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PROTECT PSC1
Programmable modular safety controller
Preface
Dipl.-Ing. Heinz Schmersal and Dipl. Wirt.-Ing. Philip Schmersal
Managing Partners of K.A. Schmersal GmbH & Co. KG
With its comprehensive range of about 25,000 products, Schmersal is one of the world‘s
biggest suppliers of safety technology.
However, Schmersal is not only a manufacturer of safety components, but also a systems
supplier. In developing the new PROTECT PSC1, we have taken a big step forward in the
field of control technology.
The multifunctional PROTECT PSC1 system consists of a reliable, programmable compact
control and dependable extension modules and can be adapted perfectly to specific applications in various branches of industry. With its combination of certain properties, the new safety
control from Schmersal is unparalleled, as the PROTECT PSC1 has unique features that
clearly set this control system apart from other solutions in the market.
The new generation of programmable modular safety controls from Schmersal is embedded
in a comprehensive offering of safety services. Many of our customers want planning and
advice from the outset, e.g. in the design of complex automation systems. This also includes
the development of custom applications and their integration in higher-order control systems.
A central element here is application consulting. Certified functional safety engineers help
our customers to choose suitable protective devices, advise them on CE conformity and risk
assessment, and perform the safety analysis of existing machines. And all this worldwide.
With another service, that of application engineering, Schmersal targets users of safety
controls in automation technology. For them, we develop customised software modules
that enable safety functions to be tailored perfectly to the machine‘s or system‘s specific
application.
Over and above this, we regularly report to our customers and experts in the field on new
developments in machine safety. In short, we offer our customers an all-embracing package
of integrated systems solutions in the safety technology sector.
Heinz Schmersal
2
Philip Schmersal
Content
Preface____________________________________________________________Page2
Content____________________________________________________________Page3
PROTECT PSC1_____________________________________________________Page4
User Software
Programming software SafePLC2_____________________________________Page5
Parameterization software SafePMT___________________________________Page5
Compact safety controller PSC1-C-100___________________________________Page6
Compact safety controller PSC1-C-10 ____________________________________Page7
Safe IO expansion modules for the compact safety controller
PSC1-C-10 and PSC1-C-100
1) Central IO expansion modules______________________________________Page8
2) Decentral IO expansion module – save remote IO communication
Ethernet SDDC (Safety Device to Device Communication)________________Page9
Safe Drive Monitoring (SDM) – Safe drive monitoring for up to 12 axes___________Page10
a) Safe drive monitoring of the compact controller PSC1-C-10_______________Page11
b) Safe drive monitoring of the compact controller PSC1-C-100______________Page11
International type code for the safety controller PROTECT PSC1_______________Page12
Topologies
Save cross communication – Ethernet SDDC____________________________Page13
Safe remote IO communication – Ethernet SDDC _________________________Page13
Modular compact controller PSC1-C-10_________________________________Page14
Modular compact controller PSC1-C-100________________________________Page14
Universal communication interface – universal fieldbus connection____________Page15
Universal communication interface – integrated SD-bus-Gateway_____________Page15
3
PROTECT PSC1
Programmable modular safety controller
The safety control system PSC1 consists of freely programmable compact controllers and I/O expansion modules
for safe signal processing of emergency stop switches, safety door switches, light curtains and other electromechanical
or electronic safety devices.
In addition, it is possible to monitor several functions axis safely. By using the universal communication interface,
connections to all common fieldbus systems can be established.
■ Save logic controller according to appendix IV of machine directive 2006/42/EC
■ Connection to all common safety switching devices up to PL e respectively SIL 3
■ Modular expandable up to 272 in-/outputs
■ Safe 2 A double p-switching semiconductor outputs, switchable to safe p-/n-switching semiconductor outputs
■ Free programmable in-/ outputs, 2 A double p-switching
■ Safe axis monitoring according to EN 61800-5-2 (SDM – Safe Drive Monitoring) for up to 12 axes
■ Universal communication module:
- Supports standard fieldbus systems including safety protocols
- Setting and resetting of fieldbus protocols by software
- Activation of the safety protocol by Safety Protocol Card
- Safe remote IOs via Ethernet Safety Device to Device Communication (SDDC)
- Safe cross communication via Ethernet SDDC
■ Integrated Schmersal SD-bus connection to the standard fieldbus systems
■ Safety functionalities up to SIL 3 according to IEC 61508 / IEC 62061, PL e and Cat. 4 according to EN ISO 13849-1
4
User Software
Programming software SafePLC2 and
parameterization software SafePMT
Programming software SafePLC2
■ Modern, object oriented application development environment
■ Preconfigured elements for safe electronic and electromechanical switching devices
■ Easy reuse of application code by macros
■ Programming assistance by various search functions
■ Simple signal tracking by different color representation and status messages
■ Easy to detect safety functions through practice oriented libraries for logic,
Safe Drive Monitoring, SD-bus and encoder elements
■ Configurable user permissions
■ Definition of variable parameters
Parameterization software SafePMT
In the programming software SafePLC2 defined parameters can be changed in the parameterization software SafePMT without revalidation.
This gives the user the possibility to adjust quick and easily parameters of the save drive monitoring to a specific application.
5
Compact safety controller PSC1-C-100
The PSC1-C-100 is a modular and freely programmable compact controller for safe signal
processing of safety devices with an optional universal communication interface.
The base version of the PSC-1-C-100 controller has the following properties:
■ 14 save inputs up to PL e respectively SIL 3
■ 10 adjustable safe in-/outputs up to PL e respectively SIL 3, 2 A, double p-switching
■ 4 adjustable save semiconductor outputs, 2 A (adjustable: double p- or p-/n-switching)
■ 2 safe relay outputs for 24 VDC or 230 VAC, 2 A
■ 2 signaling outputs, 100 mA
■ 2 pulse outputs (clock outputs) for contact sensors
■ 1 SDHC card slot for storing application programs
■ 1 connection for Schmersal SD-bus sensors
■ Modular expandable up to 8 IO-modules (central / decentral)
■ Modular expandable with up to 6 save drive monitoring modules (max. 12 axes)
■ Universal communication interface (optional)
Basic version with SDHC memory card
Universal communication interface incl. SDHC memory card
6
Compact safety controller PSC1-C-10
The PSC1-C-10 is a modular and freely programmable compact controller for safe signal processing of safety
devices with the option of an integrated drive monitoring and / or an universal communication interface.
The base version of the PSC-1-C-10 controller has the following properties:
■ 14 save inputs up to PL e respectively SIL 3
■ 4 adjustable save semiconductor outputs, 2 A (adjustable: double p- or p-/n-switching)
■ 2 safe relay outputs for 24 VDC or 230 VAC, 2 A
■ 2 signaling outputs, 100 mA
■ 2 pulse outputs (clock outputs) for contact sensors
■ Modular expandable with up to 2 IO expansion modules (central / decentral)
■ Optional expansions: Universal communication interface, memory card, safe drive monitoring
Basic unit
with memory card
with communication interface
With integrated Safe Drive Monitoring for 1 axis
With integrated Safe Drive Monitoring for 2 axis
7
Safe IO expansion modules for the compact
safety controller PSC1-C-10 and PSC1-C-100
The IO expansion modules can be freely used for the compact controllers and differ in their application:
1. Central applications
a
. in the same cabinet, directly aligned to the compact controller
b. communication via backplane bus
2. Decentral applications
a
. remote control cabinet
b. communication to the compact controller via Ethernet SDDC
1) central IO expansion modules
Technical specification:
PSC1-E-31-12DI-10DIO
Technical specification:
PSC1-E-14DI-4DO-2RO
Technical specification:
PSC1-E-33-12DI-6DIO-4RO
■ 12 safe inputs up to PL e respectively SIL 3
■1
0 adjustable safe in-/outputs
up to PL e respectively SIL 3,
2 A, double p-switching
■ 2 signaling outputs, 100 mA
■2
pulse outputs (clock outputs) for
contact sensors
■ 14 safe inputs up to PL e respectively SIL 3
■ 4 adjustable save semiconductor outputs, 2 A
(adjustable: double p- or p-/n-switching)
■ 2 save relay outputs for 24 VDC
or 230 VAC, 2 A
■ 2 signaling outputs, 100 mA
■ 2 pulse outputs (clock outputs) for contact
sensors
■ 12 safe inputs up to PL e respectively SIL 3
■ 6 adjustable safe in-/outputs
up to PL e respectively SIL 3,
2 A, double p-switching
■ 4 save relay outputs for 24 VDC
or 230 VAC, 2 A
■ 2 signaling outputs, 100 mA
■ 2 pulse outputs (clock outputs) for
contact sensors
8
Technical specification:
PSC1-E-14DI-4DO-2RO-RIO
2) Decentral IO expansion module – save remote IO communication
Ethernet SDDC (Safety Device to Device Communication)
In applications with separated collecting points for safety switching
devices, a decentral IO expansion module is available. The safety logic
for the entire system is stored only in the compact controller. The safe
remote IO modules transmit and receive their status via the safe local
communication protocol Ethernet SDDC.
■ 14 safe inputs up to PL e respectively SIL 3
■ 4 adjustable save semiconductor outputs, 2 A
(adjustable: double p- or p-/n-switching)
■ 2 save relay outputs for 24 VDC
or 230 VAC, 2 A
■ 2 signaling outputs, 100 mA
■ 2 pulse outputs (clock outputs) for
contact sensors
A mixture of centralized and decentralized applications are possible for both compact controller systems.
9
Safe Drive Monitoring (SDM) –
Safe drive monitoring for up to 12 axes
For the safe drive monitoring several safety functions are supported:
■ Safe torque off: Safe Torque OFF (STO), Safe Break Control (SBC)
■ Safe stop: Safe Stop 1 (SS1), Safe Stop 2 (SS2), Safe Operating Stop (SOS)
■ Safe movement: Safely-Limited Speed (SLS), Safe Speed Range (SSR), Safe Direction (SDI),
Safely-Limited Acceleration (SLA), Safe Acceleration Range (SAR)
■ Safe montoring: Safe Speed Monitor (SSM), Safe Cam (SCA)
■ Safe positioning: Safely-Limited Position (SLP), Safely-Limited Increment (SLI), Safely Emergency Limit (SEL)
Drive monitoring is done depending on the application requirement (Amount of axis) with one or two encoder systems.
The following encoder signals are supported:
■ 1 encoder system: TTL, SIN/COS, SSI (Graycode / binary code)
■ 2 encoder system: TTL, SIN/COS, SSI (Graycode / binary code), Resolver, HTL
10
a) Safe drive monitoring of the compact
controller PSC1-C-10
The safe drive monitoring with the compact controller PSC1-C-10 is
realized by an integrated solution. Depending on the order option,
the compact controller can safely monitor 1 or 2 axes with one
encoder system.
Order option: integrated safe drive monitoring up to 2 axes
1 axis
2 axes
b) Safe drive monitoring of the compact controller PSC1-C-100
Monitoring up to 12 axes with up to 6 expansion modules.
The safe drive monitoring is realized in the compact controller PSC1-C-100 via expansion modules. In this case, each axis can be safely
monitored by one or two encoders. The drive monitoring modules are available for one or two encoders.
Safe drive monitoring with one encoder each
For 1 axis
■ PSC1-E-21-SDM1
For 2 axes
■ PSC1-E-23-SDM2
Safe drive monitoring with two encoder each
For 1 axis
■ PSC1-E-22-SDM1-2
For 2 axes
■ PSC1-E-24-SDM2-2
11
International type code
for the safety controller PROTECT PSC1
PSC- 1 – C – 100 – SDM1 – FB1
Progammable Safety Controler
Implementation
SDM1 Safe Drive Monitoring for 1 axis
SDM2 Safe Drive Monitoring for 2 axes
First Generation
Module Hierarchy
FB1
FB2
MC
C Controller
E Extensions
A Accessoires
Group Hierarchy
10 Safe Programmable Logic Controller
100 Safe Programmable Logic Controller
2x Safe Drive Monitoring (SDM)
3x I/O Extensions Module
8x Connector
9x Software and accessoires
Ethernet based fieldbus system
Standard based fieldbus system
Memory Card (SDHC)
XY DI XY=Numbers, Digital Input
XY DIO XY=Numbers, Digital Input/Output
XY RO XY=Numbers, Relay Input
XY DO XY=Numbers, Digital Output
RIO
Remote I/O module
PROTECT PSC1 - Programmable modular safety controllers
Compact controllers
PSC1-C-10
12
Extensions modules
PSC1-C-100
Central IO
expansion
modules
Decentral IO
expansion
modules
Safe Drive
Monitoring
PSC1-E-37-14DI-4DIO-2RO-RIO
PSC1-E-21-SDM1
PSC1-C-10
PSC1-C-10-SDM1
PSC1-C-10-SDM2
PSC1-C-100-MC
PSC1-E-31-12DI-10DIO
PSC1-C-10-MC
PSC1-C-10-SDM1-MC
PSC1-C-10-SDM2-MC
PSC1-C-100-FB1
PSC1-E-32-14DI-4DIO-2RO
PSC1-E-22-SDM1-2
PSC1-C-10-FB1
PSC1-C-10-SDM1-FB1
PSC1-C-10-SDM2-FB1
PSC1-C-100-FB2
PSC1-E-33-12DI-6DIO-4RO
PSC1-E-23-SDM2
PSC1-C-10-FB2
PSC1-C-10-SDM1-FB2
PSC1-C-10-SDM2-FB2
PSC1-E-24-SDM2-2
Topologies
Save cross communication –
Ethernet SDDC (Safety Device to Device Communication)
The safe cross communication is used to exchange data safely among several devices via the local Ethernet SDDC communication.
The requirement of linked emergency stop signals or concatenated signals of interlocks in a complete system (consisting of individual
parts) can be achieved by the use of safe cross communication.
The simultaneous operation of safe cross communication and safe remote IO communication and fieldbus communication to higher
level controls is possible.
■ Safe cross communication with up
to 4 compact controller PSC1
■ Free mixture of the compact controller
PSC1-C-10 und PSC1-C-100
Safe remote IO communication –
Ethernet SDDC (Safety Device to Device Communication)
For the decentral application structure
the IO remote expansion module
PSC1-E-14DI-4DO-2RO-RIO is available.
The communication is realized as in the
safe cross communication via the Ethernet
SDDC protocol.
This ensures that simultaneous safe cross
communication and safe remote IO
communication can take place via the
universal communication interface.
13
Topologies
Modular compact controller PSC1-C-10 2 expansion modules / up to 64 IO’s
Central structure:
IO expansion modules
■ PSC1-E-31-12DI-10DIO
■ PSC1-E-32-14DI-4DO-2RO
■ PSC1-E-33-12DI-6DIO-4RO
Decentral structure:
Expandable with the
remote IO module
■ PSC1-E-37-14DI-4DO-2RO-RIO
The compact controller PSC1-C-10 can be expanded with up to 2 IO expansion modules.
A mixture of centralized and decentralized structures can be used.
Modular compact controller PSC1-C-100 8 expansion modules / up to 272 IO’s
Central structure:
IO expansion modules
■ PSC1-E-31-12DI-10DIO
■ PSC1-E-32-14DI-4DO-2RO
■ PSC1-E-33-12DI-6DIO-4RO
Decentral structure:
Expandable with the
remote IO modul
■ PSC1-E-37-14DI-4DO-2RO-RIO
The compact controller PSC1-C-100 is expandable with up to 8 IO expansion modules.
A mixture of centralized and decentralized structures can be used.
14
Topologies
Universal communication interface –
universal fieldbus connection
With the universal communication interface the required fieldbus
protocol can simply be selected and set by software. Is a safe protocol
required, it can be activated via the safety protocol card.
Parallel to the activated fieldbus protocol the local communication
within the PSC1 controller can be realized via Ethernet SDDC.
Universal communication interface –
integrated SD-Bus-Gateway
Up to 31 Schmersal SD-bus sensors can
be connected with their extended diagnostic
data and evaluated simply by the compact
controller PSC1.
The universal communication interface performs the task of a gateway to the r­ espective
fieldbus protocol (communication to the PLC)
selected by software.
15
The Schmersal Group
For many years the privately owned Schmersal Group has been developing and manufacturing
products to enhance occupational safety. What started out with the development and manufacture
of a very wide variety of mechanical and non-contact switchgear has now become the world’s
largest range of safety systems and solutions for the protection of man and machine. Over 1,600
employees in more than 50 countries around the world are developing safety technology solutions in
close cooperation with our customers, thus contributing to a safer world.
Motivated by the vision of a safe working environment, the Schmersal Group’s engineers are
constantly working on the development of new devices and systems for every imaginable
application and requirement of the different industries. New safety concepts require new solutions
and it is necessary to integrate new detection principles and to discover new paths for the
transmission and evaluation of the information provided by these principles. Furthermore, the set of
ever more complex standards, regulations and directives relating to machinery safety also requires
a change in thinking from the manufacturers and users of machines.
These are the challenges which the Schmersal Group, in partnership with machinery manufacturers,
is tackling and will continue to tackle in the future.
Product ranges
Industries
Services
Competences
Safe switching and monitoring
■ Guard door monitoring safety switches
■ Command devices with safety function
■ Tactile safety devices
■ Optoelectronic safety devices
■ Elevators and escalators
■ Packaging
■ Food
■ Machine tools
■ Heavy industry
■ Application advice
■ CE conformity assessment
■ Risk assessment in
accordance with the
Machinery Directive
■ Stop time measurements
■ Training courses
■ Machine safety
■ Automation
■ Explosion protection
■ Hygienic design
Safe signal processing
■ Safety monitoring modules
■ Safety controllers
■ Safety bus systems
Automation
■ Position detection
■ Command and signalling devices
Precautions have been taken to assure accuracy of the information in this catalogue.
Typographic or pictorial errors that are brought to our attention will be corrected in subsequent issues.
www.schmersal.com
*103009155#
2.000 / L+W / 11.2014 / Teile-Nr. 103009155 / EN / Ausgabe 01