 4
Bit 6:Error warning
Bit 7:Error (enabling path switched off)
Assembly 300
- Byte 6
Assembly 300,
- Byte 7
Assembly 300
- Byte 8
Assembly 300
- Byte 9
Detailed information about the field bus data and
bit assignment can be found in the system handbook
"Safety field box SFB" at www.schmersal.net.
8
EN
Operating instructions
Control panel with emergency stop
10. EU Declaration of conformity
EU Declaration of conformity
BDF200-SD
BDF200-FB
OriginalK.A. Schmersal GmbH & Co. KG
We hereby certify that the hereafter described components both in their basic design and construction conform
to the applicable European Directives.
Name of the component:BDF200-SD
Type:See ordering code
Description of the component:Control panel with emergency stop and
Relevant Directives:2006/42/EG
Applied standards:IEC 60947-5-5:2016
Notied body for the prototype test:TÜV Rheinland Industrie Service GmbH