BBH SMX 12-2 User Manual

Installation manual
HB-37350-810-01-51F-EN SMX Installation manual.docx Page 1 of 234
Version: 50F
Installation Manual
for
SMX series
SMX Compact and
SMX Compact, 2nd Generation (SMXGen2)

BBH SMX 12-2 Specifications

General

Brand	BBH
Model	SMX 12-2
Category	Controller
Language	English

Summary

1 Important notes

Definition of individual target groups

Defines target groups for manual sections like project engineers, technicians.

1.1 Definitions

Explains generic term "SMX", "safe" classification, and "SafePLC".

1.2 Co-valid documents

1.3 Abbreviations used

2 Safety regulations

2.1 Intended use

Specifies intended applications such as EMERGENCY STOP, safety components, and PES for risk reduction.

2.2 Use in regions with UL/CSA requirements

Details conditions for using SMX modules in USA/Canada and their cULus approval standards.

2.3 General safety regulations

Covers general safety rules for working with devices, including qualified personnel and manual adherence.

2.4 Operation and service

Provides safety notes for installation, removal, and handling of modules to prevent discharge.

2.5 Transport/storage

Advises on following information concerning transport, storage, and handling, and climate specifications.

3 Device types

Basic devices

Describes SMX10/11/12 as compact fail-safe control systems with programmable functions.

Extension modules

Covers central or decentralised I/O expansion modules for the SMX10/11/12 series.

Communications-, modules and integrated interface

Explains communication interfaces for bi-directional data transfer via field bus.

3.1 Module overview

3.2 Characteristic data of device

3.2.1 Basic modules

Details the characteristics of basic SMX modules, including their periphery and extendability.

3.2.1.1 SMX10/10A/10R/10AR (/2, /4x, /x(1))

Outlines the device design and characteristics of SMX10/10A/10R/10AR modules.

Technical characteristic data SMX10/A/R/AR (/2, /4x, /x(1))

Environmental data

Specifies environmental conditions such as temperature, protection class, humidity, and EMC compliance.

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections.

3.2.1.2 SMX11(/2, /4x, /x(1))

Technical characteristic data SMX11(/2, /4x,/x(1))

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX11.

3.2.1.3 SMX11-2(/2, /4x, /x(1))

Technical characteristic data SMX11-2(/4x, /x(1))

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX11-2.

3.2.1.4 SMX12/12A(/2, /4x, /x(1))

Technical characteristic data SMX12/12A(/2, /4x, /x(1))

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX12/12A.

3.2.1.5 SMX12-2/12-2A(/2, /4x, /x(1))

Technical characteristic data 12-2/12-2A(/2, /4x, /x(1))

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX12-2/12-2A.

3.2.2 Central expansion modules

3.2.2.1 SMX31/31R/31R-4(/2)

Details the device design and characteristics of SMX31/31R/31R-4 modules.

Technical characteristic data SMX31/31R/31R-4(/2)

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX31/31R/31R-4.

3.2.3 Decentralized expansion modules

3.2.3.1 SMX32-x/2/D, SMX32-xR/2/D

Details the device design and characteristics of SMX32 decentralized modules.

Technical characteristic data SMX32-x/2/D, SMX32-xR/2/D

Mechanical data

Details mechanical specifications including dimensions, weight, mounting, and terminal cross-sections for SMX32 modules.

3.2.4 Communication interface

3.2.4.1 SMX5x

Describes the design and characteristics of SMX5x communication modules for different fieldbuses.

Technical characteristic data SMX5x

3.2.4.2 SMX1x/4x

Technical characteristic data SMX1x/4x

3.2.4.3 Optional universal communication interface

3.2.4.3.1 Combination options

Details combination options for universal communication interfaces across different SMX module types.

Technical characteristic data: Optional universal communication interface

3.2.5 Encoder specifications

TTL

Details specifications for TTL encoders, including physical layer, signal, and connection.

SIN / Cos

Details specifications for SIN/COS encoders, including standard and high-resolution modes.

SSI-Absolut

Details specifications for SSI-Absolut encoders, including data interface and master/listener operation.

Resolver

Details specifications for Resolver sensors, including signal, frequency, and connection.

HTL

Details specifications for HTL sensors, including signal level, physical layer, and connection.

Proxi

Details specifications for Proxi sensors, including signal level and connection.

Proxi – Extended monitoring

Details specifications for extended monitoring of Proxi sensors, including signal level and frequency.

3.3 Derating outputs

3.4 Identification

3.4.1 Type plate

Lists information found on the module's type plate, such as type designation and serial number.

3.4.2 Type plate SMXGen2 (/2)

3.4.3 Scope of delivery

4 Safety related characteristics

4.1 General design, safety related architecture and characteristic data

Explains the internal structure, architecture category, and reciprocal comparison of SMX modules.

Characteristic data:

System structure

Describes the system structure as 2-channel with diagnose, relevant for safety classification.

Rating of operating mode

Specifies the rating of operating mode as "high demand" according to IEC 61508.

Probability of an endangering failure per hour (PFH-value)

Provides PFH values for different SMX variants, crucial for risk assessment.

Specific values acc. to table “safety-technical characteristic data“

Refers to a table for specific safety-technical characteristic data.

Proof-Test-Intervall (IEC 61508)

Specifies the proof-test interval for IEC 61508 compliance, indicating module replacement period.

4.2 Safety related characteristic data and wiring for the connected sensors

4.2.1 Digital sensors:

Addresses safety characteristics and wiring for digital sensors and inputs.

4.2.1.1 Characteristics of sensors / input elements

Illustrates different sensor input element characteristics and their connection types (parallel, series).

4.2.1.2 DC digital sensors/inputs

The following diagnoses for input sensors can generally be used for the safety related assessment of the entire system:

4.2.1.3 Classification of digital inputs

4.2.1.3.1 Digital inputs I01 … I14

Details classification of digital inputs I01-I04 and I09-I14, and I05-I08 with their achievable performance levels.

4.2.1.3.2 Digital inputs I/O’s (IQIx)

4.2.1.4 Exemplary connections of digital sensors

4.2.1.4.1 Single-channel sensor, without cross-shorting test

Shows wiring for a single-channel sensor without cross-shorting test, noting limited safety suitability.

4.2.1.4.2 Single-channel sensor with cross-shorting test

Shows wiring for a single-channel sensor with cross-shorting test (cycling).

4.2.1.4.3 Dual-channel sensor without timeout with cross-shorting test

4.2.1.4.4 Dual-channel sensor with time-out and cross-shorting test

4.2.1.5 Overview of achievable PI for digital safety inputs

4.2.2 Sensors for speed and/or position detection

4.2.2.1 General safety related structure of the sensor interface for position and/or speed

Explains the safety-related structure of sensor interfaces for position and speed detection.

4.2.2.2 General diagnostic measures for encoder interface

4.2.2.3 Encoder types and their combination, diagnostic data

4.2.2.4 Specific diagnostic measures with regard to the encoder type used

4.2.2.5 Safety relevant cut-off thresholds encoder systems for position and speed detection

4.2.2.6 Safety related assessment of encoder types or there combination

4.2.3 Analog sensors

4.2.3.1 Exemplary connection of analog sensors

Provides exemplary connection diagrams for analog sensors and notes on resistor configuration.

4.3 Safety related characteristic data and wiring of the outputs

4.3.1 Characteristic of the output elements

Describes the characteristics of output elements, illustrating different SMX output configurations.

4.3.2 Diagnoses in the cut-off circuit

4.3.2.1 Diagnostic Functions

Lists durably implemented diagnostic functions like cross-wise readback and cutout ability tests.

Parametrizable diagnostics functions:

4.3.2.2 Overview DC with respect to the chosen diagnostics functions

Summarizes DC values achievable based on chosen diagnostics functions for outputs.

4.3.3 Permissible capacitive and inductive load at safe outputs

4.3.4 Digital outputs

4.3.4.1 Characteristic data of the basic outputs

Lists characteristic data for basic digital outputs, categorizing them by architecture and comment.

4.3.4.2 Wiring examples basic outputs

4.3.4.2.1 Single-channel switching relay or semi-conductor output without test

Shows wiring for single-channel outputs without testing, noting limited safety suitability.

4.3.4.2.2 Single-channel switching relay or semi-conductor output with external switching amplifier and testing

4.3.4.2.3 Single-channel switching relay or semi-conductor output with dual-channel external circuit with testing

4.3.4.2.4 Two-channel switching relay output with external monitoring - group feedback

4.3.4.2.5 Dual-channel output with relay output and semi-conductor output – external control circuit with monitoring

4.3.4.2.6 Dual-channel output with relay output and external control circuit in PI e

4.3.4.2.7 Dual-channel output with semi-conductor output and external control circuit in PI e

4.3.4.2.8 Wiring of a notification output

4.3.5 Digital outputs I/O’s (IQQx)

4.3.5.1 Classification of the I/O‘s (IQQx) when used as output

Classifies IQQx outputs by achievable PI and provides comments based on static/dynamic and group configurations.

4.3.5.2 Wiring examples for safe digital outputs I/O's I/O’s (IQQx)

4.3.5.2.1 Wiring single-channel without testing

Shows single-channel wiring for two-channel IQQx outputs, noting limited safety suitability.

4.3.5.2.2 Wiring single-channel with testing

4.3.5.2.3 Wiring with safe cut-off circuit

4.3.5.2.4 Wiring in connection with two-channel switching-off circuit

4.3.5.2.5 Redundant two-channel output

4.3.5.2.5.1 Wiring dual-channel in the same group

Shows wiring for redundant dual-channel outputs in the same group with a two-channel switching-off circuit.

4.3.5.2.5.2 Wiring dual-channel in different groups

4.3.5.3 Overview of achievable PI for digital safety outputs

5 Connection and installation

5.1 General notes on installation

Covers general installation rules, protection degrees, cable lengths, EMC, and PESSRAL use.

5.2 Installation and assembly of the SMX module

5.3 Installation of backplane bus system

Explains the installation of the backplane bus system for connecting multiple SMX modules.

5.3.1 Arrangement examples

5.4 Assembling the modules

5.4.1 Assembly on C-rail

Details the procedure for mounting devices onto a C-rail, including assembly and disassembly.

5.4.2 Assembly on backplane bus

5.5 Installation und Konfiguration von Master <–> Master (SMMC) und Master <-> Slave (SDDC)

5.5.1 Network topology

Illustrates network topologies for SMX communication using SDDC CAN, SDDC Ethernet, and SMMC.

5.5.2 Installation I/O-extension

3.1.1.1 Physical address configuration of the slave modules (central/decentral)

Details how to set the bus address for slave modules using the address switch on the SMX3x module.

5.6 Terminal assignment

5.6.1 Terminal assignment SMX10

Details the terminal assignments for SMX10 and SMX10/2 modules.

5.6.2 Terminal assignment SMX10R

5.6.3 Terminal assignment SMX10A

5.6.4 Terminal assignment SMX10AR

5.6.5 Terminal assignment SMX11

5.6.6 Terminal assignment SMX11-2

5.6.7 Terminal assignment SMX12

5.6.8 Terminal assignment SMX12A

5.6.9 Terminal assignment SMX12-2

5.6.10 Terminal assignment SMX12-2A

5.6.11 Terminal assignment SMX31

5.6.12 Terminal assignment SMX31R

5.6.13 Terminal assignment SMX31R-4/2

5.6.14 Terminal assignment SMX32-0/2/D

5.6.15 Terminal assignment SMX32-0R/2/D

5.6.16 Terminal assignment SMX32-1/2/D

5.6.17 Terminal assignment SMX32-1R/2/D

5.6.18 Terminal assignment SMX5x

5.6.19 Terminal assignment SMX1x/4x

5.7 External 24 VDC – voltage supply

5.8 Connection of the external encoder supply

5.8.1 Incremental, HTL, SIN/COS, SSI

Details the connection of external supplies for Incremental, HTL, SIN/COS, and SSI encoders.

5.8.2 Resolver

5.9 Connection of digital inputs

5.10 Connection of analog inputs

5.11 Connection of position and speed sensors

5.11.1 General notes

Provides general notes on connecting encoders, including voltage supply, EMC, and mechanical interaction.

5.11.2 Assignment of encoder interface

5.11.3 Connection variants

5.11.3.1 Connection of an absolute encoder as master

Illustrates the connection of an absolute encoder as master, showing SMX clock pulses to encoder and data from encoder to SMX.

5.11.3.2 Connection of an absolute encoder as slave

5.11.3.3 Connecting an incremental encoder with TTL-signal level

5.11.3.4 Connection of a SIN/COS encoder

5.11.3.5 Connection of a resolver as master

5.11.3.6 Connection of a resolver as slave

5.11.3.7 Connection of proximity switch SMX1x(/2)

5.11.3.8 Connection of HTL/proximity switch SMX11-2/SMX12-2 (/2)

5.11.3.8.1HTL-encoder with A+/A- or B+/B- signal

Shows wiring for HTL encoders using A+/A- or B+/B- signals, including supply voltage and ground.

5.11.3.8.2HTL-encoder with A+ or B+- signal

5.12 Configuration of measuring distances

5.12.1 General description of encoder configuration

Provides general notes on connecting encoders, including voltage supply, EMC, and mechanical interaction.

5.12.2 Sensor type

Lists the types of sensors supported, including absolute, incremental, and proximity switches.

5.12.2.1 Absolute encoder:

5.12.2.2 Incremental encoder:

5.12.2.3 SinusCosinus encoder – standard mode

5.12.2.4 SinusCosinus encoder – high resolution mode:

5.12.2.5 Proxi - switch

5.12.2.6 Extended monitoring proximity switch / proximity switch

5.12.2.7 HTL – Sensor

5.12.2.8 Resolver

6 Response times of the SMX

6.1 Response times in standard operation

Lists response times for standard operations like monitoring function activation and deactivation.

6.2 Response time for FAST_CHANNEL

6.3 Response times for fault distance monitoring

6.4 Reaction times when using SMX 31x/32x

7 Start-up

7.1 Procedure

Emphasizes that start-up must be done by qualified personnel following safety regulations.

7.2 Making sequences

Describes the phases displayed on the seven-segment display during start-up and normal operation.

7.3 Reset-Function

7.3.1 Type of Reset-Functions

Details different types of reset functions (General, Internal) and their triggering elements.

7.3.2 Reset-Timing

7.3.3 Reset-Function

7.3.3.1 Example Reset-Function with safeguarding against false utilization

7.4 LED display

7.5 Parameterization

7.6 Function test

7.7 Validation

8 Safety related examination

9 Maintenance

9.1 Modification / handling changes to the device

States that maintenance must be by qualified personnel; opening voids warranty and safety approval.

9.2 Exchanging a module

Lists steps to be followed when exchanging a module, including disconnection and reconnection procedures.

10 Technical data

10.1 Environmental conditions

Lists environmental conditions like protection class, temperature, humidity, and operating altitude.

10.2 Safety related characteristic data

Summarizes safety characteristics such as SIL, PL, system structure, and PFH values.

11 Switch types

12 Notes on designing, programming, validating and testing safety related applications

12.1 Risk assessment

Explains the importance of safety assessment based on applicable standards and risk reduction to an acceptable minimum.

12.2 Required technical documents

12.3 Necessary steps for draft, realization and testing

12.3.1 Phases of the V-model

Explains the phases of the V-model for safety functions, covering design and validation stages.

12.3.2 Specification of safety requirements (structural schematic)

Example for an automatic handling machine:

Safety function:

Defines the safety function: Safely reduced speed with access door open.

Structural diagram:

Shows the structural diagram of the safety function, including sensor, PES, and actuator.

Safety related structural diagram:

Presents a safety-related structural diagram illustrating components like door closer, speed sensor, PES, and contactor.

Example for a risk analysis:

12.3.3 Specification of the functional safety system

12.3.3.1 Definition of safety functions

Outlines what must be included in the definition of a safety function, such as risk coverage and parameters.

12.3.3.2 Required performance level (PLr) (additional emergency stop)

Explains how to determine the required performance level (PLr) based on identified safety functions.

12.3.3.3 Example – Specification of safety functions in form of a table

12.3.4 Software specification

Example of software specification

Provides an example of software specification for safety functions like speed monitoring and backstop.

12.3.5 Hardware specification

12.3.5.1 Selection of SRP/CS and operating means

Guides the selection of Safety Related Parts of Control Systems (SRP/CS) and their code numbers.

12.3.5.2 Beispiel für Vorgabe HW

12.3.5.3 Consideration of systematic failures

12.3.6 Hard and Software design

Analysis of wiring diagram

Explains how to check wiring diagrams and bill of materials for compliance with safety aspects.

12.3.7 Testing of the hardware design

Details testing the hardware design for compliance with specifications and safety levels.

12.3.7.1 Iterative testing of the achieved safety level

A calculation acc. to EN ISO 13849-1 shall serve as an example:

Safety function:

Defines the safety function: Safely reduced speed with access door open.

Structural diagram:

Shows the structural diagram of the safety function, including sensor, PES, and actuator.

Safety related structural diagram:

Presents a safety-related structural diagram illustrating components like door closer, speed sensor, PES, and contactor.

12.3.8 Verification software(program) and parameters

12.3.8.1 Checking FUP

Explains how to compare programmed FUP with specifications and AWL-listing for correctness.

12.3.8.2 Validation of FUP against AWL and parameters by means of validation report.