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CONTROL CABINET

KR C2 edition2005

SBM2 for DC 2005


for safety--oriented applications

Option for axis 7 and axis 7/8

Customer documentation

Issued: 23 Nov 2005 Version: 00

SBM2 ZA 7 und 7/8 10.05.00 en


e Copyright 2005

KUKA Roboter GmbH


Zugspitzstrasse 140
D--86165 Augsburg
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the
publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions,
however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless,
discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this
documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

SBM2 ZA 7 und 7/8 10.05.00 en


Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Single--axis switching for safety--oriented applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Additional safety instructions for the “Safe stop” function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Control cabinet, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Connection panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 “Safe stop” function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13


4.1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Wiring example for safety PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 SBM2 jumpers for deactivating the “Safe stop” function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.2 PLC flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Sequence cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.1 Intervals between checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Connector pin allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


5.1 Motor connectors X7.1 and X7.2, size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Motor connector X7.1, size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 I/O interface X211.7 / X211.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6 SBM2 interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22


6.1 I/O terminals X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Brake terminals X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 CAN terminals X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Removing the SBM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Installing the SBM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1 Introduction

1 Introduction
The option described in this documentation is the Single Brake Module (SBM2) for
External Axes 7 and 8. It can be used to implement single--axis activation of the
brakes with a safe stop. If only axis 7 is installed, size 1 drive module (08/16/32)
or size 2 (48/64) can be used. If both external axes 7 and 8 are fitted, only the size
1 drive module is used. The PLC wiring example shows how the circuit is to be
tested.

1.1 Use

1.1.1 Single--axis switching for safety--oriented applications

The SBM2 brake module supports the safety functions “Safe stop” and “Protection
against unexpected start--up” according to the specifications of EN 954--1 “Control
category 3” and EN 1037 “Prevention of unexpected start--up”.

Inputs SI1 and SI2 and checkback output SO are available for these functions.
They are designed with PLC levels (24 V DC).

Inputs SI1 and SI2 disable the inverter, while checkback output SO is used for
checking the correct functioning of inputs SI1 and SI2. Output SO signals that the
axis is disconnected.

Caution!
The output SO is not safety--oriented and may not be used as a safe mes-
sage.

Output SO has floating contacts, thus enabling multiple checkback contacts


connected in series (e.g. all the checkback contacts of a specific group of drives)
to return the complete feedback.

Only components that have been approved for failsafe technology, at least
conforming to control category 3 according to EN 954--1, may be used for
activation and evaluation of these signals (e.g. PNOZ, safety controller, etc.).

The correct dual--channel functioning must be checked by the external controller


at regular intervals (see 4.3.1 Intervals between checks).

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If the check is initiated and carried out manually, the EMERGENCY STOP on the
controller must be activated first.

Drive Brake SI1 SI2 SO


Enabled 1) Enabled 2) HIGH HIGH LOW
Disabled Closed LOW HIGH LOW
Disabled Closed HIGH LOW LOW
Safe stop Closed LOW LOW HIGH

1) The drive can be activated by the controller.


2) The brake can be released by the controller.

Tab. 1Truth table for inputs SI1/SI2 and checkback output SO

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1 Introduction (continued)

1.2 Configuration
G External axes 7 and 8 for drive module size 1 (size 1) (08/16/32)

G Only external axis 7 for drive module size 1 (size 1) or


drive module size 2 (size 2) (48/64)

The external axes differ in the cable set and also in the connector pin allocation.
Functions, interface signals, installation and removal are the same for both
variants.

Identical components:

G SBM2

G Interference suppression module

G Miniature circuit--breaker F19.3

G I/O connector X16 with cable connection

G I/O connector X16 counterpart (connector package)

G Terminal strip X5.1

G Installation and fastening materials

Difference in components:

G Cable set for external axes 7 and 8 size 1

G Cable set for external axis 7 size 1 or size 2

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2 Safety

2.1 Fundamentals

Warning!
Failure to observe these safety instructions could result in injury or a fatal
accident and/or damage to the robot system or other property!

G All pertinent safety regulations as well as the booklet [Safety and Installation
Instructions] are to be observed when working on the system.

G The KUKA safety chapter [KRC Safety, General] is supplied with the robot
system and must be read and understood before commencing work.

G The safety instructions in the robot system Operating Handbook must be


observed.

G Before connection, testing and installation work, always refer to the


accompanying circuit diagram.

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2 Safety (continued)

2.2 Additional safety instructions for the “Safe stop” function


G Installation, exchange and service work on this option or individual
components thereof may be performed only by qualified personnel specially
trained for this purpose and acquainted with the risks involved.

G The “Safe stop” function may be installed and started up by qualified and
trained KUKA personnel only.

G The functions of the two safe inputs must be verified cyclically by means of
external wiring.

G All safety--oriented control components (switches, relays, PLC, etc.) must at


least conform to control category 3, meeting the requirements of EN 954--1.

G The use of wire end sleeves is absolutely essential.

G All safety--related cables outside of the control cabinet (e.g. control cables for
the safety relay, checkback contact) must be routed so that they are
protected, e.g. in cable ducts. It must be ensured that there is no chance of
short--circuits between the individual cables.
For other safety measures, see EN 954--2, Table D4.

G In the event of a fault where there is unintended motion of the axes, e.g. due
to the effects of gravity or external forces, then additional measures must be
taken (e.g. additional mechanical brakes, interlocks or cyclical brake
monitoring).

Warning!
There is no electrical isolation, service switch or repair switch between the
motor and the axis module.
The “Safe stop” function cannot be used as an axis--specific EMERGENCY
STOP. The EMERGENCY STOP function requires electrical isolation of the
cable route to the motor.

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2.3 Liability
This retrofit kit is designed and built using state--of--the--art technology and in
accordance with the recognized safety rules. Nevertheless, improper installation
of this option or its employment for a purpose other than the intended one may
constitute a risk to life and limb of operating personnel or of third parties, or cause
damage to or failure of the control cabinet, resulting in damage to or failure of the
entire robot system and other material property.

The “Retrofit Kit SBM2” may only be used in technically perfect condition in
accordance with its designated use and only by safety--conscious persons who are
fully aware of the risks involved in its operation. Connection and use must be
carried out in compliance with this documentation.

2.4 Designated use


Using this option for any purpose other than or additional to that described in
Section 1.1 is considered contrary to its designated use. The manufacturer cannot
be held liable for any damage resulting from such use.
The risk lies entirely with the user.

No liability can be accepted if these directions are disregarded.

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3 Product description

3 Product description

3.1 Control cabinet, overview

4 5

1 3
2

A B

A Inside wall, left B Front view

1 X5.1 Terminal block 2 Interference


suppression module L7

3 Interference suppression module L8 4 SBM2 for axis 8

5 SBM2 for axis 7 6 Conection panel

Fig. 1 Control cabinet with external axes 7 and 8

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3.2 Connection panel

1 2 3

1 X7.1 Motor connector, axis 7 2 X211.7 I/O connector, axis 7

3 X211.8 I/O connector, axis 8 4 X7.2 Motor connector, axis 8

Fig. 2 Configuration example: Motor connector and I/O interface

Further information
Depending on the motor package and cabinet option, the slot assignments of
the connectors and the motor connector design may differ from those shown.

All contactor, relay and valve coils that are connected to the robot controller by the
user must be equipped with suitable suppressor diodes (RC elements and VCR
resistors are not suitable).

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4 “Safe stop” function test

4 “Safe stop” function test

4.1 Fundamentals
In order to achieve control category 3, the signal “Safe stop initiated” must
additionally be checked for accuracy. This requires external wiring. You will have
to adapt the external wiring to the existing safety concepts and check them for
correct operation.

The control functions can be carried out using:

G a safety PLC

G PNOZ via a PLC program

G PNOZ via PLC or Soft PLC (KUKA Soft PLC)

For the function test it is necessary to ensure that the drives are OFF (K1 on the
KPS not energized). This can be implemented by:

G the safety PLC

G using the robot program

The safety SPS must be wired to ensure that no function test can be carried out
while the safety fence is open.

Warning!
If the function test for “Safe stop” leads to non--permissible states at the
terminals, start--up is not permitted! Function tests of “Safe stop” must be
repeated at every start--up and thereafter at regular intervals, not to exceed
one year (see Section 4.3).

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4.2 Wiring example for safety PLC


This wiring example shows the wiring of the SBM2 with a safety PLC.

+U24 EXT

Safety PLC SBM2


X211.7
S1
X2/3 +U24 EXT
E1 A1 X2/6 PE I2
E2 A2 X2/5 PE I1
E3 A3 X2/1 Ground
H1 X2/7 PE 0
GND EXT

KPS 600 F19.3

X5.1 +U24 BR
K1

X3/1
L7 X2 X5.1
X2 X1
GND BR X3/2
3 3
X3/3 GND BR
B1 1 1
X3/4 BR +

Basic unit KSD1


U
M3 ~ V
W

+UG Supply
--UG Int. circuit

S1 Drives enable (S1 closed) B1 Motor brake

S1 Safe stop (S1 open) PE I1 Servo enable

L7 Interference suppression module PE I2 Optocoupler power unit enable


(example: axis 7)

X16 I/O interface, KR C2(ed05) connection panel PE O “Safe stop”

H1 Message “Safe stop initiated”

Fig. 3 Wiring for external safety PLC

Further information
Note the response of the drive when you deactivate the “Servo enable” and/or
“Optocoupler power unit enable”. The motor brake engages immediately,
which can cause increased wear on the brake (see data sheet for the brake).

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4 “Safe stop” function test (continued)

4.2.1 SBM2 jumpers for deactivating the “Safe stop” function

During start--up it may be necessary for test purposes to take the “Safe stop”
function out of operation. To do this the terminals on the SBM2 I/O connector X2
must be jumpered as shown in Fig. 4.

Caution!
It must be ensured that the jumpers are completely removed immediately
after the test and replaced with proper wiring, otherwise the “Safe stop”
function will not operate.

1
+
2
-

1 X2 jumpers 1 --2 and 4--5--6 2 Brake

3 24 V supply from K1

Fig. 4 SBM2 jumpers for test purposes

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4.2.2 PLC flowchart

Switch on system
with safety PLC

Poll switch S

No Enabling of the
Switch S Activation of
drives single axis motor
open? (Brake released)

Yes Cyclical
function test
of the SBM2! See also Section 4.3
(e.g. every
shift)

Last No
Error message
function test displayed !
OK?

Yes

Monitor whether SO
message from SBM2
present

HIGH signal No
present

Yes

Enabling of safety
function “Safe stop”

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4 “Safe stop” function test (continued)

4.3 Sequence cycle

Safe Drive Safe Drive Safe


Stop enabled Stop enabled Stop

SI1

SI2

SO

tv tv tv tv

Cycle 1 Cycle 2

Cycle 1

G Start point: SI1 and SI2 set to LOW, SO set to HIGH (safe stop)

G Set SI1 to HIGH

G SO goes to LOW

G Set SI2 to HIGH

G SO remains LOW

G Drive is now enabled

Cycle 2

G Start point: SI1 and SI2 set to LOW, SO set to HIGH (safe stop)

G Set SI2 to HIGH

G SO goes to LOW

G Set SI1 to HIGH

G SO remains LOW

G Drive is now enabled

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The maximum delay “tv” between a change to the signals SI1 and SI2 and a
reaction from SO is 40 ms.

If the states of checkback output SO listed above do not have the correct levels,
this means that a safety--related fault has occurred. The drive controller must be
safely deactivated, e.g. by triggering EMERGENCY STOP or some other safety
input.

Caution!
The drive controller must not be restarted until the fault has been eliminated
and a test run has been successfully completed.

4.3.1 Intervals between checks

To ensure that the safety level is always maintained, the checks must be carried
out at regular intervals.
The time interval between the tests depends on the frequency of requirement of
the “Safe stop” function.

If the “Safe stop” is used once or several times in every program cycle, the test
must be carried out at least once per shift (8 hours).

If the “Safe stop” is used only once per day, per week or per month, the interval
between 2 tests can be up to a maximum of 1 year.

For the aforementioned time intervals both test cycles are to be carried out for
every check

We recommend that the check is carried out cyclically with every program run.
In this case it is sufficient to use test cycle 1 and test cycle 2 alternately.

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5 Connector pin allocation

5 Connector pin allocation

Further information
For detailed information about all connections, please refer to the accompa-
nying circuit diagrams.

5.1 Motor connectors X7.1 and X7.2, size 1

X7.1
X2
4 1 Motor M7 U1
3 2
N7 Motor M7 V1
2 6 Motor M7 W1

X2
1 4 + Brake A7
3 5
L7 GND brake
2 PE Grd. conductor

X7.2
X2
4 1 Motor M8 U1
3 2
N8 Motor M8 V1
2 6 Motor M8 W1

X2
1 4 + Brake A8
3 5
L8 GND brake
2 PE Grd. conductor

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5.2 Motor connector X7.1, size 2

Toroidal core
X2
4 U Motor M7 U1
3 V Motor M7 V1
2 W Motor M7 W1

N7 Toroidal core
X3
4

X2
1 + + Brake A7
L7 3 --
GND brake
2
Ground

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5 Connector pin allocation (continued)

5.3 I/O interface X211.7 / X211.8

X211.7 / X211.8
X2
1 D1 GND EXT
2
3 D2 +U24 EXT
4
N7.1 5 D4
PE I1
6 D5 PE I2
7 D6 PE 0
8 D7
M ST

X2
1 D9 GND EXT
2
3 D10 +U24 EXT
4
N8.1 5 D12 PE I1
6 D13 PE I2
7 D14
PE 0
8 D15
M ST

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6 SBM2 interface signals

6.1 I/O terminals X2


Pin no. Name Description
X2/1 GND EXT External ground. Common ground for digital inputs
and outputs. Isolated from brake ground GND_BR.
X2/2 GND INT Internal ground
X2/3 +U24 EXT External power supply for the digital output.
X2/4 +U24 INT Internal power supply.
X2/5 PE I1 Input 1: LOW level
-- disables the control pulses to the inverter
-- interrupts the power supply for the brake driver.
X2/6 PE I2 Input 2: LOW level
-- interrupts the activation of the transmission
elements for the control pulses to
the inverter
-- disables the activation of the brake driver
X2/7 PE O Output 1: HIGH level
Feedback signal: “Safe stop”
X2/8 M ST Output 2: HIGH level
Message: “Axis ready for disconnection”

6.2 Brake terminals X3


Pin no. Name Description
X3/1 +U24 BR Power supply for the brake
(switched by the safety logic,
e.g. via make contacts of the main contactor)
X3/2 GND BR Ground for the power supply to the brake
X3/3 GND BR Ground terminal of the brake
X3/4 BR+ Positive terminal of the brake

6.3 CAN terminals X4


Pin no. Name Description
X4/1 CAN HIGH CAN High
X4/2 CAN LOW CAN Low
X4/3 CAN GND CAN Ground
X4/4 CAN IDENT Identification

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7 Maintenance

7 Maintenance

7.1 Removing the SBM2


To avoid causing damage to the SBM2, the drive module must be removed
from the control cabinet before the removal of the SBM2.

(1) First release the two latches by inserting a suitable screwdriver in the aperture
(Fig. 5 [1]) and carefully levering downwards.
(2) Using a screwdriver (Fig. 5 [3]) carefully lever the brake module out of the
drive module. The blade of the screwdriver must not be inserted more than
a few millimeters into the recess (Fig. 5 [2]).

Caution!
In order to avoid causing component damage, the screwdriver must not be
moved upwards (Fig. 5 [4]).

Fig. 5 Removing the SBM2

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7.2 Installing the SBM2


The following explains the installation of the SBM2 when changing the drive
module.

(1) Using a screwdriver, lever the cover out of the drive module (Fig. 6 [1]).

Under the cover there is a protective cover (Fig. 6 [2]) with two jumpers (Fig. 6 [3]).

(2) Remove the protective cover.

1 2

1 Cover 2 Protective cover

3 Jumpers

Fig. 6 SBM2 slot in the KSD1

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7 Maintenance (continued)

(3) Remove the coding from X3 (Fig. 7 [1]) using an appropriate tool.

1
Fig. 7 Removing the SBM2 coding from X3
(4) Position the SBM2 parallel to the drive module housing and press it carefully
onto the connector in the drive module (Fig. 8 [1]).

Caution!
The contact pins (Fig. 8 [1]) must not be bent when the SBM2 is being
installed!

1 2

1 Contacts for SBM2 2 SBM2 installed

Fig. 8 Plugging in the SBM2

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8 Technical data
Terminal Function Electrical data
X2 “Safe stop” connection
Reference potential
X2/1 (GNDext)
“Safe stop”
Low voltage supply
X2/3 (S24) 18..30 VDC / 0.5 A
for Safe stop
LOW
Output for check-
during operation 24 VDC 0.5 A
*X2/7 (PE O) back signal “Safe
HIGH short--circuit proof
stop initiated”
“Safe stop” active

LOW LOW:
Input 1 Axis module disabled --3...+5 V / --3...+15
X2/5 (PE I1) mA
“Safe stop” HIGH
Axis module enabled HIGH:
+15...+30
15 30 V /
LOW Optocoupler +2...+15 mA
Input 2 power unit disabled Input current at
X2/6 (PE I2)
“Safe stop” HIGH Optocoupler 24 V DC :
power unit enabled 8 mA per input
X2 Other connections
Reference potential
X2/2 (GNDint)
for internal signals
Power supply for
X2/4 (U24int) 21..28 VDC / 30 mA
SBM2
Freely LOW
24 VDC 0.5 A
X2/8 (F0) programmable Output not active
short--circuit proof
output HIGH Output active
X3 Motor brake connection
Power supply to
X3/1 (24 V) 21...28 VDC / 1.6 A
motor brake
Reference potential
X3/2 (GNDBR)
for terminal X3/1
Motor brake
X3/3 (GNDBR)
connection 21...28 VDC / 1.6 A
Motor brake short--circuit proof
X3/4 (+BR)
connection
X4 CAN communication connection
X4/1 (HIGH) CAN high
X4/2 (LOW) CAN low
X4/3 (GND) CAN GND
Identification of the
X4/4 (IDENT)
CAN function

* IMPORTANT: Output SO is not safety--oriented and may not be used as a safe message

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Index

C
Checkback output, 5
Checkback output SO, 18
Coding, 25
Control category 3, 13

E
External controller, 5

I
I/O interface, 12

J
Jumpers, 24

K
KUKA Soft PLC, 13

M
Motor brake, 14
Motor connector, 12

P
PLC program, 13
PNOZ, 13
Protection against unexpected start--up, 5
Protective cover, 24

S
Safe stop, 5
Safety instructions, 8
Safety PLC, 13, 14
Safety regulations, 8
Service work, 9

U
Use, 5

Index -- i

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