FOLLOW THE INSTRUCTIONS GIVEN IN THIS MANUAL CAREFULLY. FAILURE TO DO SO MAY CAUSE CUSTOMER COMPLAINTS AND SERIOUS CALL BACKS.

Transcription

1 CEDES SafeCIS3 Safety Controller Controller in accordance with safety category 4 based on EN and SIL3 based on IEC English The safety relays SafeCIS3 Maximum safety in minimum space The most compact genius! PENDING manufactured under ISO 9001: 2000 IMPORTANT NOTE FOLLOW THE INSTRUCTIONS GIVEN IN THIS MANUAL CAREFULLY. FAILURE TO DO SO MAY CAUSE CUSTOMER COMPLAINTS AND SERIOUS CALL BACKS. KEEP INSTRUCTION MANUAL ON SITE. CEDES Version 0.7 / 28 th August 2006 Part No E

2 Content 1. Approvals and Conformity Introduction Special features Applications Typical applications Application restrictions Dimensions Terminal connection diagram Basic configuration Status outputs LED display elements SafeCIS3 main module Response time Installation Mounting location Cable and wires Supply voltage Earth connection light curtain Start mode Manual start Automatic start Minimum off time EDM or start release Safety components Safety Prevention Testing SafeCIS Fault identification through LED Causes for internal faults Causes for external faults Selection tables Accessories / Components Inspection and service Inspections Decommissioning Product labels Technical data Configuration Control Document Certificates CE Certificate TÜV Certificate Approvals and Conformity The CE-declaration (see chapter 16.1) as well as the safety approval, performed by TÜV Rheinland Product Safety GmbH (see chapter 16.2) are available, from your nearest CEDES dealer or on our homepage at The actual list of relevant safety data and applied standards is given in these documents. All CEDES products are developed and manufactured according to state of the art technology and in compliance with a total quality management system ISO 9001: Danger SafeCIS3 units can only achieve their function as a safety controller module, if the instructions given in this instruction manual and the within mentioned documents are exactly followed, as well as consulting the valid laws and regulations at the time of installation. Should these instructions not be carefully followed, serious injury or death may occur. The installer or system integrator will be fully responsible for a safe integration of this product. This instruction manual is part of the controller module type SafeCIS3. It must be kept accessible together with the other machine documentation during its entire life cycle for all personnel responsible for assembly, installation, operation and maintenance. 2 CEDES/August 2006

3 2. Introduction SafeCIS3 is a series of extremely compact safety controller modules. The main controlling module allows for the connection and control of the compact CEDES safety light curtain system (Figure 1). Depending on the configuration, other safety components can also be connected and monitored simultaneously. OptiLink 3.2. Application restrictions SafeCIS3 SafeCIS3 controller modules are not intended for application in explosive (EX) or in radioactive environments. 4. Dimensions The dimensions of the SafeCIS3 housing are illustrated in Figure 2. Main module Extension module Figure 1: SafeCIS3 controller with all safety components which can be connected (depending on the individual configuration) The main module offers two safety PNP outputs. Further extension modules are available for applications which need contact outputs. These extension modules can be easy hooked on and connected to the main module Special features The outstanding characteristics of the SafeCIS3 controller: Safety category 4 according to EN SIL Level 3 according to IEC Short response times Modular extendible Up to 3 extension modules per main module Adjustable stop delay time Different safety components suitable for connection 3. Applications 3.1. Typical applications SafeCIS3 controller modules are developed and conceived for typical applications like: Presses Robotic cells with automatic insertion Assembly lines Indexing tables Conveyor systems Automatic storage facilities 22.5 Figure 2: Main module dimensions are the same for extension modules 5. Terminal connection diagram 5.1. Basic configuration The following figures show the connection possibilities for the SafeCIS3 controller with the basic configuration. The logic of this basic version is exemplified in the accompanying Configuration Control Document (Figure 15): Figure Safety Start Start mode component release Figure 3 manual no Figure 4 manual yes Figure 5 automatic no Figure 6 automatic yes CEDES/August

4 DIN rail Start Lamp GPIO3 Receiver Lamp GPIO3 DIN rail Receiver GPIO2 GPIO1 OSSD 2 OSSD 1 Info2 Info1 In2 In1 24 V Emitter C R K3 C R K4 K3 K4 GPIO2 GPIO1 OSSD 2 OSSD 1 Info2 Info1 In2 In1 24 V Emitter Figure 3: SafeCIS3 controller (basic configuration, manual start) Figure 6: SafeCIS3 controller (basic configuration, automatic start, with start release) DIN rail C R K3 R C K4 Start K3 K4 Lamp GPIO3 GPIO2 GPIO1 OSSD 2 OSSD 1 Info2 Info1 In2 In1 24 V DIN rail Receiver Emitter Lamp Receiver SafeCIS3-2P-4IO SafeCIS3-EXT-2C GPIO3 GPIO2 GPIO1 OSSD 2 OSSD 1 Info2 13 Info1 14 K3 K4 In2 In1 23 C 24 V Emitter 24 K3 K4 Figure 4: SafeCIS3 controller (basic configuration, manual start, with start release) Figure 7: SafeCIS3 controller and SafeCIS3 2C-extension module (basic configuration, automatic start, with start release) 6. Status outputs Lamp GPIO3 GPIO2 GPIO1 OSSD 2 OSSD 1 Info2 DIN rail Receiver The SafeCIS3 main module has two status outputs ("Info1" and "Info2"). The logic of these two outputs depends on the configuration. A description of these outputs is given in the Configuration Control Document as shown in Figure 15. The following table shows the logic of the two status outputs for the basic configuration. The state of the status outputs will also be displayed through LED, visible on the front side of the main module. Info1 In2 In1 24 V Emitter Table 1: Terminal (LED) Info1 (LED) Output high () Start ok (green) Output low () No start possible (red) Info2 (LED) System okay (green) Error (Lock out) (red) Figure 5: SafeCIS3 controller (basic configuration, automatic start) Warning: Important safety advice These outputs may not perform any safety relevant functions. They serve only to communicate the status to a machine controller. 4 CEDES/August 2006

5 SafeCIS3 7. LED display elements 7.1. SafeCIS3 main module Table 2 gives information about the LED on the front side of a SafeCIS3 main control unit with the basic configuration: Table 2: Basic Configuration LED Signal / Color / Status Signal / Color / status Lamp - - / green / automatic start GPIO3 / green / manual start signal high or automatic start / off / manual start / off / manual start GPIO2 - - GPIO1 - - OSSD2 / green / not activated OSSD1 / green / not activated Info2 See chapter 6 (LED) Info1 (LED) / red / safe400 activated (e.g. interrupted) / red / safe400 activated (e.g. interrupted) See chapter 6 See chapter 6 See chapter 6 IN2 / green / start release okay IN1 / green / no test / red / no start release signal / red / test - - / green / power connected 8. Response time / off / no power connected In principal: The response time of a SafeCIS3 main module depends on the configuration. The response time for the SafeCIS3 main module with respect to the light curtain t(mmlc) is different than the response time for the SafeCIS3 main module with respect to other safety components connected to the GPIO's t(mmgpio). The standard maximum response times t(mmlc) and t(mmgpio) for the SafeCIS3 main module, are given in chapter 15. The exact maximum response times for the SafeCIS3 main module, with respect to specific light curtains t(mmlc), as well as a specific safety components (tmmgpio) may be found in the corresponding Configuration Control Document (e.g. Figure 15). The exact maximum response time of a SafeCIS3 extension module t(em) is only printed in the corresponding Configuration Control Document (e.g. Figure 15). The response time may further increase if a delay time t(delay) is configured for a safety component. No start impulse is accepted during the delay period. The safety outputs will switch off at the end of this delay period. The delay time of each configured safety component is printed in the corresponding Configuration Control Document (e.g. Figure 15). The total response time of a CEDES " / SafeCIS3 main and extension module" system, is the sum of each response time: Table 3: Calculation for the total response time of the safety light curtain Response time light curtain Response time SafeCIS3-2P-4IO Response time first, 2nd and 3rd extension module See label of light curtain: t(lc) See actual Configuration Control Document: t(mmlc) and t(delay) See actual Configuration Control Document: t(em) Total response time of OSSD outputs: t(lc) + t(mmlc) + t(delay) Total response time of extension relay outputs: t(lc) + t(mmlc) + t(delay) + t(em) Table 4: Calculation for the total response time of other safety components connected to the GPIO s Response time See label of safety component Safety component: t(sc) Response time SafeCIS3-2P-4IO Response time first, 2nd and 3rd extension module See actual Configuration Control Document: t(mmgpio) and t(delay) See actual Configuration Control Document: t(em) Total response time of OSSD outputs: t(sc) + t(mmgpio) + t(delay) Total response time of extension relay outputs: t(sc) + t(mmgpio) + t(delay) + t(em) The values given in chapter 15 are maximum values for the basic configuration. It might be that other special configurations have a longer or shorter maximum response time than given in chapter 15. Please contact your nearest CEDES partner for an individual clarification. Important safety advice: If authorized personnel reconfigure the controller using the OptiLink, then depending on the configuration the response time t(mm) may be increased. So it is very important that after every new configuration a. the actual configuration name is placed on the main module and b. the new response time is conform with the limits given in the risk analysis of the machine. CEDES/August

6 9. Installation For the professional installation and connection, please consult the relevant laws and regulations. The safety officer of the manufacturing facilities, the local authorities (OSHA in USA, HSE in GB) or the respective industry associations as well as the intensively trained employees of CEDES are available for any safety related queries. The requirements of the safety regulations of electrical engineering, the local employer's liability insurance association and the international standard IEC are to be taken into full consideration. In the following chapters the installation of all possible safety components, which can in general be connected to a SafeCIS3 main module, is also described. Which safety component has to be connected to guarantee a faultless function is printed in the corresponding Configuration Control Document for the SafeCIS3 main module (e.g. Figure 15) Mounting location The SafeCIS3 modules must be mounted in a control cabinet which is sealed to at least IP54. The units must be snapped onto a 35 mm mounting rail, which is grounded. If it is used outside of a control cabinet a housing with a protection category of IP54 and a mounting rail capability is recommend. For operation temperature see chapter Cable and wires The wires from the SafeCIS3 main module must be securely separated and guided away from the wires of the relay section (SafeCIS3 extension module). In order to decrease the effects of EMC disturbances shielded cables must be used for the safety components (chapter 9.8) Supply voltage To safeguard the controller, the terminal should be protected with an external 5 A fuse. The controller and the machine should be off-line before beginning the installation. The supply voltage must conform to the requirements of EN , it must bridge a 20 ms interruption of the supply network. When considering the supply voltage, it must be one of the following: SELV (Safety-Extra-Low-Voltage) or PELV (Protective- Extra-Low-Voltage) in accordance with IEC Earth connection The earth of each SafeCIS3 module is realized through the connection to the mounting rail. Consequently it is important to ensure, that the mounting rail has a good earth connection light curtain The two RJ45 sockets on the lower portion of the main module are for the connection of CEDES safety light curtain (white = E = emitter; blue = R = receiver). To protect the RJ45 connectors the cables have to be snapped into the provided cable holders Start mode It is possible to configure the following start modes for the connected safety components: - automatic start or - manual start. For each start mode it will also be possible to configure a minimal safety output off time (see chapter 9.6.3). A description of which start mode is configured for which safety component is given in the corresponding Configuration Control Document (e.g. Figure 15). For the basic configuration the distinction between automatic and manual start can also be managed without changing the configuration. In this case the selection can be done with the help of connecting to "GPIO3" and "" (see Figure 3 - Figure 7) Manual start When each configured safety component reports "safety okay", depressing the start button will cause the two safety OSSD outputs to change from low to high and if connected the SafeCIS3 relay extension modules will close (= manual start). If more than one safety component is configured, then all components must report "safety okay" before a start is allowed. The start button is monitored. This means, a shortcircuit of the button will not lead to a start of the machine. Pulse length manual start: min 50 ms / max. 5 sec. In case the start impulse is longer than 5 s the start is not accepted. The exact terminal to connect the start button to is given in the corresponding Configuration Control Document (e.g. Figure 15). If the Configuration Control Document shows that the manual start must be attached to terminal In1 or In2, then the meaning of the respective LED is shown in Table 5 Table 5: Terminal LED green LED red In1 or In2 No start signal present Start signal present (button pressed) Important safety advice: It is fundamental that the start button be mounted so that the danger area is clearly visible. That is, when pressing the start button it must be guaranteed that no one is detained within the danger area Automatic start If a safety component is configured for "automatic start", then, after the activation and the deactivation of the safety component, the two OSSD outputs will 6 CEDES/August 2006

7 SafeCIS3 change automatically from low to high again and if connected the SafeCIS3 extension relay blocks will automatically re-close. Important safety advice: According to EN article a system may not automatically restart, even after the cause of the shutdown has been eliminated and thereby another danger may still exist to the operator. If the SafeCIS3 unit is configured with an "automatic start", this requirement must be fulfilled by further measures Minimum off time According to the standard IEC a safety light curtain must have a minimum safety output off time of 80 ms. This means that even in the case of a very short safety light curtain interruption, the safety outputs will stay low (Relays = open) during this minimum off time. During this minimum off time a start impulse is only accepted when all safety criteria stay fulfilled. For each start mode it is also possible to increase the minimal safety output off time by reconfiguring the SafeCIS3 controller. The minimal safety output off time for the basic configuration is set to 80 ms EDM or start release Often a SafeCIS3 module is connected to external relays. Reasons to do this might be: The relays of the extension modules do not have enough contacts or if the required switching capacity is more than the specified capacity. These external relays can be connected a. to the two safety PNP outputs (OSSD) of the main module (e.g. Figure 4) and / or b. to the contacts of an extension module, e.g. if the power of the two OSSD outputs is not adequate (e.g. Figure 7). In any case when using external relays the function of these external relays must be monitored. For category 4 contact extension, two external contactors, each with force guided contacts must be inserted. For monitoring the function of these contactors, each relay block must have at least one normally closed contact which is fed back in series to the corresponding terminal of the SafeCIS3 controller (e.g. Figure 7). Two options are possible for this monitoring: 1. Start release: The signal at the corresponding input terminal must be high before the start button is pressed (this means: the normally closed contacts of the external relays must be closed before allowing a start). 2. EDM (external device monitoring): The input signal of the EDM terminal is always monitored. This means: not only at the beginning before a start the signal must be correct. Also after the start a signal change must happen, otherwise an emergency stop occurs. In case the wrong signal is present for longer than 5 seconds a lock-out will occur. The option "start release" can be realized with the basic configuration. The option "EDM" can only be realized by reconfiguring the SafeCIS3 main module with the help of the OptiLink. If the Configuration Control Document shows that EDM or start release must be attached to terminal In1 or In2, then the meaning of the respective LED is shown in Table 6 Table 6: Terminal LED green LED red EDM at In1 or In2 Start release at In1 or In2 EDM signal okay Start release signal okay EDM signal wrong Start release signal wrong The start release or EDM input is not cross-fault monitored. Therefore the wiring of these inputs must be permanently installed, and protected against external damage, according to EN ISO (i.e. cable channel, or armored conduit). Additionally, they must be realized within separate plasticsheathed cables, as well as inside a protective enclosure. Prerequisite, is that both the wire and the protective enclosure fulfill the corresponding requirements (according to EN ). Important safety advice: 1. In cases where the SafeCIS3 main module is installed without extension modules the function external device monitoring (EDM) or start release must always be realized, the only exceptions are if the PNP outputs are connected with another safety relay or a safety PLC. 2. Through the use of start release or EDM, it is possible to switch external "power" contactors within the safety circuit. Such contactors often deal with large inductive loads, which during the switching off phase can create large potential peaks. For this reason surge suppressors are highly recommended. Surge suppressors must be connected parallel to the external contactors (e.g. Figure 1 and Figure 7). They may never be connected parallel to the contacts of a SafeCIS3 extension module. It must be noticed, that surge suppressors may drastically increase the off delay time of the contactors. Diodes are not allowed to be used as surge suppressors, for exactly this reason. Recommended surge suppressors are: Supply voltage [V] Resistor R [Ώ] Condenser C [µf] CEDES/August

8 9.8. Safety components The connected safety components (e.g. safety switches for securing doors, position switch, emergency stop button, a cable pull safety switch) must satisfy the relevant standards for application within safety areas: Emergency stop button : EN 418 Safety switch : EN , EN Light curtains : EN 61496/-1 & /-2 etc. as well as the requirements of the safety analysis. Essential is that the components contain 2 force guided, normally closed (NC) contacts (Figure 8), and that they are approved for the relevant safety level or category. As a basic rule to increase reliability, it is recommended to use safety components with integrated gold contacts. To connect safety components, the four terminals "GPIO1" "" are available. The connections are short-circuit and cross fault monitored. Table 7: Terminal LED green LED off GPIO3 Contact GPIO1/GPIO3 closed Contact GPIO1/GPIO3 open Contact GPIO2/ closed 9.9. Safety Prevention Contact GPIO2/ open Certain applications require that at certain times safety components must be overridden (e.g. during installation). Specialists are familiar with different terms for this kind of overriding: Safety Prevention, Override or Bypass. Hereafter we will refer to this as "Safety Prevention". In Figure 9 a "Safety Prevention" key switch and a safety prevention lamp is shown. With the "Safety Prevention" key switch it is possible to prevent the safety function of the light curtain. This means that if the prevention key switch is activated, the safety outputs stay high even if e.g. the protective field is interrupted. GPIO3 GPIO2 GPIO1 + 24V Lamp GPIO3 GPIO2 GPIO1 Figure 8: Connecting an emergency stop In general the two circuits of dual channel safety components are cross-fault monitored. A connection of these two circuits would lead to an emergency stop (see chapter 10) of the SafeCIS3 main module. The two circuits are also time monitored. This means, if one circuit changes e.g. of an emergency stop, the second circuit has to follow within 5 seconds. If this is not the case, the SafeCIS3 interprets this as a fault and the controller switches off the safety circuit. Depending on the configuration and depending on the application, there may be more safety components defined than necessary. In such a case it is sufficient to bridge the respective terminals of the missing components directly in the control cabinet. In order to decrease the effects of EMC disturbances shielded cables must be used. Furthermore a high number of connections within the cables to the safety components as well as poor contacts within the safety components may have an adverse effect on reliability. Figure 9: Connecting a Safety Prevention key switch and the associated lamp Normally if a key switch is used, a safety prevention lamp must also be connected. In accordance with some regulations, the SafeCIS3 monitors the function of these lamps. The connection for this safety prevention lamp is current controlled (see Technical Data chapter 15). This means, the current (I) of the individual lamp must remain between (I min < I < I max ). For this purpose, CEDES recommends: Safety prevention lamp 806 (chapter 12). The safety prevention lamp used has to fulfill the requirements of EN and has to be mounted close to the protective field and be clearly visible to the machine operator. Safety Prevention only takes place when both circuits are closed. Likewise safety prevention only takes place when both circuits were opened before becoming closed. A cross-fault will be detected and stop the Safety Prevention function from becoming activated. After one of the circuits is opened, the amount of time until the safety function of a safety component is once again active is maximum the response time of the SafeCIS3 unit. If an application does not require a safety prevention lamp (only allowed after a safety evaluation corresponding to EN 292), then either 8 CEDES/August 2006

9 a. a resistor (1 kω / 2 W) may be connected between and terminal "Lamp" or b. the output "Lamp" may be configured as "current check not active" Alternatively to a safety prevention key switch, it is possible to attach depending on the application and the required safety analysis so-called threestage enable switch or two independent, safety position sensors. Table 8: Terminal LED green LED red GPIO3 Contact GPIO1/GPIO3 closed Contact GPIO1/GPIO3 open Contact GPIO2/ closed Contact GPIO2/ open Table 9: Terminal LED off LED orange Lamp Safety prevention circuits opened Safety prevention circuits closed Important safety advice: 1. The use of the "Safety Prevention" function is only allowed in applications, for which the risk analysis (EN 292 and EN 1050) permits for the prevention of a safety component. As a general rule, emergency stop buttons may never be prevented! The safety prevention key for this switch has to be stored securely, so that only authorized personnel have access to this key. 2. The function "Safety Prevention" can not be understood as the function "Muting" which is specified as the temporary automatic suspension of a safety function in the standard IEC A.7! Additional requirements have to be fulfilled to realize the "Muting" function which are not described here Testing SafeCIS3 Important safety advice: The SafeCIS3 main module complies with safety category 4 based on EN According to EN the execution of the security function must be tested at regular intervals via higher level controllers. The frequency of this check is based on the results of threat and risk analyze of the machine (EN and EN 1050). Furthermore the SafeCIS3 unit is certified according to SIL3 of IEC If necessary please contact your next CEDES partner to receive more information about the safety specific data. Normally the test input at the main module is connected to. If an external test is desired according to the risk analysis, a contact can be connected to In1. In case of operation in the modus "self testing" both OSSD outputs have to be connected separately to the safety circuit of the machine. SafeCIS3 Following possibilities are available for connecting the input. Input (In1) Input (In1) Figure 10: Connection possibilities for the input The timing of test input is as follows (Figure 11): Table 10: Timing during testing Time Value in ms Response time to test signal t 1 t R Time to test t 2 > t 1 Restart time after test t 3 t R Test input short circuited OSSD 1 / OSSD 2 t 1 open t 2 t 3 Figure 11: Test timing diagram (minimum off time = see Configuration Control Document, e.g. Figure 15) t R means the max response time of the total CEDES system (see chapter 8). In case of a test failure the status output "Info2" will provide a failure signal. For this reason the information output must be connected to the machine controller. After each test cycle the machine controller must check if the output "Info2" is high again (Info2 = + 24 V). If the status output remains low (Info2 = 0 V), an error has occurred and the machine controller should not allow the machine to restart, respectively must stop the machine immediately. Alternatively the machine controller can also check the output of the OSSD during such a test. Table 11: Terminal LED green LED red In1 or In2 External test signal high External test signal low (test running) 10. Fault identification through LED Causes for internal faults In the event of an internal fault condition, it will be indicated by one of the info outputs (if configured) and can be visually noticed in that the blue OptiLink LED (located on the side of a SafeCIS3 unit) is off. In this situation both safety outputs are low and the relays of the extension modules are open, and the controller unit is now in the so-called lock-out mode. CEDES/August

10 Two options exist to leave the lock-out mode: 1. Power up. If the fault is still present the controller will again show the lock-out mode. 2. A start impulse longer than 10 s acts like a power up Causes for external faults Following an external fault, it must be checked which components could have led to this fault. For example in case of Figure 9: A non illuminated GPIO3 LED indicates that one channel of the safety prevention switch GPIO1 GPIO3 is open. The following fault conditions will lead to an emergency stop or to a lock-out mode of a SafeCIS3 controller: Table 12 No Fault profile Fault description Measures and Instructions 1 "GPIO3" / Short-circuit or no connection of the supply lines of configured safety component. 2 "" LED illuminate not green although safety component is closed. 3 Safety outputs do not switch on even although all safety components are okay Only one channel of a two channel safety device is closed. EDM or Start release signal from external contactors are wrong Check connections (shortcircuit, cable breakage) Check safety component Check wiring and function of external contactors. The following fault conditions will lead to a lock-out mode of a SafeCIS3 main module: Table 13 No Fault profile Fault description 1 Blue OptiLink LED off or if configured: "Info2 The connection to the safety light curtain emitter or receiver is interrupted. output = low and 2 LED Info2" Defect in the electronics of the light = red curtain or the SafeCIS3 controller module. 3 Low voltage identification High voltage identification 4 Fault at one of the SafeCIS3 extension modules Measures and Instructions Check supply lines and connectors Possibly swap emitter and receiver connections Switch off + on controller unit. If continuously lit, contact your nearest CEDES partner. The supply voltage is lower / higher than the permissible voltage (< 0.85 UN, i.e. > 1.15 UN, + 5 % ripple). Check internal bus connection cable. If okay, controller must be repaired. The lock-out mode of a SafeCIS3 unit may be reset by one of two methods (see chapter 10.1). Further diagnosis possibilities are possible with the CEDES software Configuration Tool in combination with the OptiLink (see chapter 12). If the SafeCIS3 unit has a lock-out, the exact fault description can be determined with these tools. An exact description is available at any time after a lock-out, as long as the SafeCIS3 unit is still in the lock-out condition. 11. Selection tables Table 14 CEDES Part number Controller / Extension type SafeCIS3-2P-4IO SafeCIS3-EXT-2C including extension cable SafeCIS3-EXT-3C including extension cable SafeCIS3-EXT-4C (= 2x SafeCIS3-EXT-2C including extension cable) 12. Accessories / Components Table 15 CEDES Part number Xxx xxx Description Blank configuration control label Terminal strip block 6 pin Terminal strip block 5 pin Terminal strip block 4 pin Software Configuration Tool USB OptiLink Standard system Cascade system Perimeter system Emergency Stop Button Start button Key switch Safety prevention lamp 806 For further accessories please contact your nearest CEDES sales partner CEDES/August 2006

11 SafeCIS3 13. Inspection and service The SafeCIS3 modules are built electronically and do not need preventive maintenance B Inspections The SafeCIS3 modules have to be tested periodically in accordance with valid regulations - by qualified and trained personnel to discover prohibited manipulations or unauthorized modifications Decommissioning The SafeCIS3 modules can only be removed, when the machine or the equipment is shut down completely and can no longer be operated without tools. If a controller has to be disposed, it can be simply dismantled. The separated materials can be recycled according to state of the art technology and corresponding regulations of the country it was used in. 14. Product labels All the necessary safety information can be found on the product labels and the Configuration Control Label, which can be found on every controller module (example): Figure 13: Example of a product label SafeCIS3 main module with a special configuration All of the configuration information will also be found on the Configuration Control Document (Figure 15), which is included with the delivery of every SafeCIS3 main control module. Note: In the event that a SafeCIS3 main controller will be reconfigured by authorized personnel using an OptiLink, a new Configuration Control Label must be printed, and applied over the existing label (Figure 14). Details of the new configuration are given in the Configuration Control Document. New Name Cat.4 / SIL3 Cat.4 / SIL3 Figure 14: Product label of a basic SafeCIS3 main module which was reconfigured. The new special configuration identification "New name" is positioned on the existing label. Figure 12: Product label SafeCIS3 main module the with basic configuration Explanation of terminology Table 16 Lot-no HW Prod. date YYMMDD/ Order confirmation number/ Code of final inspection / Serial number Hardware Version Safety Level Cat. Safety category according to EN Safety Level SIL Power class Safety integrity level according to EN Power supply Temperature range OSSD Operating temperature range Max. current available per OSSD output, at the listed voltage CEDES/August

12 15. Technical data General data Nominal working mode Temperature range Enclosure rating according EN Housing Terminals Conductor connection: 4-, 5-, 6-pin, terminal strip (plug-in) Continuous process Environment temp.: C Stock temp.: C IP20 IP20 Wire cross section: max 2.5 mm 2 spring clamping technology Quick mounting Top hat rail 35 mm (EN 50022) Net weight Housing dimensions Housing material Vibration according to EN Shock resistant according to EN Installation position Approvals Interfaces Weight and packaging Dispatch packaging Dispatch weight SafeCIS3 4IO: 130 g SafeCIS3 Ext-2C: 150 g SafeCIS3 Ext-4C: 300 g 111 x 22,5 x 125 mm (incl. plugs) Figure 2 Polyamide Amplitude: 0.35 mm Frequency: Hz Acceleration: 100 ms -2 Impulse length: 16 ms Number of shocks: 1000 per direction No restrictions TÜV, CE (UL pending) optical (OptiLink) 280 mm x 200 mm x 70 mm Net weight g Inputs DC (EN ) Power supply: U N [chapter: 9.3] at 5 % residual ripple U N Current consumption Current max. 1.7 A + 70 ma per relay extension module (semi conductor outputs unloaded) Current nominal: 70 ma Max. power consumption at 2.1 W (semiconductor outputs max. supply voltage unloaded) Controller protection (external) 5 A slow Control current into: 2 ma each (min.) (in accordance IN1, IN2 with EN ) Minimum voltage at: 11 VDC at activated controller (EN IN1, IN ) Start pulse duration Min. 50 ms Max. 5s [chapter and 10.1] Test pulse duration (min.) response time x 2 Control current into: GPIO1 Maximum cable length for safety switches Safety Prevention Lamp Minimum current at Lamp Outputs to safety components Nominal voltage at: GPIO1 OSSD semi conductor outputs (PNP) Status outputs: Terminals: Info1, Info2 Max. response time t(mmlc) with U N protective mode (chapter 8) Max. response time t(mmgpio) with U N protective mode (chapter 8) Safety outputs OSSD1, OSSD2 7 ma each at U N (coded) 50 m out and back (total 100 m) [chapter 9.8] 8 ma with lamp switched on 0.9 A with lamp switched on U N - 1V (coded) (Short circuit protected) PNP Voltage: U N - 1V Max. current: 100 ma (short-circuit protected) 15 ms 130 ms Voltage: U N - 1V Max. current: 400 ma (short-circuit protected and with cross-fault detection) 12 CEDES/August 2006

13 15.1. Configuration Control Document Figure 15: Configuration Control Document for the SafeCIS3 controller with the basic configuration 13 CEDES/August 2006

14 16. Certificates CE Certificate 14 CEDES/August 2006

15 SafeCIS TÜV Certificate CEDES/August

16 CEDES / Switzerland Fax info@cedes.com