Festo CMXH User manual

Description

STO

Safe Torque Off

(STO)

8067357

1612a

[8067359]

CMXH

Controller

CMXH

2 Festo – CMXH-STO-EN – 1612a – English

Translation of the original instructions

CMXH-STO-EN

Identification of hazards and instructions on how to prevent them:

Danger

Immediate dangers which can lead to death or serious injuries

Warning

Hazards that can cause death or serious injuries

Caution

Hazards that can cause minor injuries

Other symbols:

Note

Material damage or loss of function

Recommendations, tips, references to other documentation

Essential or useful accessories

Information on environmentally sound usage

Text designations:

 Activities that may be carried out in any order

1. Activities that should be carried out in the order stated

– General lists

èResult of an action/References to more detailed information

CMXH

Festo – CMXH-STO-EN – 1612a – English 3

Table of Contents – CMXH

Instructions on this documentation 4.................................................

1 Safety and requirements for product use 5......................................

1.1 Safety 5..................................................................

1.1.1 Safety instructions for use of the STO safety function (Safe torque off) 5......

1.1.2 Intended use of the STO function 6.....................................

1.1.3 Safety characteristics 6..............................................

1.1.4 Foreseeable misuse of the STO function 6...............................

1.1.5 Diagnostic coverage (DC) of the controller 6.............................

1.2 Requirements for product use 7...............................................

1.2.1 Qualification of specialized personnel 7.................................

1.2.2 Range of application 7..............................................

1.2.3 Specified standards 7...............................................

2 Function and application 8...................................................

2.1 Circuitry of the STO inputs 9..................................................

2.2 Functional description 10.....................................................

2.3 STO function of the interface [X4] 11.............................................

2.3.1 Switching statuses 11................................................

2.3.2 Switching times 12..................................................

2.3.3 Logic supply 24 V logic 12.............................................

3 Electrical installation 13......................................................

3.1 Installation 13..............................................................

3.2 Notes on commissioning 14....................................................

3.3 Diagnostics 15..............................................................

3.4 Obligations of the machine operator 15..........................................

A Technical appendix 16........................................................

A.1 Technical data 16............................................................

A.1.1 Safety engineering 16................................................

A.1.2 Electrical data 17....................................................

A.2 Product conformity and certifications 18.........................................

CMXH

4 Festo – CMXH-STO-EN – 1612a – English

Instructions on this documentation

This document only describes the utilisation of the safety function STO – “Safe Torque Off” in accord

ance with EN 61800-5-2, which is implemented in the controller CMXH, in combination with the related

planar surface gantry EXCM-30/-40.

Documentation

The complete description of the system, comprising controller and gantry, includes the following docu

ments:

Designation Contents

Assembly instructions

CMXH

Notes on mechanical installation of the CMXH.

Description

EXCM-30/-40

Description of the mechanical installation of the planar surface gantry

EXCM-30/-40

Description

EXCM-30/40-...-PF-...

Commissioning of the planar surface gantry EXCM-30/-40 with the CMXH

controller

Help system

for the FCT plug-in CMXH

Help system in the FCT for support of commissioning and

parameterisation of the CMXH controller

Description

CMXH

Use of the STO safety function (“Safe Torque Off”).

Tab. 1 Documentation for the system EXCM-30/-40 with CMXH

Product identification, versions

This documentation refers to the following software versions:

CMXH firmware version Required CMXH plug-in

V1.2 or later V2.0 or later

Tab. 2 Software versions

The hardware version, firmware version and serial number are displayed in the software

with an active online connection (èConfiguration software FCT, “Controller” page).

If an online connection is currently unavailable, information relating to the last connection

will be displayed.

Additional information about the product:

– Overview of accessories (catalogue) èwww.festo.com/catalogue

– Certificates, declaration of conformity èwww.festo.com/sp

Note

Before using a newer firmware version:

 Check whether a newer corresponding version of the FCT plug-in or user documenta

tion is available èwww.festo.com/sp.

1 Safety and requirements for product use

Festo – CMXH-STO-EN – 1612a – English 5

1 Safety and requirements for product use

1.1 Safety

When commissioning electrical drives:

 Always observe the safety instructions and warnings in the documentation of the controller

(èTab. 1) and the documentation of the components used.

 Before mounting and installation work: Switch off the supply voltage. Secure against accidental

reactivation. Only switch on the supply voltage again when mounting and installation work is com

plete.

 Never remove or insert a plug when the motor controller is powered.

 Observe the handling specifications for electrostatically sensitive devices.

 Only enable the controller if the drive has been professionally installed and fully parameterised.

 Do not carry out repairs on the controller. In the event of a defect: Replace the complete controller.

1.1.1 Safety instructions for use of the STO safety function (Safe torque off)

Caution

In order to achieve safety characteristics according to EN ISO 13849-1:

 Conduct a risk assessment of the application.

 Select the components and their wiring corresponding to the required category

according to EN ISO 13849-1.

Caution

Failure of the safety function can result in serious, irreversible injuries, e.g. due to unex

pected movements of the actuators.

 Do not bypass the connections for safety equipment.

 Observe the input voltage ranges of the controller èChapterA.1.

 Only use the STO function when all of the necessary safeguards have been set up

and are functional.

 Validate the STO function to complete commissioning.

Caution

Severe injuries as a result of uncontrolled movement of the passive actuators when

switching off the power output stage. The STO function is insufficient as the sole safety

function for drives that are subject to permanent torque (e.g. through suspended

loads).

 Shut down the passive actuators mechanically if required, e.g. via a brake, to ensure

that movements are prevented. This especially applies to vertical axes without auto

matic locking mechanics, clamping units or counterbalancing.

1 Safety and requirements for product use

6 Festo – CMXH-STO-EN – 1612a – English

1.1.2 Intended use of the STO function

The controller supports the STO safety function (STO, Safe Torque Off) in accordance with

EN61800-5-2. The STO function is intended to shut down the torque from a motor that is connected to

the CMXH, thereby preventing an unexpected restart of the motors. The STO function may only be used

for applications in which the specified safety characteristics suffice.

1.1.3 Safety characteristics

The STO function of the CMXH fulfils requirements for the following characteristic safety values:

– PL e/Cat. 3 according to ENISO13849-1

– SIL CL 3 in accordance with EN61800-5-2 / in accordance with EN62061 / IEC 61508

The achievable safety level of the complete system depends on the other components that are used to

implement the safety function.

To protect against unintended start-up, the controller must be activated via the connection [X4] with the

category required for the application according to EN ISO 13849-1, e.g. via an external safety relay.

1.1.4 Foreseeable misuse of the STO function

Unintended use includes the following misuses:

– Bypassing of the safety function

– Use in applications where switching off can result in hazardous movements or conditions.

The STO function does not provide protection against electric shock, only against dangerous move

ments!

1.1.5 Diagnostic coverage (DC) of the controller

The diagnostic coverage (èChapter A.1) is influenced by the interconnection of the controller in the

control chain as well as the measures implemented for diagnostics.

In order to achieve the diagnostic coverage, the status of the diagnostic contacts must be evaluated by

the control system with each request of the STO function.

If the signal does not correspond to the expected value, it can allude to a potentially dangerous mal

function, e.g. a wire break. In this case, appropriate measures must be implemented to maintain the

safety level.

Note

The controller cannot detect a cross circuit in the input circuit by itself.

 Find out if cross-circuit detection is needed for the input circuit and wiring in your

application.

 If required, use a safety switching device with cross-circuit detection.

1 Safety and requirements for product use

Festo – CMXH-STO-EN – 1612a – English 7

1.2 Requirements for product use

For correct and safe use of the product in a machine or system:

 Provide the complete product documentation to the following specialists

– the design engineer and installer of the machine or system

– the personnel responsible for commissioning

 Keep the documentation safe throughout the entire product lifecycle.

 Ensure compliance with all of the specifications in the documentation for the controller

(èTab. 1 Documentation for the system EXCM-30/-40 with CMXH).

 Also take into consideration the documentation for the other components (e.g. motors, cables,

etc.).

 Take into consideration all of the legal regulations that are applicable for the installation site, as

well as the following documents:

– regulations and standards

– regulations of the testing organisations and insurers

– national specifications

For correct and safe use of the STO function:

 Conduct a risk assessment for your machine or system.

 Comply with the specified safety characteristics (èChapter A.1, Technical data).

 Comply with the connection and environmental conditions, in particular the voltage ranges of the

product and all connected components. Only compliance with the limit values and load limits will

enable operation of the product in compliance with the specified safety regulations.

1.2.1 Qualification of specialized personnel

The function should only be integrated into the machine by a qualified electrical technician of the ma

chine manufacturer. The qualified technician must be familiar with:

– Installation and operation of electrical control systems

– the applicable regulations for operating safety-engineered systems

– the applicable regulations for accident prevention and occupational safety

– the documentation for the product

1.2.2 Range of application

The controller has the CE marking. The product-relevant EU directives can be found in the declaration of

conformity. Additional information:

– Certificates and the declaration of conformity (èwww.festo.com/sp)

– Standards and test values (èChapter A.1,Technical data)

1.2.3 Specified standards

ENISO13849-1:2015

EN 60204-1:2006/AC:2010

IEC 61508-1…2/4…7:2010-04

EN 61800-5-2:2007-10

EN 62061:2005/A2

Tab. 1.1 Standards specified in the document

2 Function and application

8 Festo – CMXH-STO-EN – 1612a – English

2 Function and application

Caution

Unexpected movement of the vertically built-in planar surface gantry when the output

stage is shut down.

Risk of impact and crushing injuries.

 Only planar surface gantries with holding brakes may be installed vertically.

 Note the mechanical inertia of the holding brake.

Note

Failure of the output stage.

If the output stage of the controller fails when an STO function is active, it may result in

the drive jerking through a limited detent movement of the rotor. The rotation angle/

travel corresponds to the pole pitch of the motor used.

The STO function (“Safe Torque Off”) enables 2-channel, secure disconnection of the power supply to

both motors connected to the controller.

The safety function is requested solely via the control ports of the switch-off functions interface [X4] on

the controller. Safety-oriented circuitry for additional interfaces of the controller is not required.

1Switch-off functions interface [X4]

Fig. 2.1 Switch-off functions interface [X4]

2 Function and application

Festo – CMXH-STO-EN – 1612a – English 9

2.1 Circuitry of the STO inputs

To protect against unintended start-up, the controller must be activated via the connec

tion [X4] with the category required for the application in accordance with

EN ISO 13849-1. Attainable safety level of the STO function èChapter 1.1.3.

The following components for requesting the STO function, for example, can be connected to the STO

inputs (èTab. 3.1 Switch-off functions interface [X4]):

– Semiconductor safety outputs (electronic safety switching devices, active safety sensors, e.g. light

curtains with OSSD signals) (OSSD = “Output Signal Switching Device”)

– Switch contacts (safety switching devices with relay outputs, passive safety sensors, e.g. forced

position switches)

+24 V/+48 V DC, load

Controller CMXH

Logic

Load

0 V

STO1

STO2

0 V DC

DIAG1

DIAG2

OSSD1

OSSD2

S1 13

+24 V DC, logic

Receiver

Transmitter

Input circuit

Feedback circuit

PLC input:

Safety feedback

1Controller CMXH

(only relevant connections depicted)

2Emergency stop switches

3Guard door (alternative to 2)

4Light curtain (alternative to 2)

5Safety switching device (alternative to 2)

Fig. 2.2 Switching example (without cross-circuit detection)

2 Function and application

10 Festo – CMXH-STO-EN – 1612a – English

2.2 Functional description

The STO function is requested over 2 channels via switch S1, whereby the control voltage (+24 V DC,

logic èFig. 2.2) is switched off at both inputs STO1 and STO2.

The STO inputs are of equal value, i.e. it makes no difference in which sequence they are connected.

The controller monitors the status of the STO inputs and switches off the driver supply for the output

stages as soon as logic 0 (0 V) is present at one of the STO inputs. Power supply of the motors is inter

rupted via the power output stages:

– Behaviour of the drive with running motors: The movement of the drive is not decelerated via a

braking ramp of the controller. The drive continues to move uncontrolled due to inertia or external

forces until it comes to a standstill by itself.

– Behaviour of the drive with a stopped motor: The drive is uncontrolled and can move due to external

forces.

Note

For motors with integrated holding brake, the holding brake is activated by the non-

safety-relevant firmware of the device. When the output stage is switched off, there is

no deceleration of the drive via a braking ramp. The holding brake is closed immediately.

If the motor is running, this results in increased wear and can lead to damage to the

motors if it occurs repeatedly.

The 2-channel disconnection of the output stages is indicated by the DIAG1/DIAG2 diagnostic contact.

The status of the STO function can be reported to an external safety switching device for diagnostics,

for example, via the diagnostics contact. The diagnostics contact is not evaluated in terms of safety

engineering.

STO1

STO2

+24 VDC

+24 VDC load

1Input circuit (e.g. safety relay)

2Power output stage in CMXH

(only one phase shown)

3Driver supply

4Motor (only one phase shown)

Fig. 2.3 “Safely switched off torque” functional principle

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