Bosch Rexroth R911326028 Inline Module Manual
Publicité
Publicité
The Drive & Control Company
Rexroth Inline Module with
safe digital outputs
R-IB IL 24 PSDO 8-PAC
Application Description
R911326028
Edition 04
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Title Rexroth Inline Module with safe digital outputs
R-IB IL 24 PSDO 8-PAC
Type of Documentation Application Description
Document Typecode DOK-CONTRL-ILPSDO8****-AW04-EN-P
Internal File Reference 7809_en_04, R911326028_04.pdf
Purpose of Documentation This document describes the Rexroth Inline Module with safe digital outputs
R-IB IL 24 PSDO 8-PAC as of the version HW/FW/FW 01/201/100.
Record of revision
Edition Release date
Note
02
03
04
12.2013
First edition
04.2016
Modification in Table 13-1
(rows 1 + 2)
05.2018
HW/FW/FW version updated (as of...)
Chapters updated: Use of the Safety Instructions, Disposal,
Service and Support
Information about safety seals removed (Chapter General Safety
Notes and Chapter Repair)
Information on test pulses in the chapter Safe digital outputs added
EMC Directive updated
Conditions for Use at Altitudes greater than 2000 m above Sea
Level inserted
Copyright © Bosch Rexroth AG 2016
This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product.
Editorial department Engineering automation systems control hardware, SB
Bosch Rexroth AG I/
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Table of Contents
Table of Contents
Page
Inline Potential and Data Routing, and Inline Connectors..................................... 25
..................................................................................................................................25
.................................................................................................................................26
II
Bosch Rexroth AG
Table of Contents
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Page
10 Maintenance, Repair, Decommissioning, and Disposal ......................................... 63
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Table of Contents
Page
12 PROFIsafe Terms Used in the Application Description ......................................... 73
15 Conditions for Use at Altitudes greater than 2000 m above Sea Level................ 85
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
1
1.1
Use of the Safety Instructions
Structure of the Safety Instructions
The safety instructions are structured as follows:
Bosch Rexroth AG
Use of the Safety Instructions
1.2
Abb. 1-1 Structure of the safety instructions
Explaining Signal Words and Safety Alert Symbol
The safety instructions in this documentation contain specific signal words (danger, warning, caution, notice) and, if necessary, a safety alert symbol (according to ANSI Z535.6-2006).
The signal word is used to draw attention to the safety instruction and also provides information on the severity of the hazard.
The safety alert symbol (a triangle with an exclamation point), which precedes the signal words danger, warning and caution is used to alert the reader to personal injury hazards.
DANGER
In case of non-compliance with this safety instruction, death or serious injury will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury can occur.
VCAUTION
In case of non-compliance with this safety instruction, minor or moderate injury can occur.
NOTICE
In case of non-compliance with this safety instruction, material damage can occur.
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Use of the Safety Instructions
1.3
Symbols used
Hints are represented as follows:
This is an information.
Tips are represented as follows:
This is a tip for the user.
1.4
Signal Graphic Explanation on the Device
Prior to the installation and commissioning of the device, refer to the device documentation.
2
2.1
Bosch Rexroth AG
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
For Your Safety
For Your Safety
Purpose of this application description
The information in this document is designed to familiarize you with how the
R-IB IL 24 PSDO 8-PAC safety module works, its operating and connection elements, and its parameter settings. This information will enable you to use the module within an PROFIsafe system according to your requirements.
Validity of the application description
This application description is only valid for the R-IB IL 24 PSDO 8-PAC module in the version indicated on the inner cover page.
User group of this application description
The use of products described in this manual is oriented exclusively to qualified electricians or persons instructed by them, who are familiar with applicable standards and other regulations regarding electrical engineering and, in particular, the relevant safety concepts.
Bosch Rexroth accepts no liability for erroneous handling or damage to products from Bosch Rexroth or third-party products resulting from disregard of information contained in this manual.
General Safety Notes
Requirements
•
•
•
•
•
•
WARNING
Depending on the application, incorrect handling of the safety module can pose serious risks for the user
When working with the safety module within the PROFIsafe system, please observe all the safety notes included in this section.
Knowledge of the following is required:
The non-safety-related target system (e.g., PROFIBUS, PROFINET)
The PROFIsafe system
The components used in your application
The Inline product range
Operation of the software tools used
Safety regulations in the field of application
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
For Your Safety
Qualified personnel In the context of the use of the PROFIsafe system, the following operations may only be carried out by qualified personnel:
•
•
•
Planning
Configuration, parameterization, programming
Installation, startup, servicing
• Maintenance, decommissioning
This application description is therefore aimed at:
•
•
Qualified personnel who plan and design safety equipment for machines and systems and are familiar with regulations governing safety in the workplace and accident prevention.
Qualified personnel who install and operate safety equipment in machines and systems.
In terms of the safety notes in this application description, qualified personnel are persons who, because of their education, experience and instruction, and their knowledge of relevant standards, regulations, accident prevention, and service conditions, have been authorized to carry out any required operations, and who are able to recognize and avoid any possible dangers.
Documentation
Safety of personnel and equipment
You must observe all information in this application description as well as in the
documents listed in Chapter “Documentation” on page 12
.
The safety of personnel and equipment can only be assured if the safety module is used correctly (see
Chapter “Correct Usage” on page 11
).
Error detection
Do not carry out any repairs Repair work may not be carried out on the safety module.
In the event that an error cannot be removed, please contact Bosch Rexroth immediately, engage a service engineer or send the faulty module directly to
Bosch Rexroth.
Do not open the housing
Depending on the wiring and the corresponding setting of the safe output module parameters, the PROFIsafe system can detect various errors within the safety equipment.
Measures to prevent incorrect connection and polarity reversal
It is strictly prohibited to open the housing. If the housing is opened, correct operation of the module can no longer be ensured.
Take measures to prevent the incorrect connection, polarity reversal, and manipulation of connections.
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Bosch Rexroth AG
For Your Safety
2.2
Electrical Safety
Direct/indirect contact
Power supply units for
24 V supply
Insulation rating
Installation and configuration
WARNING Hazardous body currents and the loss of functional safety
Disregarding instructions for electrical safety may result in hazardous body currents and the loss of functional safety.
In order to ensure electrical safety, please observe the following points.
Protection against direct and indirect contact according to VDE 0100 Part 410 must be ensured for all components connected to the system. In the event of an error, parasitic voltages must not occur (single-fault tolerance).
This can be achieved by:
•
•
Using power supply units with safe isolation (PELV).
Decoupling circuits, which are not PELV systems, using optocouplers, relays, and other components, which meet the requirements of safe isolation.
Only use power supply units with safe isolation and PELV according to EN
50178/VDE 0160 (PELV). This prevents short circuits between primary and secondary sides.
Make sure that the output voltage of the power supply does not exceed 32 V even in the event of an error.
When selecting the operating equipment, please take into consideration the contamination and surge voltages, which may occur during operation.
The R-IB IL 24 PSDO 8-PAC module is designed for surge voltage category II
(according to DIN EN 60664-1). If you expect surge voltages in the system, which exceed the values defined in surge voltage category II, take into consideration additional measures for voltage limitation.
Please observe the instructions for installing and configuring the system
(see
Chapter “Documentation” on page 12 ).
WARNING Depending on the application, incorrect installation and upgrades can pose serious risks for the user
The user is obliged to design the devices used and their installation in the system according to these requirements. This also means that existing plants and systems retrofitted with PROFIsafe must be checked and tested again in this respect.
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
For Your Safety
2.3
Safety of the Machine or System
Draw up and implement a safety concept
Check hardware and parameterization
The machine/system manufacturer and the operator are solely responsible for the safety of the machine or system and the implemented application, in which the machine or system is used. The Machinery Directive must thus be observed.
In order to use the safety module described in this document, you must have drawn up an appropriate safety concept for your machine or system. This includes a hazard and risk analysis according to the directives and standards specified in
Chapter “Directives and Standards” on page 11
, as well as a test report (checklist) for validating the safety function (see
).
The target safety integrity level (SIL according to EN 61508, SIL CL according to
EN 62061 or performance level and category according to EN ISO 13849-1) is ascertained on the basis of the risk analysis. The safety integrity level ascertained determines how to connect and parameterize the safety module within the overall safety function.
Within a PROFIsafe system, the R-IB IL 24 PSDO 8-PAC safety module can be used to achieve safety functions with the following requirements:
•
•
•
•
•
Up to SIL 3 according to standard EN 61508
Up to SIL CL 3 according to standard EN 62061
• Up to Cat. 4/PL e according to standard EN ISO 13849-1
Carry out a validation every time you make a safety-related modification to your overall system.
Use your test report to ensure that:
The safe devices are connected to the correct safe sensors and actuators
The safe input and output devices have been parameterized correctly
The variables have been linked to the safe sensors and actuators correctly
(single-channel or two-channel)
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
2.4
2.5
Bosch Rexroth AG
For Your Safety
Directives and Standards
The manufacturers and operators of machines and systems, in which the
R-IB IL 24 PSDO 8-PAC module is used, are responsible for adhering to all applicable directives and legislation.
For the standards observed by the module, please refer to the certificate issued by the approval body and the EC declaration of conformity. These documents are available on the Internet at www.boschrexroth.com/electrics .
Correct Usage
Only use the PROFIsafe system in accordance with the instructions in this section.
The R-IB IL 24 PSDO 8-PAC safety module is designed exclusively for use in a
PROFIsafe system.
It can only perform its safety-related tasks within the system if it has been integrated into the execution process correctly and in such a way as to avoid errors.
You must observe all information in this application description as well as in the documents listed in
. In particular, only use the module according to the technical data and ambient conditions specified in
Chapter 11, “Technical Data and Ordering Data”
on
Within a PROFIsafe system, the safety module can be used to achieve safety functions with the following requirements depending on the conditions of use:
•
•
•
Up to SIL 3 according to standard EN 61508
Up to SIL CL 3 according to standard EN 62061
Up to Cat. 4/PL e according to standard EN ISO 13849-1
It is designed for connecting single-channel or two-channel actuators, which can be used in association with safety technology.
For example, the module can be used in the following applications:
• Safety circuits according to EN 60204 Part 1
• Safe shutdown of contactors, motors (24 V DC), valves, ohmic, inductive, and capacitive loads
The module is not suitable for applications, in which stop category 1 also has to be observed in the event of an error.
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
For Your Safety
2.6
Documentation
Latest documentation
PROFIsafe
Rexroth Inline product range
Make sure you always use the latest documentation. Changes or additions to this document can be found on the Internet at www.boschrexroth.com/electrics .
When working on the PROFIsafe system and its components, you must always keep this application description and other items of product documentation to hand and observe the information therein.
Application descriptions:
• For the safe controller used
•
•
For PROFIsafe I/O modules
For PROFIsafe function blocks
Please also observe the relevant information about PROFIBUS, PROFINET, and
PROFIsafe, which is available on the Internet at www.profisafe.net
.
DOK-CONTRL-ILSYSINS***-AW..-EN-P
Automation modules of the Rexroth Inline product range (configuration and installation)
Documentation for the bus coupler used
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
2.7
2.8
Bosch Rexroth AG
For Your Safety
Abbreviations Used
Abbreviation
SIL
SIL CL
Cat.
PL
Fig. 2-1
Meaning
Safety integrity level
SIL claim limit
Category
Performance level
Abbreviations used
Standard
EN 61508
EN 62061
EN ISO 13849-1
EN ISO 13849-1
Example
SIL 2, SIL 3
SIL CL 3
Cat. 2, Cat. 4
PL e, PL d
Abbreviation
PELV
EUC
Fig. 2-2
Meaning
Protective extra-low voltage
A circuit in which the voltage cannot exceed30 V AC, 42.4 V peak value or 60 V DC under normal conditions, and under single-fault conditions, except earth faults in other circuits.
A PELV circuit is like a SELV circuit, but is connected to protective earth ground.
(According to EN 61131-2)
Equipment under control
Abbreviations used
For terms and abbreviations used for PROFIsafe, please refer to
“PROFIsafe Terms Used in the Application Description” on page 73 .
Safety Hotline
Should you have any technical questions, please contact our 24-hour hotline.
Phone:
E-mail:
+ 49 9352 40 5060 [email protected]
14
Bosch Rexroth AG
For Your Safety
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
3
3.1
Bosch Rexroth AG
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Product Description
Product Description
Brief Description of the Safety Module
The R-IB IL 24 PSDO 8-PAC module is an output module, which is designed for use within a Rexroth Inline station.
The R-IB IL 24 PSDO 8-PAC safety module can be used as part of an Rexroth
Inline station at any point within a PROFIsafe system.
One transmission speed must be used seamlessly in a Rexroth Inline station.Please note that standard Rexroth Inline modules operate with 500 kbaud only. Therefore, you also have to set the baud rate of the safety modules to 500 kbaud in a combined system.
The module has a 10-pos. DIP switch, which is used to set the PROFIsafe address.
The module has four safe positive switching digital outputs for two-channel assignment or eight safe positive switching digital outputs for single-channel assignment.
The outputs can be parameterized according to the application and enable the integration of actuators in the PROFIsafe system.
Within a PROFIsafe system, the safety module can be used to achieve safety functions with the following requirements depending on the conditions of use:
•
•
Up to SIL 3 according to standard EN 61508
Up to SIL CL 3 according to standard EN 62061
• Up to Cat. 4/PL e according to standard EN ISO 13849-1
The output data is exchanged between the safe controller and the module using safety-relevant messages.
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Product Description
3.2
Structure of the Safety Module
6
4x
1
2
3
4
5
D
1 2
0
PS
DO
8
FS
1 2
1
UM
2
1 2
P
3
1 2
9
Fig. 3-1
7
Structure of the safety module
8
4x
76193002
1 Data jumpers (local bus)
2 Electronics base with labeling including hardware/firmware/firmware version designation (not shown)
3 Switch for setting the transmission speed and operating mode
4 Switch for setting address
For more detailed information about setting the switches, please refer to
“Setting the DIP Switches” on page 32 .
5 Potential jumper
6 Diagnostic and status indicators; for assignment and meaning see
Diagnostic and Status Indicators” on page 20
7 Rexroth Inline connector; for assignment see
Chapter “Terminal Point Assignment” on page 28
8 Terminal points
9 Labeling field
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3.3
Housing Dimensions
71,5
Bosch Rexroth AG
Product Description
Fig. 3-2
48,8
Housing dimensions (in mm)
76192008
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Product Description
3.4
Safe Digital Outputs
Technical data
Parameterization
The safety module has safe positive switching digital outputs, which can be used as follows:
• For two-channel assignment:
• Four two-channel outputs
For single-channel assignment: •
• Eight single-channel outputs
For the technical data for the safe outputs, please refer to page 68 .
The individual safe digital outputs of a safety module can be parameterized differently. This means that the outputs can be adapted to various operating conditions and different safety integrity levels can be implemented (SIL, SIL CL,
Cat., PL).
In order to achieve a high level of error detection, the test pulses must be enabled.
If this is not possible for the connected loads, the test pulses can be disabled.
However, in this case error detection is reduced.
The safety integrity level (SIL, SIL CL, Cat., PL) and error detection that can be achieved depend on the parameterization, the structure of
the actuator, and the cable installation (see “Connection Examples for
Diagnostics
For information about parameterization, please refer to
Chapter “Parameterization of the Safe Outputs” on page 38 .
Diagnostics are provided via both the local diagnostic indicators and the diagnostic messages, which are transmitted to the safe controller (PROFIsafe).
For information about the diagnostic messages of the outputs, please refer to
Chapter “Safe Digital Output Errors” on page 57 .
CAUTION Diagnostic data is not safety-related
Do not use the diagnostic data to execute safety-related functions or actions.
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Requirements for controlled devices/actuators
Product Description
•
•
The error detection of the module varies depending on the parameterization. This results in specific requirements for the actuators.
If the outputs are parameterized with test pulses, the output circuits are tested by test pulses at regular intervals. These test pulses are visible at the output and can trigger undesirable reactions with quick responding actuators. The test pulses are either light pulses (brief activation) which can be disabled or dark pulses (brief deactivation) which cannot be disabled.
•
•
•
WARNING Unintentional machine startup
If the process does not tolerate this behavior, actuators with sufficient inertia must be used.
In general, the load must not be so dynamic that it causes dangerous states within 1 ms.
Quick actuators, which offer a safety-related response to pulses in under 1 ms, may not generally be used.
Note: Switching off the test pulses affects the error detection of the module.
Please observe the achievable safety integrity level, which is specified in
Chapter “Connection Examples for Safe Outputs” on page 41
.
The failure detection time is 20 ms. Please refer to “Single-Channel
Assignment of Safe Outputs” on page 45 and
Safe Outputs” on page 48 for additional information.
Only use appropriately qualified actuators.
Use reliable components. These include, for example:
•
•
•
Control contactors according to EN 60947-4-1
Power contactors
Relays with positively driven contacts according to DIN EN 50205
Use relays or contactors with positively driven N/C contacts to safely monitor the state (pick-up, drop-out).
Please observe any special environmental requirements in your application when selecting the controlled devices.
Please note applicable C standards in your application (e.g., EN 1010), in which, for example, the number of controlled devices required to achieve a particular category is specified.
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Product Description
3.5
Connection Options for Actuators Depending on the Parameterization
"Output" parameterization
Test pulses
Achievable category
For connection example, see page
Actuators that meet various safety requirements depending on the parameterization can be connected to the outputs. For connection examples,
please refer to Chapter 7, “Connection Examples for Safe Outputs”
.
The maximum achievable SIL/SIL CL/Cat./PL is specified in the table.
In order to achieve this:
•
•
Observe the information in the connection examples (see Chapter 7,
“Connection Examples for Safe Outputs”
)
Observe the requirements of the standards with regard to the external wiring and the actuators to be used to achieve a SIL/SIL CL/Cat./PL (see
Required to Achieve a Specific Safety Integrity Level” on page 43
)
Output OUT0 to OUT3
Single-channel
Any
SIL 2/SIL CL 2/Cat. 3/PL d
Two-channel
ON/OFF*
SIL 3/SIL CL 3/Cat. 4/PL e
Key:
* If the test pulses are disabled, a cross circuit between the outputs is only detected if the output is enabled.
To achieve Cat. 3, two-channel actuators are usually used.
3.6
Local Diagnostic and Status Indicators
1
D
0
2
PSDO8
1
FS
1
2
1
UM
2
2
1
P
3
2
D
0
1 2
PS
DO
8
FS
1
1 2
UM
2
1 2
P
3
1 2
Fig. 3-3 Local diagnostic and status indicators on the
R-IB IL 24 PSDO 8-PACmodule
76192003
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
D
FS
UM
P
OUT
0.1 - 3.2
Fig. 3-4
Bosch Rexroth AG
Product Description
Green LED Diagnostics
OFF:
Flashing at
0.5 Hz:
Communications power is not present
Communications power present, local bus not active
Flashing at 4 Hz: Communications power present, error at the interface between previous and flashing terminal (the terminals after the flashing terminal cannot be addressed).
(E.g., loose contact at the bus interface, terminal before the flashing terminal has failed, another terminal was snapped on during operation (not permitted))
Observe the module startup time of approximately 16 s. During this time the D LED flashes at 4 Hz and the bus cannot be started up.
ON:
Red LED
Flashing at 1 Hz: Device not parameterized or parameterization was not accepted
ON: Hardware fault
Communication to safe controller disabled and output driver enable reset.
Green LED
OFF:
Monitoring the supply voltage U
M
Communications power is not present
Flashing at 1 Hz: U
M
below the permissible voltage range (undervoltage)
ON:
Green LED
U
M
present
Status indicator for safe communication
OFF:
Flashing at
0.5 Hz:
ON:
Green/red LED
Communications power present, local bus active
Failure state
No safe communication
Safe communication running, the controller requests operator acknowledgment
Safe communication running without errors
Status of each output
(see
“Terminal Point Assignment” on page 28 )
Green:
OFF:
Red ON:
Output at logic 1
Output at logic 0, no error
Output short circuit/overload
(This diagnostic message is stored temporarily on the module. The message is stored in the volatile memory and will be lost after a voltage reset.)
In the event of an error (red LED ON), the output is switched off until the acknowledgment sent by the safe controller is received by the safety module (see also
Local diagnostic and status indicators
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Product Description
3.7
3.7.1
Safe State
The safe state for the module is the low state at the output terminals (see
“Safe Digital Outputs” on page 18
).
PROFIsafe:
The safe state for the F-Output data is “0”.
The safe state is entered by means of passivation (see
).
The safe state can be entered in the following cases:
1.
Operating state
2.
Error detection in I/O devices
3.
Device errors
4.
Parameterization errors
Operating State
3.7.2
In the operating state, the outputs can enter states “1” or “0”. In general, state “0” is the safe state.
WARNING No communication; loss of the safety function possible due to undetected accumulation of errors
If there is no communication with the safe controller: Disconnect the module from the supply voltage after a maximum of eight hours.
Error Detection in I/O Devices
Outputs If an error is detected at an output, the affected output is disabled (“0” = OFF = safe state).
Depending on the parameterization, the following errors can be detected at outputs:
•
•
Short circuit
Cross circuit
• Overload
The relevant diagnostic message is transmitted to the safe controller (see Chapter
“Safe Digital Output Errors” on page 57
). For information about which errors are detected and when, please refer to
“Connection Examples for Safe Outputs” on page 41 .
If an error occurs on a channel of an output parameterized as “twochannel”, the other corresponding channel also enters the safe state.
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3.7.3
Bosch Rexroth AG
Product Description
Device Errors
Outputs
Serious errors
If a hardware fault in the internal circuit is detected at an output, all module outputs are disabled (“0” = OFF = safe state).
The relevant diagnostic message is transmitted to the safe controller (see Chapter
“Safe Digital Output Errors” on page 57 ).
All serious errors that can result in the loss of or adversely affect the safety function cause the entire module to enter the safe state. The FS LED on the safety module is permanently on.
The following errors result in the safe state:
•
•
Serious hardware fault in the internal circuit
User error
•
•
Module overload
Overheating of the module
• Incorrect supply
The relevant diagnostic message is transmitted to the safe controller (see Chapter
“Errors: Messages and Removal” on page 55
).
WARNING Loss of the safety function due to sequential errors
In the event of a device error, the following measures should be taken to prevent sequential errors:
Disconnect the module from the power supply and replace it.
3.7.4
Parameterization Errors
Parameterization errors are indicated:
• or
As long as the module is not parameterized
• In the event of faulty parameterization
Parameterization errors cause the entire module to enter the safe state. The FS
LED on the safety module flashes.
In the event of faulty parameterization, the relevant diagnostic message is transmitted to the safe controller (see
Chapter “Parameterization Errors” on page 59 ).
Exception:
If an output is operated in stop category 1 and this output is within the switch-off delay time, then faulty parameterization results in the entire module switching to the safe state only once the switch-off delay time has elapsed.
24
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Product Description
3.8
Enabling Safe Outputs for PROFIsafe
A “1” is only forwarded by the PST (PROFIsafe driver for F-Slaves) to the SAL
(safety application layer) for a safe output if the consecutive number has changed in the corresponding PROFIsafe container.
A “0” is always forwarded.
This prevents the toggling of an output by telegrams with the same consecutive number (e.g., by changing the order of PROFIsafe containers with the same consecutive number).
3.9
PROFIsafe process Data Words (PROFIBUS, PROFINET)
The module occupies four words in the Rexroth Inline system. The way in which these words are mapped in the higher-level control system is specific to the controller used and is described in the system documentation for the controller system used.
3.10
Programming Data/Configuration Data
3.10.1
Local Bus
Switch address
Mode switch
ID code
Length code
Input address area
Output address area
Parameter channel (PCP)
Register length
PROFIsafe
Any, 1 hex
.... 3FE hex
Mode 1
CB hex
(203 dec
)
04 hex
(04 dec
)
Controller-specific
Controller-specific
1 word
4 words
The PCP channel is only used internally.
3.10.2
PROFIBUS, PROFINET
The programming data/configuration data is defined in the device description (e.g., GSD, GSDML, etc.) according to the bus or network used.
4
4.1
4.2
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Inline Potential and Data Routing, and Inline Connectors
Inline Potential and Data Routing, and Inline Connectors
Inline Potential and Data Routing
In order to operate the safety module it must be integrated in a Rexroth Inline station within the PROFIsafe system.
The bus signals are transmitted via the Inline data jumpers. The required supply voltages are transmitted via the Inline potential jumpers.
For more detailed information about potential and data routing within a Rexroth Inline station, please refer to the DOK-CONTRL-ILSYS-
INS***-AW..-EN-P application description.
The segment circuit is looped through the safety module and is available again after the module. The segment circuit cannot be accessed in the safety module.
Supply Voltage U
L
Supply the 24 V supply voltage U
BK
/U
24V
at a bus coupler or a suitable power terminal (R-IB IL 24 PWR IN/R-PAC). The 7.5 V voltage U
L
is generated from this
24 V supply voltage in the bus coupler or power terminal. It is supplied to the safety module via the Inline potential jumper U
L
.
WARNING Loss of the safety function when using unsuitable power supplies
Please note for the voltage supply at the bus coupler or power terminal that:
Only power supplies according to EN 50178/VDE 0160 (PELV) may be used.
Make sure that the output voltage of the power supply does not exceed 32 V even in the event of an error.
Please also observe the points in
Chapter “Electrical Safety” on page 9 .
The supply voltage U
L
is used to supply the communications power. For the technical data for supply voltage U
L
, please refer to “Supply voltage U
The maximum current carrying capacity for the supply voltage U
L
is 2 A.
This current carrying capacity can be reduced if certain terminals are used. Please refer to the information in the terminal-specific data sheets.
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4.3
Supply Voltage U
M
Supply the supply voltage at a bus coupler or a power terminal. It is supplied to the safety module via the Inline potential jumper U
M
.
WARNING Loss of the safety function when using unsuitable power supplies
Please observe the points in Chapter “Electrical Safety” on page 9 .
The supply voltage U
M
is used to supply the output circuits. For the technical data for supply voltage U
M
, please refer to
The maximum current carrying capacity for the main circuit U
M
is 8 A (total current with the segment circuit that is not used in the safety terminal). This current carrying capacity can be reduced if certain terminals are used. Please refer to the information in the terminal-specific data sheets.
If the limit value of the potential jumpers U
M
and U
S
is reached (total current of U
S and U
M
), a new power terminal must be used.
NOTICE Module damage due to polarity reversal
Polarity reversal places a burden on the electronics and, despite protection against polarity reversal, can damage the module. Therefore, polarity reversal must be prevented.
For the behavior of the safety module in the event of an error at the supply voltage,
please refer to Chapter “Supply Voltage Errors” on page 58 .
230 V
24 V
+
-
24 V DC
(PELV)
External fuse
8 A, maximum
U for supply at a bus coupler or a power terminal (not required in the safety terminal)
U for supply at a bus coupler or a power terminal
Fig. 4-1
GND for supply at a bus coupler or a power terminal
76192004
Supply U
M
with connection to functional earth ground according to
EN 60204-1
WARNING Loss of functional safety due to parasitic voltages
Supply the supply voltages U
M
and U
S
at a bus coupler and/or a power terminal from the same power supply unit, so that the loads of R-IB IL 24 PSDO 8-PAC are not affected by parasitic voltages in the event of an error.
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Inline Potential and Data Routing, and Inline Connectors
NOTICE Damage to module electronics in the event of surge voltage
Do not use a DC distribution network.
DC distribution network according to IEC 61326-3-1:
A DC distribution network is a DC power supply network, which supplies a complete industrial hall with DC voltage and to which any device can be connected. A typical system or machine distribution is not a DC distribution network. For devices that are provided for a typical system or machine distribution, the DC connections are viewed and tested as I/O signals according to IEC 61326-
3-1.
28
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Inline Potential and Data Routing, and Inline Connectors
4.4
Terminal Point Assignment
1 2 1 2 1 2 1 2
1.1
2.1
3.1
4.1
5.1
6.1
7.1
8.1
1.1
1.2
1.3
1.2
2.2
3.2
4.2
5.2
6.2
7.2
8.2
1.3
2.3
3.3
4.3
5.3
6.3
7.3
8.3
1.4
1.4
2.4
3.4
4.4
5.4
6.4
7.4
8.4
8.1
8.2
8.3
8.4
Fig. 4-2
73411004
Terminal point assignment
The Inline connectors are supplied with the module. They are keyed and labeled accordingly for connection to prevent polarity reversal. If other connectors are used according to the ordering data, they must also be keyed.
Only use the connectors supplied with the module or connectors that
are approved as replacement items (see “Ordering Data: Documentation” on page 71 ).
•
•
•
The following applies for the tables below:
All outputs are safe digital outputs
0 V (GND): Common ground for outputs
FE: Common functional earth ground
LED
0.1
0.2
Terminal point
1.1
2.1
1.2
2.2
1.3
2.3
1.4
2.4
Fig. 4-3
Signal
OUT0_Ch1
OUT0_Ch2
Not used
Not used
0 V (GND)
0 V (GND)
FE
FE
Channel assignment
Output 0, channel 1
Output 0, channel 2
Channel 1 and channel 2
Channel 1 and channel 2
Terminal point assignment for connector 1
Terminal point
3.1
4.1
3.2
4.2
3.3
Fig. 4-4
Signal
OUT1_Ch1
OUT1_Ch2
Not used
Not used
0 V (GND)
Channel assignment
Output 1, channel 1
Output 1, channel 2
Channel 1 and channel 2
Terminal point assignment for connector 2
LED
1.1
1.2
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Terminal point
4.3
3.4
4.4
Fig. 4-4
Signal
0 V (GND)
FE
FE
Channel assignment
Channel 1 and channel 2
Terminal point assignment for connector 2
Terminal point
5.1
6.1
5.2
6.2
5.3
6.3
5.4
6.4
Fig. 4-5
Signal
OUT2_Ch1
OUT2_Ch2
Not used
Not used
0 V (GND)
0 V (GND)
FE
FE
Channel assignment
Output 2, channel 1
Output 2, channel 2
Channel 1 and channel 2
Channel 1 and channel 2
Terminal point assignment for connector 3
Terminal point
7.1
8.1
7.2
8.2
7.3
8.3
7.4
8.4
Fig. 4-6
Signal
OUT3_Ch1
OUT3_Ch2
Not used
Not used
0 V (GND)
0 V (GND)
FE
FE
Channel assignment
Output 3, channel 1
Output 3, channel 2
Channel 1 and channel 2
Channel 1 and channel 2
Terminal point assignment for connector 4
LED
LED
2.1
2.2
LED
3.1
3.2
WARNING Loss of functional safety due to parasitic voltages
Connect the ground of the actuator to the ground terminal point of the corresponding output on the Inline connector. An external ground may not be used.
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5
5.1
5.1.1
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Assembly, Removal, and Electrical Installation
Assembly, Removal, and Electrical Installation
Assembly and Removal
Unpacking the Module
The module is supplied in an ESD box together with a package slip with installation instructions. Please read the complete package slip carefully.
The module may only be installed and removed by qualified personnel.
NOTICE Electrostatic discharge
The safety module contains components that can be damaged or destroyed by electrostatic discharge. When handling the safety module, observe the necessary safety precautions against electrostatic discharge (ESD) according to
EN 61340-5-1 and EN 61340-5-2.
5.1.2
General
WARNING Unintentional machine startup
Do not assemble or remove the module while the power is connected.
Before assembling or removing the module, disconnect the power to the module and the entire Rexroth Inline station and ensure that it cannot be switched on again.
Make sure the entire station is reassembled before switching the power back on.
Observe the diagnostic indicators and any diagnostic messages.
The system may only be started provided neither the station nor the system poses a hazard.
The R-IB IL 24 PSDO 8-PAC safety terminal is designed for use within a Rexroth
Inline station. Only use the safety terminal in the 24 V DC area of an Inline station.
To ensure reliable operation, install the safety terminal in housing protected from dust and humidity (IP54 or higher). In order to prevent manipulation, secure the housing (control cabinet/control box) against being opened by unauthorized persons.
Mount all Inline terminals on 35 mm DIN rails.
Only connect the cables using the supplied Rexroth Inline connectors or Inline connectors listed in the ordering data.
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Assembly, Removal, and Electrical Installation
5.1.3
Setting the DIP Switches
The module has a 2-pos. and a 10-pos. DIP switch.
The DIP switches are located on the left-hand side of the safety module.
500KBD
Mode2 9 8 7 6 5 4 3 2 1 0
2MBD Mode1
A
2MBD Mode1
B 9 8 7 6 5 4 3 2 1 0
F-Address on off
76023004
Fig. 5-1
A B
DIP switches
2-pos. DIP switch:
Left switch:
Transmission speed
A
B
Switch for setting the transmission speed and the operating mode
Switch for setting the address
The transmission speed and the operating mode (Mode) are set via the 2-pos. DIP switch.
The transmission speed can be set to 500 kbaud or 2 Mbaud.
The transmission speed is set to 500 kbaud by default.
Only use devices with a uniform transmission speed within an Inline station (a local bus). A mixture of devices with different transmission speeds cannot be operated.
For PROFIsafe, set Mode 1.
Right switch:
Mode
10-pos. DIP switch: Address Use this DIP switch to set the PROFIsafe address (F-Address).
PROFIsafe addresses 1 to 1022 (1 hex to 3FF hex
) are permitted. The DIP switch
3FF hex is not valid. The DIP switch is set to 200 hex
by default (DIP-9 switch to “on”).
Overview of the switch positions
Procedure
Mode switch
9 8 7
PROFIsafe
Address switch
6 5 4 3 2 1 0
Mode 1
1 hex
to 3FE hex
Fig. 5-2 Switch position
If the DIP switch settings have to be modified, proceed as follows:
• Use the switch to set the transmission speed to 500 kbaud or 2 Mbaud.
• Set the address.
Set the DIP switches before assembling the module in the Rexroth
Inline station. The switches cannot be accessed when the safety terminal is installed in the Inline station.
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Assembly, Removal, and Electrical Installation
Assembly and Removal of the Safety Module
For general information about mounting and removing Rexroth Inline terminals, please refer to the DOK-CONTRL-ILSYS-
INS***-AW..-EN-P application description.
Assembly
•
•
Set the DIP switches prior to assembly (see
DIP Switches” on page 32 ). The DIP switches cannot be ac-
cessed when the safety module is installed in the Inline station.
Observe a mounting distance of 30 mm above and 40 mm below the safety module. Shorter distances may inhibit proper handling during installation.
• Disconnect the power to the station.
– Snap on base • Before snapping on the safety module, remove the inserted connectors from the safety terminal and the adjacent connector from the neighboring Inline terminal on the left.
This prevents the potential routing knife contacts and the keyway/featherkey connections from being damaged.
• Hold the safety module perpendicular and snap it onto the DIN rail (7.5 mm in height).
Ensure that all featherkeys and keyways on adjacent terminals are securely interlocked.
A B
Fig. 5-3 Snapping on the safety module base
• Check that all the snap-on mechanisms are securely snapped into place.
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Assembly, Removal, and Electrical Installation
– Insert connectors • Insert the connectors in the specified order (A, B).
Only use the connectors supplied with the module or connectors that
are approved as replacement items (see “Ordering Data: Documentation” on page 71 ).
B
Fig. 5-4
A
Inserting the connector
Removal • Disconnect the power to the station.
• Before snapping on the safety module, remove the connectors from the safety module and the adjacent connector from the neighboring Inline terminal on the left.
– Remove connectors • Remove the connector by pressing the back shaft latching (A) and levering off the connector (B).
A
B
Fig. 5-5 Removing the connector
– Remove base • Release the base by pressing on the front and back snap-on mechanisms (A) and pull it out perpendicular to the DIN rail (B).
A
B
Fig. 5-6
A
Removing the safety module base
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5.2
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Assembly, Removal, and Electrical Installation
Electrical Installation
WARNING Electric shock/unintentional machine startup
Prior to electrical installation, disconnect the power to the system and make sure that it cannot be switched on again unintentionally.
Make sure installation has been completed before switching the power back on.
The system may only be started provided the system does not pose a hazard.
5.2.1
5.2.2
Electrical Installation of the Rexroth Inline Station
Electrical installation of the Rexroth Inline station includes the following:
•
•
Connecting PROFIBUS or PROFINET to the Inline station
Connecting the supply voltages for the Rexroth Inline station
Carry out electrical installation for the Rexroth Inline station according to the
DOK-CONTRL-ILSYSINS***-AW..-EN-P application description or the Inline system manual for your bus system. Please also observe the specifications in the documentation for the bus coupler used.
Electrical Installation of the Safety Module
During installation, always observe the instructions in “Electrical Safety” on page 9
.
Take measures to prevent the incorrect connection, polarity reversal, and manipulation of connections.
The supply voltages are supplied at a bus coupler and/or a power terminal and are supplied to the safety module via the potential jumpers. Therefore the electrical installation of the safety module only involves connecting the actuators.
The actuators are connected via Inline connectors.
• Wire the connectors according to your application. For the terminal point assignment, please refer to
Chapter “Terminal Point Assignment” on page 28 .
For wiring, proceed as follows:
• Strip 8 mm off the cable.
Inline wiring is normally done without ferrules. However, it is possible to use ferrules. If using ferrules, make sure they are properly crimped.
• Push a screwdriver into the slot of the appropriate terminal point (
that you can insert the wire into the spring opening.
Bosch Rexroth recommends a screwdriver with a 0.6 mm x 3.5 mm x 100 mm shaft.
•
, detail 2). Remove the screwdriver from the opening. This clamps the wire.
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1
2
6452C032
Fig. 5-7 Connecting unshielded cables
• Insert the assembled connectors in the corresponding module slot (see
Chapter “Terminal Point Assignment” on page 28 ).
• Label all connections to prevent connections to the Inline connectors being mixed up
(see DOK-CONTRL-ILSYSINS***-AW..-EN-P application description).
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6
Parameterization of the Safety Module
Parameterization of the Safety Module
6.1
Parameterization in a PROFIsafe System
PROFIsafe address
Parameterization of outputs
F-Parameters and iParameters
Parameterization includes the following:
• Assigning the PROFIsafe address via the configuration software of the control system manufacturer
•
•
Parameterization of outputs
Specifying the parameterizable F-Parameters and iParameters
The PROFIsafe address is a unique ID for the safety module in the PROFIsafe structure. It is assigned in the configuration software. Set this address via the DIP
switches prior to assembly (see “Setting the DIP Switches” on page 32 ).
The parameterization of the safe outputs determines the behavior of the module and thus has a considerable effect on the safety integrity level that can be achieved.
To parameterize the module, the parameterization of the safe controller created in the parameterization tool is automatically written to the module on every power up or reset.
The following conditions must be met:
•
•
The supply voltage is present.
The communication connection has been established between the controller and safety module.
The module cannot be operated if it is not parameterized.
In this case, the FS LED flashes.
The module is ready to operate if the parameters for all outputs are valid and transmitted without errors. Valid output data is only written in this state. In any other state, every output is set to the safe state.
If errors are detected during parameterization, the parameterization data is not transmitted. The invalidity of the parameterization is indicated on the module by the flashing FS LED.
In addition, errors are indicated at the safe controller. In this case, check and correct the settings. For information about error messages and instructions for their removal, please refer to
Chapter “Errors: Messages and Removal” on page 55 .
Assign the parameterizable F-Parameters and iParameters. For an overview of the module parameters and possible settings, please refer to
Chapter “F-Parameters and iParameters” on page 75
.
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Parameterization of the Safety Module
6.2
Parameterization of the Safe Outputs
Two-channel
Single-channel
Parameterization
The individual outputs of a safety module can be parameterized differently and thus achieve different safety integrity levels (SIL, SIL CL, Cat., PL).
If the outputs are operated via two channels, the following fixed assignment applies:
•
•
•
OUT0_Ch1 to OUT0_Ch2
OUT1_Ch1 to OUT1_Ch2
OUT2_Ch1 to OUT2_Ch2
• OUT3_Ch1 to OUT3_Ch2
If two-channel operation in the external wiring of the outputs is not required, the outputs can be parameterized in such a way that they operate independently of one another (single-channel).
Parameterize all safe outputs individually. The parameterization options are
Parameterization
Assignment
Output
Switch-off delay for stop category 1
Switch-off delay for stop category 1
Value range
OUT0 - OUT3
Not used
Used
Single-channel
Two-channel
Disabled
Enabled
1 to 63
Value range of switch-off delay for stop category 1
Value x 10 in ms
Value x 100 in ms
Value in s
Value x 10 in s
Disabled
Enabled
Test pulses (output disabled) (in software: test impulses (output switched off))
Fig. 6-1 Parameterization of outputs
Remark
The unused outputs are disabled. However, the monitoring of these outputs remains active.
In two-channel operation, the assignment of the outputs to one another is specified and cannot be parameterized.
Disabled (default): No switch-off delay.
Enabled: The outputs are switched off once the parameterized switch-off delay has elapsed.
Please observe the notes below this table.
Time conversion according to the parameterization of the “Value range of switch-off delay for stop category 1” parameter.
Permissible value range:
OUT0 to OUT3:
Accuracy:
150 ms to 630 s
±5% of parameterized value
Please observe the notes below this table.
Value range/unit for the parameterization of the “Switch-off delay for stop category 1” parameter.
Please observe the notes below this table.
Activation and deactivation of test pulses. For these test pulses, the output drivers that are switched off are temporarily switched on for test purposes.
See note below this table.
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Parameterization of the Safety Module
Test pulses
Switch-off delay for stop category 1
Two-channel parameterization
Note on test pulses
If the test pulses are disabled, cross circuits and short circuits cannot be detected.
Regardless of the parameterization selected under “Test impulses
(output switched off)”, the outputs parameterized as “Not used” are tested by test pulses.
Please also observe Chapter “Requirements for controlled devices/actuators” on page 19
and
Chapter “Connection Examples for
The switch-off delay for stop category 1 is calculated from the “Switch-off delay for stop category 1” and “Value range of switch-off delay for stop category 1” parameters.
Switch-off delay for stop category 1 =
Switch-off delay for stop category 1 *
Value range of switch-off delay for stop category 1
If the switch-off delay for stop category 1 is parameterized with a value less than 150 ms, this value is rejected as a parameterization error
(error code 028x hex
).
Please note the following for two-channel parameterization:
Ensure that the values for the switch-off delay for stop category 1 are the same for both channels. This means that the time must have the same value and the same value range.
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Parameterization of the Safety Module
6.3
Behavior of the Outputs in the Event of Enabled Switch-
Off Delay for Stop Category 1
Depending on the event that causes the outputs to be switched off, the parameterization of the switch-off delay the time until the outputs are actually switched off can vary.
Disconnection of outputs Influence of parameterized switch-off delay
Yes
Disconnection of outputs
•
•
By the safe controller
After a bus error Yes
After the parameterized switchoff delay has elapsed
After the parameterized switchoff delay has elapsed
Immediately (only stop category 0)
• After a short circuit, cross circuit, failure of the supply voltage or hardware fault
No
Fig. 6-2 Disconnection of the outputs according to the trigger event and the parameterization
WARNING Delayed shutdown when using stop category 1
For stop category 1 please take into consideration the following:
In the event of an error (excluding bus errors) the affected outputs are switched off immediately (without delay). In this case, only stop category 0 is supported.
WARNING Incorrect design of safety distances due to incorrect calculation of the overall shutdown time
When designing the safety distances, please take into consideration the parameterized switch-off delay time.
•
•
For the switch-off operation, please take into consideration the following:
•
•
The switch-off operation can be interrupted by switching the output on again.
If the parameterization of the module is modified, the modified parameterization does not take effect until all the outputs have been switched off.
If the parameterization is modified before the switch-off operation is complete, diagnostic message 02F2 hex
is generated.
Carry out a validation every time the parameterization is modified.
Please note that when the parameterization is modified, this can result in delayed startup due to the switch-off delay time.
7
7.1
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Connection Examples for Safe Outputs
Connection Examples for Safe Outputs
Explanation of the Examples
Depending on the type of wiring, the outputs of a module can achieve different safety integrity levels (SIL, SIL CL, Cat., PL) at the same time (as long as the settings do not contradict one another).
The following examples only describe the options for the electrical connection of controlled devices/actuators to the safe outputs.
Should you have any questions regarding applications to be implemented, please contact the Bosch Rexroth safety hotline (see
“Safety Hotline” on page 13 ).
The following are specified for each example:
•
•
Basic specifications
The main data for the example is specified in the table.
Device diagnostics and behavior of the module in the event of an error
Diagnostic capability depends on the parameterization.
If a message is transmitted to the safe controller in the event of an error, the message is specified in the tables. For information about the relevant error code, possible remedies, and information about whether acknowledgment is
required, please refer to Chapter “Errors: Messages and Removal” on page 55 .
• Typical parameterization
The table illustrates an example of all the parameters for the specified assignment.
Key for all tables in this section:
Representation
SF
OUTx
Meaning
Safety function
OUT1 or OUT2 LED; diagnostic message for each output
Fig. 7-1 “Device diagnostics and behavior of the module in the event of an error” tables
Representation
Meaning
Bold
Normal
–
Mandatory setting
Typical setting, another setting is possible depending on the application
Not evaluated
Fig. 7-2 Parameterization tables
Errors (cross circuits, short circuits), which can be prevented by correct installation
(e.g., protected cable installation, isolated cable installation, double insulation, use of ferrules) are not described in the following tables.
Therefore, for example, only errors between outputs, which are on the same connector, are described. For example, in the event of correct installation, cross circuits with outputs of other connectors cannot occur.
For all examples, please also observe the measures specified in the individual tables, which must be taken to achieve the specified
SIL/SIL CL/Cat./PL and all measures according to standards EN
61508, EN 62061, and EN ISO 13849-1 to achieve the specified
SIL/SIL CL/Cat./PL.
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Connection Examples for Safe Outputs
WARNING Disregarding this warning may lead to the loss of the safety function
An external voltage may not be supplied in an output (e.g., via cross circuits).
These errors can adversely affect the operation of the module (or even destroy the module) and thus result in the loss of the safety function. Therefore, these errors must be prevented. Install the connecting cables for connecting the actuators so that they are protected against cross circuits.
Please observe the load capacity of the outputs according to the technical data in
“Safe Digital Outputs” on page 18
.
7.2
Notes on the Protective Circuit for External
Relays/Contactors (Free Running Circuit)
Fig. 7-3
K1
69401021
Example of the free running circuit for an external relay
•
•
•
Limit the voltage induced on circuit interruption to < -15 V (e.g., with RC elements, suppressor diodes or varistors).
Please note that the free running circuit affects the fall time and the service life of the contactor.
Please observe the specifications of the relay manufacturer when sizing the relay protective circuit.
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7.3
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Connection Examples for Safe Outputs
Measures Required to Achieve a Specific Safety Integrity
Level
The safety integrity level (SIL, SIL CL, performance level, and category) that can be achieved is specified for each connection example.
SIL, SIL CL
In order to determine the probability of failure according to EN 61508
(SIL), use the standard.
In order to determine the probability of failure according to EN 62061
(SIL CL), use the standard.
When the SIL/SIL CL is specified, the module takes up 1% of the specified SIL/SIL
CL.
SIL 2/SIL CL 2
SIL 3/SIL CL 3
Fig. 7-4
PFD
1% of 10
-2
1% of 10
-3
PFD and PFH depending on the SIL/SIL CL
PFH
1% of 10
-6
1% of 10
-7
Performance level
Use standard EN ISO 13849-1 to determine the performance level.
Category
•
•
In order to actually achieve the specified category, the required measures listed below must be implemented.
Cat. 2
•
•
•
•
•
Use proven safety principles.
Use appropriately qualified actuators (see
Chapter “Requirements for controlled devices/actuators” on page 19
).
Please note that mechanical failure of the switching device can result in the loss of the safety function.
Prevent the welding of contacts on the connected contactors or safety relays with appropriate protection against overcurrent and surge voltage.
Please note that a single error can result in the loss of the safety function between tests.
Ensure that the external wiring is tested by the machine control system on machine startup and at suitable intervals. This test must detect the loss of the safety function.
In the event of an error, either safe disconnection must be implemented or a warning (optical and/or audible) must be generated depending on the application.
44
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Connection Examples for Safe Outputs
•
•
•
Cat. 3
•
•
•
•
•
Use proven safety principles.
Use appropriately qualified actuators (see
Chapter “Requirements for controlled devices/actuators” on page 19
).
Please note that mechanical failure of the switching device can result in the loss of the safety function.
Prevent the welding of contacts on the connected contactors or safety relays with appropriate protection against overcurrent and surge voltage.
All errors (e.g., cross circuits) that cannot be detected can result in the loss of the safety function. Take appropriate measures to prevent such errors.
Suitable measures include, for example, protected cable installation or double insulation. Please note the information in the following tables.
Please take into consideration errors with a common cause.
Ensure that a single error does not result in the loss of the safety function.
Once the test pulses have been disabled, test the shutdown capability of the actuators at regular intervals.
•
•
Cat. 4
•
•
•
•
•
•
Use proven safety principles.
Use appropriately qualified actuators (see
Chapter “Requirements for controlled devices/actuators” on page 19
).
Please note that mechanical failure of the switching device can result in the loss of the safety function.
Prevent the welding of contacts on the connected contactors or safety relays with appropriate protection against overcurrent and surge voltage.
An accumulation of errors must not result in the loss of the safety function.
Following the third error, evaluation can be aborted if the probability of further errors occurring is low.
All errors (e.g., cross circuits) that cannot be detected can result in the loss of the safety function. Take appropriate measures to prevent such errors.
Suitable measures include, for example, protected cable installation or double insulation. Please note the information in the following tables.
Please take into consideration errors with a common cause.
Once the test pulses have been disabled, test the shutdown capability of the actuators at regular intervals.
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7.4
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Connection Examples for Safe Outputs
Single-Channel Assignment of Safe Outputs
OUT1_Ch1
K1
K1 (R)
GND
K2
K2 (R)
Actuator
Achievable
SIL/SIL CL/Cat./PL
Fig. 7-5
M
73422005
Single-channel assignment of outputs
•
•
In order to achieve Cat. 3 or PL d with single-channel assignment of the outputs, a two-channel actuator must be used. The two-channel operation of the actuator with the corresponding connection is represented on a gray background.
The failure detection time is 20 ms. This means that high pulses of this width can occur in the event of an error.
If the application responds to these pulses, use the two-channel assignment of the outputs.
K1 (R) and K2 (R) represent the positively driven N/C contacts for monitoring the state of the relay (readback contacts). Connect these contacts via safe digital inputs. Evaluate the readback and thus the state of the switching elements in your safe application program.
WARNING Loss of safety function
Connect the actuator ground directly to terminal point GND of the safety module.
An external ground may not be used.
Basic specifications
Single-channel
SIL 2/SIL CL 2/Cat. 2/PL c
Two-channel
SIL 2/SIL CL 2/Cat. 3/PL d
•
•
•
•
•
WARNING Loss of electrical and functional safety
To achieve the specified safety integrity level, please refer to Chapter
“Measures Required to Achieve a Specific Safety Integrity Level” on page 43
.
Please note that in order to achieve the specified PL, the actuator must have a medium level of diagnostic coverage (90% to 99%) and medium MTTFd. A high level of diagnostic coverage (> 99%) is recommended for the application according to PL d.
To achieve Cat. 3 and PL d the test pulses must be enabled.
Use actuators that can achieve the required safety integrity level.
Evaluate the readback contacts to achieve the corresponding safety integrity level.
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Connection Examples for Safe Outputs
Enable the test pulses to improve device diagnostics.
If the test pulses for the actuator are faulty, they can be disabled. In this case, test the switching capability of the outputs at regular intervals.
Device diagnostics and behavior of the module in the event of an error
Error type Detection
Error in the actuator
Despite being disabled, the actuator does not switch to the safe state (e.g., a contact will not open)
No
Actuator cannot be enabled
(e.g., interrupt)
No
Diagnostics
None
None
Loss of
SF
Remark
Yes
No
Detect errors using external monitoring. Please take into consideration all the possible errors for the actuator used.
Test the shutdown capability of the actuator at regular intervals.
If necessary, use a two-channel actuator.
Detect errors using external monitoring. Please take into consideration all the possible errors for the actuator used.
Ensure that this error does not result in delayed system startup.
Please take into consideration all possible errors that can occur in the actuator.
Other errors
(depending on the actuator)
Error in the wiring
Interrupt
Cable interrupt between output and actuator or between actuator and ground
Cross circuit
Output to output
No None No
Yes All LEDs
OUT:
Red ON
Yes
Short circuit
Output to ground or output to FE
Fig. 7-6
Yes Short circuit or overload,
OUTx
No
Single-channel: Test pulses enabled
Detect errors using external monitoring. Please take into consideration all the possible errors for the actuator used.
Ensure that this error does not result in delayed system startup.
When the outputs are disabled, a cross circuit between the outputs is only detected if the test pulses are enabled. If an error is detected, the module disables all its outputs.
The error is detected in the ON state. The output is disabled (safe state). The module cannot be switched on again with an edge from “0” to “1” until the error has been removed and acknowledged.
WARNING Unexpected machine startup
An operator acknowledgment leads to a positive edge and can thus result in the outputs being re-enabled.
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Connection Examples for Safe Outputs
Typical parameterization
Parameterization
Assignment
Parameterized as
Used
Output
Switch-off delay for stop category
1
Single-channel
Enabled
Switch-off delay for stop category
1
Value range of switch-off delay for stop category 1
30
Value in s
Test pulses (output disabled) (in software: test impulses (output switched off))
Enabled
Remark
Or disabled
Application-specific
Application-specific
Or disabled
According to the “Value range of switch-off delay for stop category 1” and “Switchoff delay for stop category 1” parameters, in this example, the switch-off delay is
30 x 1 s = 30 s.
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Connection Examples for Safe Outputs
7.5
Two-Channel Assignment of Safe Outputs
For two-channel assignment of the safe outputs, two adjacent outputs are always used. This assignment is fixed and cannot be parameterized (see
Chapter “Twochannel” on page 38 ).
Actuator
Achievable SIL/SIL
CL/Cat./PL
OUT1_Ch1
K1
K1 (R)
GND
OUT1_Ch2
GND
Fig. 7-7
K2
K2 (R)
M
73421006
Two-channel assignment of outputs
K1 (R) and K2 (R) represent the positively driven N/C contacts for monitoring the state of the relay (readback contacts). Connect these contacts via safe digital inputs. Evaluate the readback and thus the state of the switching elements in your safe application program.
WARNING Loss of safety function
•
•
Connect the actuator ground directly to terminal point GND of the safety module. An external ground may not be used.
The failure detection time is 20 ms. This means that high pulses of this width can occur at the faulty output (channel) in the event of an error. The two-channel assignment means that this does not result in a hazardous state.
Basic specifications
Two-channel
SIL 3/SIL CL 3/Cat. 4/PL e
•
•
•
•
•
WARNING Loss of electrical and functional safety
To achieve the specified safety integrity level, please refer to Chapter
“Measures Required to Achieve a Specific Safety Integrity Level” on page 43
.
Please note that in order to achieve the specified PL, the actuator must have a medium level of diagnostic coverage (90% to 99%) and medium MTTFd. A high level of diagnostic coverage (> 99%) is recommended for the application according to PL d.
Use actuators that can achieve the required safety integrity level.
Evaluate the readback contacts to achieve Cat. 3 or Cat. 4.
If the test pulses are disabled:
Test the outputs and external wiring by enabling the outputs at regular intervals. The time between two tests must not exceed eight hours.
Enable the test pulses to improve device diagnostics.
If the test pulses for the actuator are faulty, they can be disabled. In this case, test the switching capability of the outputs at regular intervals.
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Connection Examples for Safe Outputs
Device diagnostics and behavior of the module in the event of an error
Error type Detection
Error in the actuator
Despite being disabled, a switching element of the two-channel actuator does not switch to the safe state (e.g., a contact will not open)
No
Actuator cannot be enabled
(e.g., interrupt)
No
Diagnostics
None
None
Loss of
SF
Remark
No
No
No loss of the safety function as the second switching element of the two-channel actuator can be disabled.
Detect errors using external monitoring.
Implement a restart inhibit in the event of this error.
Please take into consideration all the possible errors for the actuator used.
Test the shutdown capability of the actuator at regular intervals.
Detect errors using external monitoring. Please take into consideration all the possible errors for the actuator used.
Ensure that this error does not result in delayed system startup.
Please take into consideration all possible errors that can occur in the actuator.
Other errors
(depending on the actuator)
Error in the wiring
Interrupt
Cable interrupt between output and actuator or between actuator and ground
Cross circuit
Output to output
No None No Detect errors using external monitoring. Please take into consideration all the possible errors for the actuator used.
Ensure that this error does not result in delayed system startup.
Yes (conAll LEDs ditional) OUT:
Red ON
No When the outputs are disabled, a cross circuit between the outputs is only detected if the test pulses are enabled. If an error is detected, the module disables all its outputs.
If the test pulses have been disabled, test the circuit and the external wiring at regular intervals by enabling the outputs.
Short circuit
Output to ground or output to FE
Yes Short circuit or overload,
OUTx
No The error is detected in the ON state. The output is disabled (safe state). The module cannot be switched on again with an edge from “0” to “1” until the error has been removed and acknowledged.
Fig. 7-8 Two-channel
WARNING Unexpected machine startup
An operator acknowledgment leads to a positive edge and can thus result in the outputs being re-enabled.
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Connection Examples for Safe Outputs
Typical parameterization
Parameterization
Assignment
Output
Parameterized as
Channel 1
Used
Two-channel
Switch-off delay for stop category
1
Enabled
Switch-off delay for stop category
1
30
Value range of switch-off delay for stop category 1
Value in s
Test pulses (output disabled) (in software: test impulses (output switched off))
Enabled
Channel 2
Used
Two-channel
Enabled
30
Value in s
Enabled
Remark
Or disabled
Application-specific
Application-specific
According to the “Value range of switch-off delay for stop category 1” and “Switchoff delay for stop category 1” parameters, in this example, the switch-off delay is
30 x 1 s = 30 s.
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Startup and Validation
8 Startup and Validation
8.1
Initial Startup
To start up, proceed as described in Fig. 8-1
.
Step
Set the transmission speed and the operating mode.
Set the address.
Install the safety module within the Inline station.
Connect the bus system and supply voltage cables to the
Inline station.
Wire the outputs according to your application.
Application descriptions for the function blocks used
Before applying the operating voltage:
• Ensure that there are no wiring errors (e.g., cross circuit or short circuit) or grounding errors by testing with a multimeter.
• Check whether the ground connection is safe.
Connect the required voltages to the Inline station.
Connect the required voltages (U
M
) to the safety module.
Once the operating voltage has been applied:
•
•
•
If possible, measure the wave form of the voltages to ensure that there are no deviations.
Measure the output voltages on the module, as well as the supply voltages, which supply the connected loads (e.g., motor) to ensure that they are in the permissible range.
Use the LEDs on the devices to check that the module starts up without any errors (there must be no red LEDs permanently on; the FS LED flashes because the device is not parameterized).
DOK-CONTRL-ILSYSINS***-AW..-EN-P application description or documentation for the bus coupler
Check the assembly and installation.
Carry out the necessary parameterization.
Checklist
“Assembly, Removal, and Electrical Installation” on page 31
Chapter “Parameterization of the Safety Module” on page 37
Documentation for the controller used
Fig. 8-1 Steps for startup
Relevant section and literature
Chapter “Setting the DIP Switches” on page 32
Chapter “Setting the DIP Switches” on page 32
Chapter “Assembly, Removal, and Electrical Installation” on page 31
DOK-CONTRL-ILSYSINS***-AW..-EN-P application description or documentation for the bus coupler
Chapter “Assembly, Removal, and Electrical Installation” on page 31
Chapter “Inline Potential and Data Routing, and Inline
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Startup and Validation
Step
Program the safety function.
Relevant section and literature
Application descriptions for the function blocks used
For PROFIsafe: When verifying the safety function, check whether the F_iPar_CRC parameter is greater than 0 for all devices. If not, modify the settings.
Documentation for the controller used
Checklist
Quick start guide for configuring Inline modules with safe inputs or outputs under PROFIsafe on your controller
Checklist
Perform a function test and validation. Check whether the safety function responds as planned during programming and parameterization.
Fig. 8-1 Steps for startup [...]
When connecting the supply voltages, use the diagnostic and status indicators to check whether the module has started up correctly or whether any errors are indicated. For instructions on how to proceed in the event of an error, please refer
to Chapter “Errors: Messages and Removal” on page 55
.
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Startup and Validation
8.2
8.2.1
Restart after Replacing a Safety Module
Replacing a Safety Module
8.2.2
8.3
WARNING Unintentional machine startup
Do not assemble or remove the module while the power is connected.
Before assembling or removing the module, disconnect the power to the module and the entire Inline station and ensure that it cannot be switched on again.
Make sure the entire station is reassembled before switching the power back on.
Observe the diagnostic indicators and any diagnostic messages.
The system may only be started provided neither the station nor the system poses a hazard.
•
•
If replacing a module, proceed as described for assembly and removal (see
Chapter “Assembly, Removal, and Electrical Installation” on page 31 ).
Ensure that the new safety module is mounted at the correct position in the local bus. The new module must meet the following requirements:
Same device type
Same or later version
Restart
Once the safety module has been replaced, proceed as described for initial startup
(see
Chapter “Initial Startup” on page 51
).
The parameterization of the previous module remains the same and is transmitted to the new module when the system is started.
Plug the Inline connectors into the correct connections.
Perform a function test after replacing the module.
Validation
Carry out a safety validation every time you make a safety-related modification to the PROFIsafe system.
When validating your individual EUC, check the assignment of the actuator connections.
Determine whether:
•
•
•
The correct safe actuators are connected to the safety module
The safety module has been parameterized correctly
The variables used in your application program have been linked to the safe actuators correctly
Please observe the checklist “Validation” on page 83 during validation.
54
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Startup and Validation
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Errors: Messages and Removal
Errors: Messages and Removal
Depending on the error type, errors that are diagnosed are displayed via the local diagnostic indicators and/or transmitted to the safe controller as diagnostic messages.
The tables below provide an overview of the diagnosed errors, their causes, effects, and possible measures for error removal.
For every error that occurs, the cause of the error must first be removed. If necessary, the error is then acknowledged. Errors that must be acknowledged are indicated in the “Acknowledgment” column in the tables below.
Error removal
Acknowledge error
Module replacement following an error
If error codes are indicated by the system, which do not appear in the tables below, please contact Bosch Rexroth.
To remove the cause of an error, please proceed as described in the “Remedy” column in the tables below.
Instructions on how to acknowledge an error can be found in
Chapter “Acknowledging an Error” on page 61
.
WARNING Unexpected machine startup
An operator acknowledgment leads to a positive edge and can thus result in the outputs being re-enabled.
If in the event of failure the safety module is replaced, please proceed as described in
Section 5, “Assembly, Removal, and Electrical Installation”
“Restart after Replacing a Safety Module” on page 53
.
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Errors: Messages and Removal
Notes on the tables below
The error code of a diagnostic message is comprised of the code for the error cause and the code for the error location.
Structure of the error code
Error code
Error location
Example:
Error code
Code for error cause
Code for error location x E.g., 003
The error code is specified in
In the error code specified, “x” specifies the location of the error. The value range for “x” is specified in the relevant row of the table.
For some errors a single channel is specified as the error location (e.g., OUT-
0_Ch1).
Some errors only occur for outputs parameterized for two-channel operation.
Here, the channel pair is specified as the error location (e.g., OUT0_Ch1&2).
Safe output errors (
)
Error cause
Short circuit or overload
Error code (hex)
003x x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
LED
Acknowledgment
003 x Short circuit or overload
003 x Error location
This means, for example:
0032
003A
Cross circuit at OUT2_Ch1 (output 2 channel 1)
Cross circuit at OUT3_Ch2 (output 3 channel 2)
The “LED” column specifies which local diagnostic LEDs indicate the error.
Errors that must be acknowledged are indicated with “Yes” in the
“Acknowledgment” column. Special conditions for re-enabling an output or the module are specified in brackets [e.g., Yes (1)] in the “Acknowledgment” column and explained below the relevant table.
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Errors: Messages and Removal
9.1
Safe Digital Output Errors
Error cause
Hardware fault
Error code
(hex)
001x x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
LED
All OUT:
Red ON x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
Short circuit or overload
003x OUTy:
Red ON
Remark Effect
The indicated output cannot be disabled
All module outputs are in the safe state
Affected output is in the safe state
Remedy
Power up with error-free selftest
Replacement
Check actuator
Check connector and cabling
Acknowledgmen t
Yes (1)
Yes (2)
Error at the output or short circuit during the test
005x All OUT:
Red ON
Pulse test (brief activation) at the output failed
All module outputs are in the safe state
Check free running circuit at the contactor
Power up with error-free selftest
Replacement
Yes (1) x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
006x Error at the output or short circuit during the test
All OUT:
Red ON
Pulse test (brief deactivation) at the output failed
All module outputs are in the safe state
Power up with error-free selftest
Replacement
Yes (1) x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
Hardware fault
0091 All OUT:
Red ON
Detected by internal tests.
All module outputs are in the safe state
Power up with error-free selftest
Yes (1)
Cross circuit at the indicated output
00Ax x = 0 ... 3: OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A: OUT0_Ch2 ... OUT3_Ch2
Fig. 9-1 Safe output errors
All OUT:
Red ON
Cross circuit with another output or with an external signal
All module outputs are in the safe state
Replacement
Remove error
Power up with error-free selftest
Yes (1)
Acknowledgment: Yes (1)
Acknowledgment: Yes (2)
Acknowledge all errors that are present. Only then can the outputs be re-enabled.
Acknowledging the diagnostic message deletes the message. The module can only be restarted following power up and error-free selftest.
Acknowledging the diagnostic message deletes the message and enables a restart. Following successful acknowledgment, the module also expects a positive edge from the application for the output.
WARNING Unexpected machine startup
An operator acknowledgment leads to a positive edge and can thus result in the outputs being re-enabled.
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Errors: Messages and Removal
9.2
Supply Voltage Errors
Error cause
Undervoltage
U
M
Error code
(hex)
01F0
LED
UM flashing
Remark Effect Remedy Acknowledgment
Yes (1) U
M
below the permissible voltage range
All module outputs are in the safe state
Check and supply voltage level
Check supply line length and load
Fig. 9-2 Supply voltage U
M
errors
Acknowledgment: Yes (1)
Undervoltage at U
M
Acknowledging the diagnostic message deletes the message and activates the outputs.
Supply voltage U
M
is measured. If U
M
< 17 V, a diagnostic message is generated.
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Errors: Messages and Removal
9.3
Parameterization Errors
Error cause
Incorrect parameterization
Fig. 9-3
Error code
(hex)
LED
See
FS LED
(flashing)
Parameterization errors
Remark
Each output is parameterized individually
Effect Remedy
Module is in the safe state
Check and correct parameterization.
Acknowledgment
–
In order to determine what type of parameterization error has occurred, use the corresponding control software to access the safe controller online and read the error.
Error code
(hex)
023x x = 0 ... 3:
OUT0_Ch1&2 ...
OUT3_Ch1&2
(dec)
560 : OUT0_Ch1&2
:
563 : OUT3_Ch1&2
028x x = 0 ... 3:
OUT0_Ch1 ... OUT3_Ch1; x = 7 ... A:
OUT0_Ch2 ... OUT3_Ch2
640 : OUT0_Ch1
:
643 : OUT3_Ch1;
647 : OUT0_Ch2
:
650 : OUT3_Ch2
029x x = 0 ... 3:
OUT0_Ch1&2 ...
OUT3_Ch1&2
656 : OUT0_Ch1&2
:
659 : OUT3_Ch1&2
02F2 754
Short description
The parameterization of two related outputs does not correspond to the twochannel setting.
Correct value and resend parameter data to the module.
The parameterized switch-off delay time for the output is outside the permissible value range.
Correct value and resend parameter data to the module.
For outputs parameterized for twochannel operation, the same settings were not assigned for the switch-off delay.
At least one output with parameterized switch-off delay is still performing a switch-off operation.
Remedy
Correct setting and resend parameter data to the module.
Wait until the switch-off operation is complete and resend parameter data to the module.
Fig. 9-4 Parameterization errors
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Errors: Messages and Removal
9.4
General Errors
Error cause
Device temperature at critical value
Error due to receipt of an unexpected message
Error due to receipt of an unexpected value in the process data image
Hardware fault
Fig. 9-5
Error code
(hex)
LED
01F2
01F3
01F4
General errors
Remark Effect Remedy
Immediate shutdown. Further temperature increase causes the module to switch to the safe state.
•
•
Check and adapt:
•
•
Ambient conditions
Derating
Output loads
Switching frequency
FS ON
Error due to receipt of an unexpected message while acknowledging a diagnostic message.
The device firmware handles this diagnostic message with the highest priority. Only when this message has been acknowledged correctly are other errors indicated (if present).
The acknowledgment process, during which an unexpected message was received, is aborted.
The corresponding error remains in the error memory.
Diagnostic message
01F3 is indicated.
Check and adapt the assignment of the diagnostic and confirmation variables at the
DEVICE_STATE function block.
Acknowledge diagnostic message
01F3 so that the next message from the error memory can be indicated.
At least one reserved bit in the process data image was set.
Error in the logic area
All outputs are disabled immediately. A parameterized switch-off delay is not observed.
Check process data assignment.
Module is in the safe state
Replacement
Acknowledgment: Yes (1)
Acknowledgment: Yes (2)
Acknowledgment
Yes (1)
Yes (1)
Yes (2)
Acknowledging the diagnostic message deletes the message.
Acknowledging the diagnostic message deletes the message and enables the outputs.
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9.5
9.6
Bosch Rexroth AG
Errors: Messages and Removal
PROFIsafe Errors
In addition to the module errors specified, the following errors can occur:
•
•
PROFIsafe system errors: These messages can be found in Chapter
“Diagnostic Messages for Parameter Errors” on page 77
.
PROFIBUS or PROFINET system errors: For information about these errors, please refer to the documentation for the system used.
Acknowledging an Error
After removing the cause of an error, the diagnostic message must be acknowledged.
For instructions on error acknowledgment, please refer to the documentation for the system used.
WARNING Acknowledgment may result in a hazardous system state
With the exception of a few special cases, the acknowledgment of an error immediately returns the safe output to the operating state. Before acknowledging an error you must therefore make sure that the acknowledgment will not cause the machine to switch to a dangerous state.
When planning the machine or system, ensure that acknowledgment is only possible if the danger zone is visible.
If in the event of failure the safety module is replaced, please proceed as described in
Section 5, “Assembly, Removal, and Electrical Installation”
“Restart after Replacing a Safety Module” on page 53
.
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Errors: Messages and Removal
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Maintenance, Repair, Decommissioning, and Disposal
10 Maintenance, Repair, Decommissioning, and Disposal
10.1
Maintenance
The device is designed in such a way that maintenance work is not required during the duration of use. However, depending on the application and connected I/O devices it may be necessary to test the function of the I/O devices and the safety chain at regular intervals.
The duration of use of the module is 20 years.
Repeat testing within this time is not required.
Carry out maintenance of connected I/O devices (e.g., light grid) according to the relevant manufacturer specifications.
10.2
Repair
It is prohibited for the user to carry out repair work or make modifications to the module.
The housing must not be opened. If the housing is opened, correct operation can no longer be ensured.
In the event of an error, send the module to Bosch Rexroth or contact
Bosch Rexroth immediately and engage a service engineer.
10.3
Decommissioning and Disposal
The machine or system manufacturer specifies the procedure for decommissioning.
Decommissioning may only take place according to these specified procedures.
When decommissioning an PROFIsafe system or parts thereof, ensure that the safety modules used:
•
•
Are correctly reused in another system.
In this case, please observe the storage and transport requirements according to the technical data (see
“R-IB IL 24 PSDO 8-PAC” on page 65 ).
Or
Are disposed of according to the applicable environmental regulations, and in this case can never be reused.
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Maintenance, Repair, Decommissioning, and Disposal
Bosch Rexroth AG
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Technical Data and Ordering Data
11 Technical Data and Ordering Data
11.1
System Data
11.1.1
Rexroth Inline
For the system data for the Rexroth Inline system, please refer to the DOK-CON-
TRL-ILSYSINS***-AW..-EN-P application description.
11.1.2
PROFIsafe
PROFIsafe
PROFIsafe profile
Processing time of the module
2.4
1.5 ms
For the system data for your system, please refer to the corresponding documentation.
11.2
R-IB IL 24 PSDO 8-PAC
General data
Housing dimensions (width x height x depth)
Weight (with connectors)
Operating mode
PROFIsafe
48.8 mm x 119.8 mm x 71.5 mm
200 g
Process data mode with 4 words and 1 word PCP (internal use)
500 kbaud or 2 Mbaud Transmission speed (local bus)
Ambient temperature
Operation
Storage/transport
Humidity
Operation
-25°C to +55°C
-25°C to +70°C
75% on average, 85% occasionally (no condensation)
In the range from -25°C to +55°C appropriate measures against increased humidity must be taken.
Storage/transport 75% on average; 85% occasionally (no condensation)
For a short period, slight condensation may appear on the outside of the housing.
Air pressure
Operation
Storage/transport
Degree of protection
Housing material
Air and creepage distances
Protection class
80 kPa to 108 kPa (up to 2000 m above sea level)
66 kPa to 108 kPa (up to 3500 m above sea level)
IP20
Plastic PBT, self-extinguishing (V0)
According to IEC 60439-1, derived from IEC 60664-1
III (PELV), IEC 61140, EN 61140, VDE 0140-1
Gases that may endanger functions according to DIN 40046-36, DIN 40046-37
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Technical Data and Ordering Data
General data [...]
Sulfur dioxide (SO
2
Hydrogen sulfide (H
)
2
S)
Concentration 10 ±0.3 ppm
Ambient conditions:
– Temperature 25°C ±2 K
– Humidity 75% ±5%
– Test duration 10 days
Concentration 1 ±0.3 ppm
Ambient conditions:
– Temperature 25°C ±2 K
– Humidity 75% ±5%
– Test duration 4 days
Resistant
Resistant
Not resistant to chloroform
Resistance of the housing material to termites
Resistance of the housing material to fungal decay
Ambient compatibility
Connection data for Inline connectors
Connection method
Conductor cross section
Supported stop category according to EN 60204
Spring-cage terminals
0.2 mm
2
to 1.5 mm
2
(solid or stranded), 24 - 16 AWG
0
1 in error-free state
Mechanical requirements
Vibration according to IEC 60068-2-6
Shock according to IEC 60068-2-27
Operation: 2g, Criterion A
15g over 11 ms, Criterion A
Safety characteristic data according to IEC 61508/EN 61508
Achievable SIL
Probability of a dangerous failure on demand by the safety function (PFD)
Probability of a dangerous failure per hour for the entire module (PFH)
Hardware fault tolerance (HFT) of the module
SIL 2 (single-channel)
SIL 3 (two-channel)
Depends on the parameterization and wiring (see
“Connection Options for Actuators Depending on the Parameterization” on page 20 and
Chapter “Connection Examples for Safe Outputs” on page 41 )
SIL 2: 1% of 10
-2
, maximum (corresponds to 1 x 10
-4
)
SIL 3: 1% of 10
-3
, maximum (corresponds to 1 x 10
-5
)
SIL 2: 1% of 10
-6
, maximum (corresponds to 1 x 10
-8
)
SIL 3: 1% of 10
-7
, maximum (corresponds to 1 x 10
-9
)
Depends on the parameterization (see
1
Permissible duration of use 20 years
Safety characteristic data according to EN 62061
Achievable SIL claim limit
Safe failure fraction (SFF)
SIL CL = SIL 2 (single-channel)
SIL CL = SIL 3 (two-channel)
Depends on the parameterization and wiring (see
“Connection Options for Actuators Depending on the Parameterization” on page 20 and
Chapter “Connection Examples for Safe Outputs” on page 41 )
99%
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Technical Data and Ordering Data
Safety characteristic data according to EN 62061
Probability of a dangerous failure per hour for the entire module (PFH)
Hardware fault tolerance (HFT) of the module
SIL 2: 1% of 10
-6
, maximum (corresponds to 1 x 10
-8
)
SIL 3: 1% of 10
-7
, maximum (corresponds to 1 x 10
-9
)
Depends on the parameterization (see
1
Permissible duration of use 20 years
Safety characteristic data according to EN ISO 13849-1
Achievable performance level
Diagnostic coverage (DC)
Mean time to dangerous failure (MTTFd)
PL d (single-channel)
PL e (two-channel)
Depends on the parameterization and wiring (see
“Connection Options for Actuators Depending on the Parameterization” on page 20 and
Chapter “Connection Examples for Safe Outputs” on page 41 )
99%
For single-channel assignment: 100 years
For two-channel assignment: 100 years
Supply voltage U
L
(logic)
The safety terminal is supplied with communications power via the bus coupler or a designated power terminal in the station. The communications power is led in the Inline station via potential routing. For the technical data, please refer to the data sheet for the bus coupler or power terminal used.
Current consumption 230 mA, maximum
Supply voltage U
M
(actuators)
The safety terminal is supplied with main voltage UM via the bus coupler or a power terminal in the station. The main voltage is led in the Inline station via potential routing. For the technical data, please refer to the data sheet for the bus coupler or power terminal used.
WARNING Loss of the safety function when using unsuitable power supplies
Only use power supplies according to EN 50178/VDE 0160 (PELV).
Nominal voltage
Tolerance
Ripple
Permissible voltage range
Current consumption
Permissible interruption time
Surge protection
Protection against polarity reversal
24 V DC according to EN 61131-2 and EN 60204
-15%/+20% including an entire AC voltage component with peak value of 5%
3.6 V pp
19.2 V DC to 30.0 V DC, including all tolerances, ripple included
30 mA, typical (all outputs set) (plus actuator current)
10 ms;
Within this time, the output voltage for the safe outputs fails as the outputs are not internally buffered.
Yes (in the bus coupler/power terminal)
Yes (in the bus coupler/power terminal)
NOTICE Module damage due to polarity reversal
Polarity reversal places a burden on the electronics and, despite protection against polarity reversal, can damage the module. Therefore, polarity reversal must be prevented.
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Technical Data and Ordering Data
Supply voltage U
M
(actuators) [...]
Undervoltage detection
Diagnostic indicators
Yes, at 17 V, approximately
Green U
M
LED
(see
“Local Diagnostic and Status Indicators” on page 20
)
Maximum 8 A, slow-blow External fuse protection
NOTICE Module damage in the event of overload
The power supply unit must be able to supply four times (400%) the nominal current of the external fuse.
Safe digital outputs OUT0 to OUT3
Number
Supply
Maximum output current per output
Maximum output current for all outputs (total current)
4 two-channel or 8 single-channel (positive switching)
From supply voltage U
M
2 A
6 A (observe derating and maximum output current for each group)
Maximum output current for each group (total current)
Group 1 (OUT0_K1, OUT1_K1, OUT2_K1, OUT3_K1)
Group 2 (OUT0_K2, OUT1_K2, OUT2_K2, OUT3_K2)
Maximum output voltage in the low state
3 A
3 A
< 5 V
WARNING Loss of safety function
At this voltage, the load must not switch to nor remain in the ON state. Please take this into consideration when selecting the actuator.
Maximum leakage current in the low state 2 mA
WARNING Loss of safety function
At this current, the load must not switch to nor remain in the ON state. Please take this into consideration when selecting the actuator.
Minimum withstand voltage of the connected loads
Maximum inductive load
Maximum capacitive load depending on the current
Maximum capacitive load depending on the load current
> 5 V
1 H
C = 1 s/(R x 1400)
Where:
C Load capacity in F
R Load resistance in ohms
C
60
µF
50
40
30
20
10
0 0.50
1.00
1.50
2.00
A 2.50
I
73423007
Key:
C Load capacity in µF
I Load current in A
Hatched area: Permissible range
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Technical Data and Ordering Data
Safe digital outputs OUT0 to OUT3 [...]
Minimum load
Limitation of the voltage induced on circuit interruption
Output voltage
Simultaneity
Derating
Maximum switching frequency
Filter time
Switch-off delay for shutdown according to stop category 1
1.5 k
(16 mA at 24 V)
-15 V
U
M
- 1 V, approximately
100% up to 45°C (observe maximum current load)
Up to 50°C, total current of all outputs 6 A, maximum
Up to 55°C, total current of all outputs 4 A, maximum
1 Hz; 0.2 Hz at > 1 A
None
Can be parameterized; 150 ms to 630 s; see
Chapter “Parameterization of the Safe Outputs” on page 38
Accuracy ±5% of the parameterized value
1 ms Maximum duration of the test pulses (when switched off; active driving)
Maximum duration of the test pulses (when switched on)
Status indicators
Diagnostic indicators
3 ms (depending on the load capacity)
One green LED (two-color LED green/red) per output
(see
“Local Diagnostic and Status Indicators” on page 20 )
One red LED (two-color LED green/red) per output
(see
“Local Diagnostic and Status Indicators” on page 20 )
WARNING Loss of safety function
– Connect the ground of the actuator directly to the ground terminal point of the corresponding output on the Inline connector. An external ground may not be used.
–
The connected load must not respond in a hazardous way to test pulses.
Electrical isolation/isolation of the voltage areas
To provide electrical isolation between the logic level and the I/O area, it is necessary to supply the station bus coupler and this safety module from separate power supply units. Interconnection of the power supply units in the
24 V area is not permitted (see also application description).
Separate potentials in the system comprising bus coupler/power terminal and safety module
- Test distance - Test voltage
5 V supply incoming remote bus/7.5 V supply (bus logic)
5 V supply outgoing remote bus/7.5 V supply (bus logic)
7.5 V supply (bus logic)/24 V supply U
M
, FE
500 V AC, 50 Hz, 1 min.
500 V AC, 50 Hz, 1 min.
500 V AC, 50 Hz, 1 min.
Approvals
For the latest approvals, please visit www.boschrexroth.com
.
70
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Technical Data and Ordering Data
11.3
Conformance with EMC Directive
Conformance with EMC Directive 2014/30/EU
Noise immunity test according to DIN EN 61000-6-2
Electrostatic discharge (ESD) EN 61000-4-2
(IEC 61000-4-2)
Electromagnetic fields
Fast transients (burst)
Surge voltage
EN 61000-4-3
(IEC 61000-4-3)
EN 61000-4-4
(IEC 61000-4-4)
EN 61000-4-5
(IEC 61000-4-5)
Criterion B
6 kV contact discharge, 8 kV air discharge
Criterion A, field strength 10 V/m
Criterion B, test voltage 2 kV
Test intensity 2, Criterion B
DC supply lines:
0.5 kV/0.5 kV (symmetrical/asymmetrical)
Signal lines:
1.0 kV/2.0 kV (symmetrical/asymmetrical)
Criterion A, test voltage 10 V Conducted interference EN 61000-4-6
(IEC 61000-4-6)
Noise emission test according to DIN EN 61000-6-4
Noise emission EN 55011 Class A, industrial applications
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
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Technical Data and Ordering Data
11.4
Ordering Data
11.4.1
Ordering Data: Safety Module
Description
Rexroth Inline module with safe digital outputs
Order code
R-IB IL 24 PSDO 8-PAC
MNR Pcs. / Pkt.
R911172847 1
For additional ordering data (accessories), please refer to the product catalog at www.boschrexroth.com/electrics .
11.4.2
Ordering Data: Documentation
Description
Inline
“Automation terminals of the Rexroth Inline product range” application description
Order code
DOK-CONTRL-ILSYSINS***-AW..-
EN-P
PROFIsafe
"PROFIsafe - Profile for Safety Technology on PROFI-
BUS DP and PROFINET IO, Version 2.4, February
2007" specification
See http://www.profisafe.net
MNR Pcs. / Pkt.
R911317021 1
Make sure you always use the latest documentation.
It can be downloaded at www.boschrexroth.com/electrics .
Documentation for PROFIsafe, PROFIBUS, and PROFINET is available on the Internet at www.profibus.com/pall/meta/downloads .
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Technical Data and Ordering Data
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
PROFIsafe Terms Used in the Application Description
12 PROFIsafe Terms Used in the Application Description
CRC
Consecutive number
F-CPU
F_Destination_Address
F-I/O device
F-Parameter
F-Slave
F_Source_Address
Some of the terms that are used in connection with PROFIsafe in this application description are described below.
A definition of PROFIsafe terms is also provided in the PROFIsafe profile.
Cyclic Redundancy Check
A cyclic redundancy check is used to verify the validity of the process data contained in the safety telegram, check whether the assigned address relationships are correct, and verify the safety-related parameters. This value is part of the safety telegram.
Method for ensuring that the safe data is transmitted completely and in the correct order.
Failsafe control system, safe controller
F-Parameter; PROFIsafe destination address; address of the safe device
(see also
)
Failsafe I/O device; safe input and/or output modules
Modules with integrated safety functions, which are approved for safety-related operation.
(According to PROFIsafe system description, Version 09, November 2007)
F-Parameters contain information for adapting the PROFIsafe layer to specific customer specifications and for checking the parameterization by means of a separate method (diverse). The main F-Parameters are:
F_S/D_Address
(F-Address for short)
F_WD_Time
F_SIL
F_iPar_CRC
F_Par_CRC
A unique address for F-Devices within a PROFIsafe island. The technology part of the F-Device compares the value with the address switch locally or with an assigned F-Address in order to check the authenticity of the connection.
Specifies the millisecond value for the watchdog timer. The timer monitors the time that elapses until the next valid PROFIsafe message is received.
Indicates the SIL that the user can expect from the relevant
F-Device. It is compared with the manufacturer's specification that is stored locally.
A checksum that is calculated from all iParameters of the technology-specific part of the F-Device.
A CRC signature, which is created via all F-Parameters and ensures error-free transmission of the F-Parameters.
Failsafe slave
F-Parameter; PROFIsafe source address; address of the safe controller
(see also
)
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
PROFIsafe Terms Used in the Application Description
F-System iParameter
Passivation
PROFIsafe
PROFIsafe address
PROFIsafe monitoring time
Failsafe system
A failsafe system is a system that remains in the safe state or immediately enters a safe state when specific failures occur.
Individual safety parameter of a device
If the safety module (F-I/O device) detects an error, it switches the affected channel or all channels of the module to the safe state; the channels are then passivated. The detected errors are indicated at the safe controller.
For a safe input module when the F-System is passivated, instead of the process values present at the safe inputs, substitute values (0) are provided for the safety program.
For a safe output module when the F-System is passivated, instead of the output values provided by the safety program, substitute values (0) are transferred to the safe outputs.
Safety-related bus profile based on PROFIBUS DP or PROFINET. It defines the communication between a safety program and the safe I/O device (F-I/O device) in a safe system (F-System).
Each safe module has a PROFIsafe address. This address must be set on the safety module (F-I/O device) via DIP switches and then configured in the configuration tool for the safe controller used.
Monitoring time for safety-related communication between the safe controller (F-
CPU) and safe I/O device (F-I/O device).
This time is parameterized in the F_WD_Time F-Parameter.
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F-Parameters and iParameters
13 F-Parameters and iParameters
13.1
F-Parameters
The values indicated in italics in
Table 13-1 are preset by the system
and cannot be modified manually.
F-Parameter
F_Source_
Address
F_Destination_
Address
F_WD_Time
F_SIL
-
-
Default value Description
The parameter uniquely identifies the PROFIsafe source address (controller address).
The address is assigned manually.
PROFIsafe destination address (address of the safe device)
150
The address is assigned manually and the value can be modified.
Make sure that the value set under F_Destination_Address and the value that you have set via the 10-pos. DIP switch are the same.
Value range: 1 ... 1022
Monitoring time in the safety module.
SIL 3
A valid current safety telegram must arrive from the safe controller within the monitoring time. Otherwise, the safety module enters the safe state.
The selected monitoring time must be sufficiently high for telegram delays to be tolerated by the communication, but still ensure a sufficiently fast error response in the event of an error (e.g., interruption in communication).
Value range: 1 ... 65534, in 1 ms increments
Unit: ms
Safety integrity (SIL according to IEC 61508) of the safety module
WARNING
Safety functions up to SIL 3 can be achieved with the safety module. The safety integrity level that can actually be achieved depends on the parameterization, the structure of the sensor, and the cable installation (see
“Connection Examples for Safe Outputs” on page 41
).
F_CRC_Length 3-byte CRC
F_Block_ID
F_Par_Version 1
F_iPar_CRC
Table 13-1
1
0
This parameter transmits the length of the CRC2 code to be expected in the safety telegram to the safe controller.
Parameter block type identification
1: The parameter block of the F-Parameters contains the F_iPar_CRC parameter.
Version number of the F-Parameter block.
1: Valid for V2 mode
CRC checksum via the iParameters
The value must be greater than 0.
When verifying the safety function, check whether the F_iPar_CRC parameter is greater than 0 for all devices. If not, check the iParameters and the CRC checksum in the iParameter and F-Parameter.
Overview of the F-Parameters for the module
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC iParameters
13.2
iParameters
iPar_CRC
F_Destination_Address
The iParameters are individual device parameters. These include:
• Device parameters from (see
Chapter “Parameterization of the Safe Outputs” on page 38 )
•
•
PST_Device_ID (20 hex
for R-IB IL 24 PSDO 8-PAC)
F_Destination_Address (not included in the checksum calculation)
The device parameters are verified with a checksum: iPar_CRC.
This address is the PROFIsafe address of the module. Make sure that it matches the switch position of the 10-pos. DIP switch.
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Diagnostic Messages for Parameter Errors
13.3
Diagnostic Messages for Parameter Errors
Error code dec hex
64 40
65
66
67
68
69
70
71
255
41
42
43
44
45
46
47
FF
Table 13-2
Error cause Remedy
The parameterized F_Destination_Address does not match the PROFIsafe address set on the safety module (F-
Module).
Make sure that the PROFIsafe address of the safety module and the value in F_Destination_Address are the same.
Invalid parameterization of F_Destination_Address.
Addresses 0000 hex
and FFFF hex
are not permitted.
Invalid parameterization of F_Source_Address.
Addresses 0000 hex
and FFFF hex
are not permitted.
Invalid parameterization of F_WD_Time.
A monitoring time of 0 ms is not permitted.
Correct value.
Correct value.
Correct value.
Invalid parameterization of F_SIL.
The safety module (F-Module) cannot support the required
SIL.
Use a device with the required SIL.
The safety module achieves SIL 3, maximum.
Invalid parameterization of F_CRC_Length.
The CRC length generated by the safety module
(F-Module) does not match the required length.
Check device description.
Invalid F-Parameter record version.
The safety module (F-Module) version does not match the required version.
Check device description.
Only V2 mode permitted.
The checksum determined by the safety module
(F-Module) via the PROFIsafe parameters (CRC1) does not match the CRC1 transmitted in the parameter telegram.
Check F-Parameters, repeat calculation.
During active process data communication, a new
F-Parameter block was received, which differs from the F-
Parameter block currently used.
Only send modified parameter data when process data communication is not active.
Incorrect type ID for the F-Parameter block (F_Block_ID).
Check device description.
F-Parameter parameter errors
Error code
(hex)
03F2
03FA
03FB
Error cause iPar_CRC is incorrect iPar_CRC is not equal to F_iPar_CRC
PST_Device_ID is incorrect
03FC F_Destination_Address in the iParameters is incorrect
Remedy
Check iParameters, repeat calculation.
Apply correct value.
Correct value (20 hex
for
R-IB IL 24 PSDO 8-PAC).
Correct value.
Make sure that the value set under F_Destination_Address and the value that you have set via the 10-pos. DIP switch are the same.
Check infrastructure components.
03FD
Table 13-3
Incorrect order of iParameter blocks iParameter parameter errors
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Diagnostic Messages for Parameter Errors
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Checklists
14 Checklists
The checklists listed in this section provide support during the planning, assembly and electrical installation, startup, parameterization, and validation of the
R-IB IL 24 PSDO 8-PAC module.
These checklists may be used as planning documentation and/or as verification to ensure the steps in the specified phases are carried out carefully.
Archive the completed checklists to use as reference for recurring tests.
The checklists do not replace the validation, initial startup, and regular testing performed by qualified personnel.
The following section of a checklist shows an example of a completed checklist.
Checklist . . .
Device type/equipment identification
Version: HW/FW/FW 00/201/100
Editor John Smith
R-IB IL 24 PSDO 8-PAC/BK20NA10
Date March 1, 2013
Test engineer Jane Brown
Remark System XXX has been checked for engine hood production
No. Requirement (mandatory)
X . . .
Yes Remark
No. Requirement (optional)
Y . . .
Yes No Remark
Key:
Equipment identification
Version: HW/FW/FW
Date
Editor
Test engineer
Remark
Requirement (mandatory)
Requirement (optional)
Enter the device type and/or the equipment identification for the relevant device.
Enter the hardware and firmware version of the device (see Chapter “Structure of the
Enter the date on which you began to fill in this checklist.
Enter the names of the editor.
Enter the names of the test engineer.
Enter a remark, if necessary.
These requirements must be met for a safety application, in order to complete the relevant phase using the checklist.
These requirements are optional. For points that are not met, please enter an appropriate remark in the relevant field.
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Planning
14.1
Planning
Checklist for planning the use of the safety module
Device type/equipment identification
Version: HW/FW/FW
Editor
Date
Test engineer
Remark
No. Requirement (mandatory)
1 Has the current module application description been used as the basis for planning?
2 Are the actuators approved for connection to the module (according to the technical data and parameterization options)?
3 Has the voltage supply been planned according to the specifications for the protective extra-low voltage in accordance with PELV?
4 Has the power supply of U
M
and U
S
from a power supply unit been planned?
5 Is external fuse protection of the module planned (according to the specifications in this application description for supply voltage U
M
)?
6 Are measures planned to prevent simple manipulation?
7 Are measures planned to prevent connectors being mixed up?
8 Are requirements for the actuators and cable installation observed according to the SIL/SIL CL/Cat./PL to be achieved and is the corresponding implementation planned?
9 Are the specifications for the parameterization for each channel specified?
10 Are test intervals specified for testing the shutdown capability of the actuators, if this is required to achieve a SIL/SIL CL/Cat./PL?
11 Has it been ensured that any person intentionally starting hazardous movements has a direct view of the danger zone?
12 Does the planned use correspond to the intended use?
13 Are the ambient conditions observed according to the technical data?
Yes Remark
Revision:
14 Have test intervals been defined?
15 Has the switch-off delay for stop category 1 been observed in the calculation of the total response time for the machine/system?
No. Requirement (optional)
16 Have specifications for assembly and electrical installation been defined (e.g., EPLAN) and communicated to the relevant personnel?
17 Have specifications for startup been defined and communicated to the relevant personnel?
Yes No Remark
Date Signature (editor)
Date Signature (test engineer)
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Bosch Rexroth AG
Assembly and Electrical Installation
14.2
Assembly and Electrical Installation
Checklist for assembly and electrical installation of the safety module
Device type/equipment identification
Version: HW/FW/FW
Editor
Date
Test engineer
Remark
No. Requirement (mandatory)
1 Was assembly completed according to the specifications
(specifications from the planning phase or according to the application description)?
2 Was the safety module installed in the control cabinet (IP54)?
Yes Remark
3 Do the cable cross sections correspond to the specifications?
No. Requirement (optional)
4 Is the transmission speed set correctly according to the specifications?
Yes No Remark
5 Is the data width set correctly according to the specifications?
6 Is the profile/PROFIsafe address set correctly according to the specifications?
Date Signature (editor)
Date Signature (test engineer)
82
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Startup and Parameterization
14.3
Startup and Parameterization
Checklist for startup and parameterization of the safety module
Device type/equipment identification
Version: HW/FW/FW
Editor
Date
Test engineer
Remark
No. Requirement (mandatory)
1 Was startup completed according to the specifications (specifications from the planning phase or according to the application description)?
2 During startup, is it ensured that any person starting hazardous movements intentionally can only do so with a direct view of the danger zone?
3 Are all parameters parameterized for the outputs?
Yes Remark
4 For outputs that are parameterized for two-channel operation, are both channels parameterized correctly for each other?
5 Are the output test pulses parameterized according to the actuator to be connected?
6 Has the switch-off delay for stop category 1 been observed in the calculation of the total response time for the machine/system?
No. Requirement (optional)
7 Are safety distances that must be observed calculated according to the response and delay times implemented?
Yes No Remark
Date Signature (editor)
Date Signature (test engineer)
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Bosch Rexroth AG
Validation
14.4
Validation
Checklist for validating the safety module
Device type/equipment identification
Version: HW/FW/FW
Editor
Date
Test engineer
Remark
No. Requirement (mandatory)
1
Have all the mandatory requirements for the "Planning" checklist been
met?
2
Have all the mandatory requirements for the "Assembly and Electrical
checklist been met?
3
Have all the mandatory requirements for the "Startup and
Parameterization" checklist been met?
4 Does the parameterization of the safe outputs correspond to the version and the actual connection of the controlled device?
5 Has the assignment of the actuators to the outputs and the variables of the safe application program been tested (also as online status in the software)?
6 Has a function test been performed to check all safety functions, in which the module is involved?
7 Have measures been taken to achieve a specific Cat.?
8 Do all cables correspond to the specifications?
9 Does the voltage supply correspond to the specifications for the protective extra-low voltage in accordance with PELV?
10 Has the power supply of U
M
and U
S
in the Inline system from a power supply unit been implemented?
11 Is external fuse protection of the module implemented (according to the specifications in this application description for supply voltage U
M
)?
12 Have measures been taken to prevent simple manipulation?
13 Have measures been taken to prevent connectors being mixed up?
14 Are the requirements for the actuators and cable installation observed according to the SIL/SIL CL/Cat./PL to be achieved?
15 Are the specifications for the parameterization for each channel implemented?
16 Are test intervals specified for testing the shutdown capability of the actuators, if this is required to achieve a SIL/SIL CL/Cat./PL?
17 For PROFIsafe: Is the F_iPar_CRC parameter greater than 0 for all devices?
18 Has it been ensured that any person intentionally starting hazardous movements has a direct view of the danger zone?
Date
Yes
Date
Remark
Signature (editor)
Signature (test engineer)
84
Bosch Rexroth AG
Validation
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
15
Bosch Rexroth AG
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Conditions for Use at Altitudes greater than 2000 m above Sea Level
Conditions for Use at Altitudes greater than
2000 m above Sea Level
This section describes the conditions for using safe Inline I/O modules at altitudes greater than 2000 m above sea level to a maximum of 4500 m above sea level.
Observe the relevant data (technical data, derating, etc.) that is specific to the module being used.
15.1
Conditions
Use of the module at altitudes greater 2000 m above sea level to a maximum of
4,500 m above sea level is possible under the following conditions:
1.
Determine the maximum ambient temperature for operation with the corresponding factor in accordance with the table below.
2.
If derating is specified, offset all the derating points by the corresponding factor in accordance with the table below.
Altitude above sea level
2000 m
2500 m
3000 m
3500 m
4000 m
4500 m
Temperature derating factor
1
0.953
0.906
0.859
0.813
0.766
For relay outputs:
3.
Limit the maximum switching voltage for relay outputs in accordance with the table below. Observe the technical data for the module.
Max. switching voltage according to the technical data for the module
Max. switching voltage when used at altitudes greater than 2000 m above sea level
< 150 V AC/DC
> 150 V AC/DC
Max. switching voltage according to the technical data for the module still valid
Limited to max. 150 V AC/DC
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Conditions for Use at Altitudes greater than 2000 m above Sea Level
15.2
Example Calculation
The following calculation is an example for using a safe Inline I/O module at an altitude of
3000 m above sea level.
Perform the actual calculation for the module used according to the technical data from the user documentation for the module.
Data in the “Technical data and ordering data” section (example):
Derating Up to 50 °C, total current of all outputs 6 A, maximum
Up to 55 °C, total current of all outputs 4 A, maximum
Calculation:
50 °C
0.906
45 °C
55 °C
0.906
50 °C
Reduced derating:
Derating at
3,000 m above sea level
Up to
Up to
45 °C
50 °C
, total current of all outputs 6 A, maximum
, total current of all outputs 4 A, maximum
Bosch Rexroth AG
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Disposal
16 Disposal
16.1
General Information
Dispose the products according to the respective valid national standard.
16.2
Return
For disposal, our products can be returned free of charge. However, the products must be free of remains like oil and grease or other impurities.
Furthermore, the products returned for disposal must not contain any undue foreign substances or components.
Send the products free of charge to the following address:
Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main, Germany
16.3
Packaging
The packaging material consists of cardboard, plastics, wood or styrofoam.
Packaging material can be recycled anywhere.
For ecological reasons, please do not return empty packages.
16.4
Batteries and Accumulators
Batteries and accumulators can be labelled with this symbol.
The symbol indicating "separate collection" for all batteries and accumulators is the crossed-out wheeled bin.
The end user within the EU is legally obligated to return used batteries. Outside the validity of the EU Directive 2006/66/EC keep the stipulated directives.
Used batteries can contain hazardous substances, which can harm the environment or the health of the individual when they are stored incorrectly or disposed of.
After use, the batteries or accumulators contained in Rexroth products have to be disposed of according to the country-specific collection system.
Bosch Rexroth AG
Disposal
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Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
17
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DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Service and Support
Service and Support
Service Germany
Our worldwide service network provides an optimized and efficient support. Our experts offer you advice and assistance should you have any queries.
You can contact us 24/7 .
Our technology-oriented Competence Center in Lohr, Germany, is responsible for all your service-related queries for electric drive and controls.
Contact the Service Hotline and Service Helpdesk under:
Phone:
Fax:
E-mail:
Internet:
+49 9352 40 5060
+49 9352 18 4941 [email protected]
http://www.boschrexroth.com
Service worldwide
Preparing information
•
•
Additional information on service, repair (e.g. delivery addresses) and training can be found on our internet sites.
Outside Germany, please contact your local service office first. For hotline numbers, refer to the sales office addresses on the internet.
To be able to help you more quickly and efficiently, please have the following information ready:
•
Detailed description of malfunction and circumstances
Type plate specifications of the affected products, in particular type codes and serial numbers
Your contact data (phone and fax number as well as your e-mail address)
Bosch Rexroth AG
Service and Support
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Bosch Rexroth AG
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Index
18 Index
A
Abbreviations ............................................................ 13
Actuators
Connection options
............................................. 20
Requirements
...................................................... 19
Address
...................................................................... 32
Assembly ................................................................... 33
C
Conformance with EMC Directive .......................... 70
Connection examples .............................................. 41
Consecutive number .......................................... 73, 74
CRC
............................................................................ 73
Current carrying capacity
.................................. 25, 26
D
Decommissioning
..................................................... 63
Device errors
Outputs
................................................................. 23
Serious errors
...................................................... 23
Diagnostic indicators ................................................ 20
DIP switches
.............................................................. 32
Directives ................................................................... 11
Disposal
..................................................................... 63
Documentation, latest .............................................. 12
E
Error code
.................................................................. 56
Error location
............................................................. 56
Errors
Acknowledgment .......................................... 55, 61
General ................................................................. 60
Module replacement ........................................... 55
Outputs
................................................................. 57
Parameterization
................................................. 59
Removal ............................................................... 55
Supply voltage ..................................................... 58
F
F-CPU ........................................................................ 73
F_Destination_Address
........................................... 73
F-I/O device
............................................................... 73
F-Parameters
.................................................37, 73, 75
Free running circuit
.................................................. 42
F-Slave ....................................................................... 73
F_Source_Address .................................................. 73
F-System
................................................................... 74
H
Hotline
........................................................................ 13
Housing dimensions
................................................ 17
I
ID code ....................................................................... 24
Indicators, diagnostic and status
............................ 20
Initial startup
.............................................................. 51
Input address area
................................................... 24
Installation
Instructions
.......................................................... 31
Insulation rating .......................................................... 9
iParameters
....................................................37, 74, 76
L
Length code .............................................................. 24
M
Maintenance
............................................................. 63
Measures required ................................................... 43
Mode
.......................................................................... 32
Mounting
Location
............................................................... 31
O
Output address area ................................................ 24
Outputs ...................................................................... 18
Device errors
....................................................... 23
Errors
.................................................................... 57
I/O errors
.............................................................. 22
Parameterization ................................................. 38
Positive switching
............................................... 18
Requirements for actuators ............................... 19
Single-channel assignment ............................... 18
Two-channel assignment .................................. 18
92
Bosch Rexroth AG DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Index
P
Package slip
.............................................................. 31
Parameter channel
................................................... 24
Parameterization
...................................................... 37
Errors .................................................................... 59
Outputs ................................................................. 38
PROFIsafe
........................................................... 37
Single-channel
.................................................... 38
Two-channel ........................................................ 38
Parameterization errors ........................................... 23
Passivation ................................................................ 74
PELV .......................................................................9, 25
Power supply units
..................................................... 9
PROFIsafe
................................................................. 74
Address
...........................................................37, 74
Monitoring time
................................................... 74
Protective circuit
....................................................... 42
Q
Qualified personnel
.................................................... 8
R
Register length .......................................................... 24
Removal .................................................................... 33
Repair ........................................................................ 63
Replacement, module
............................................. 53
Restart ....................................................................... 53
S
Safe state .................................................................. 22
Error detection in I/O devices
............................ 22
Operating state ................................................... 22
Outputs ............................................................22, 23
Safety notes
................................................................ 7
Security seal ................................................................ 8
Sicherheitshinweise für elektrische Antriebe
und Steuerungen ........................................................ 5
Standards
.................................................................. 11
Startup ....................................................................... 51
Status indicators
....................................................... 20
Stop category 1
...................................................39, 40
Supply voltage
Errors .................................................................... 58
UL
......................................................................... 25
UM ........................................................................ 26
T
Test pulses ...........................................................19, 39
Transmission speed
................................................. 32
U
Usage, correct .......................................................... 11
V
Validation ................................................................... 53
DOK-CONTRL-ILPSDO8****-AW04-EN-P
Rexroth Inline Module with Safe Digital Outputs R-IB IL 24 PSDO 8-PAC
Notes
Bosch Rexroth AG
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400 www.boschrexroth.com/electrics
The Drive & Control Company
R911326028
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