Murr Elektronik

Cube67 I/O modules

Safe switchoff of nonfunctional protected modules

EN ISO 13849-1 EN 954-1

INSTRUCTION MANUAL Art. No. 56 972

Version 2.5

Safe Switchoff of Nonfunctional Protected Modules

Table of Contents 1

ABOUT THIS INSTRUCTION MANUAL................................................................... 7

1.1 Explanation of Symbols ................................................................................................................. 8 1.1.1 Use of Notes .............................................................................................................................. 8 1.1.2 Use of Hazard Warnings ........................................................................................................... 8 1.1.3 Use of Numbers in Figures ...................................................................................................... 8 1.1.4 Use of Action Instructions ....................................................................................................... 8 1.1.5 Use of Footnotes ....................................................................................................................... 8

2

SAFETY INSTRUCTIONS ........................................................................................ 9

2.1

Intended Purpose ........................................................................................................................... 9

2.2

Applicable Standards ...................................................................................................................10

2.3

Qualified Personnel ......................................................................................................................10

3

ADVANTAGES OF/DIFFERENCES IN PASSIVE SAFETY MODULES ................ 12

3.1 Cube67 Art.No. 56 650 DO16 C Valve K3 (compared with standard Cube67 Art.No. 56 651xx DO16 E Valve): ...........................................................................................................................................12 3.2 Cube67 Art.No. 56 65003 DO8 C Valve CPV(9) K3 (compared with standard Cube67 Art.No. 56 65501 DO8 E Valve CPV(9)): ................................................................................................................12 3.3 Cube67 Art.No 56 605 DO6 (DO6) E 6xM12 K3 (compared with Cube67 Art.No. 56 601 DIO16 E 8xM12): ....................................................................................................................................................12

4

INSTALLATION ...................................................................................................... 13

4.1 Terminal Overview ........................................................................................................................13 4.1.1 Terminal Overview of DO6 (DO6) E 6xM12 K3 – Art. No. 56605 .........................................13 4.1.2 Terminal Overview of Cube67 DO16 C Valve K3 – Art. No. 56650; Cube67 DO8 C Valve (9) K3 – Art.-Nr. 5665003 .......................................................................................................................14 4.2 Internal System Connection ........................................................................................................14 4.2.1 Current Load Rating of Internal System Connection ..........................................................15 4.3 External Actuator Power Supplies ..............................................................................................16 4.3.1 External Actuator Power Supply for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 ...16 4.3.2 External Actuator Power Supply for Cube67 DO16 C Valve K3 – Art. No. 56650; Cube67 DO8 C Valve (9) K3 – Art.-Nr. 5665003 .................................................................................................16 4.3.3 Connection of Actuators for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 ................17 4.3.4 Connector for FESTO CP Valve Terminal DO16 C Valve K3 Art. No. 56650......................17 4.3.5 Connector for FESTO CP Valve Terminal DO8 C Valve K3 Art.-No. 5665003 ...................18

5

DIAGNOSTICS ....................................................................................................... 19

5.1 LED Displays .................................................................................................................................19 5.1.1 Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 .................................................................19 5.1.1.1 External Actuator Power Supply (Power IN) Display .........................................................20

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5.1.1.2 M12 Sockets – LED Diagnostic Display ............................................................................ 21 5.1.1.3 Correlation Between Signal – Logic Display and LED Response ..................................... 22 5.1.2 Cube67 DO16 C Valve K3 Art. No. 56650; Cube67 DO8 C Valve K3 Art.-Nr. 5665003 ..... 22 5.1.2.1 Diag – LED Display ........................................................................................................... 22 5.1.2.2 US – LED Display............................................................................................................... 23 5.1.2.3 UA – LED Display............................................................................................................... 24

6

STARTUP IN A SAFETY NETWORK .................................................................... 25

6.1 General Principles ....................................................................................................................... 25 6.1.1 Integrated Safety Functions .................................................................................................. 25 6.1.2 Fuse Protection....................................................................................................................... 26 6.1.3 Schematic Diagram of a Safety Relay .................................................................................. 26 6.1.4 Schematic Diagram with Supply Via Two Safety Relays .................................................... 27 6.1.4.1 Variant with one power supply unit.................................................................................... 27 6.1.4.2 Variant with two power supply units .................................................................................. 27 6.2

Required Tests ............................................................................................................................. 28

6.3 Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 ..................................................................... 29 6.3.1 Connecting Wire for Actuator Voltage ................................................................................. 29 6.3.1.1 Safe Wiring of 5-pin M12 ................................................................................................... 30 6.3.1.2 Use of a cross-circuit-proof cable in rugged environments ............................................... 31 6.3.2 Connecting Actuators ............................................................................................................ 31 6.4 Cube67 DO16 C Valve K3 Art. No. 56650 and Cube67 DO8 C Valve(9) K3 Art,.Nr. 5665003 32 6.4.1 Connecting Wire for Actuator Voltage ................................................................................. 33 6.4.1.1 Use of Murrelektronik cables (yellow, cross-circuit-proof) Art.No. 7000-15101-1380500 (5.0 m), Art.No. 7000-15101-1381000 (10 m) Art.No.7000-46045-1380300 (3.0 m), -1380500 (5.0 m) and -1380100 (10 m) ........................................................................................................................... 33 6.4.1.2 Use of a Standard Cable (not cross-circuit-proof) ............................................................. 33 6.4.2 Safe (Protected) Wiring Compliant with EN 60204-1........................................................... 34 6.4.3 Connecting Wire for Valve Terminal ..................................................................................... 35 6.4.4 Connecting Wire for Valve Terminal ..................................................................................... 35 6.5 Component Description .............................................................................................................. 36 6.5.1 Pin Assignment of Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 ............................... 36 6.5.2 Pin Assignment of Cube67 DO16 C Valve K3 – Art. No. 56650 .......................................... 37 6.5.3 Pin Assignment of Cube67 DO8 C Valve(9) K3 – Art.-Nr. 5665003 .................................... 38 6.6

7

Handling in Various Fieldbus Systems ..................................................................................... 40

TECHNICAL DATA ................................................................................................ 41

7.1

56605 Cube67 DO6 (DO6) E 6xM12 K3 ....................................................................................... 41

7.2

56650 Cube67 DO16 C Valve K3 ................................................................................................. 43

7.3

5665003 Cube67 DO16 C Valve K3 ............................................................................................. 45

8

LIMITS AND FURTHER NOTES... ......................................................................... 47

9

LIST OF FIGURES ................................................................................................. 48

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LIST OF TABLES ................................................................................................ 48

5


Manual supplements / corrections

Version 1.0 1.1 1.2 1.3 1.4 1.5

1.6

Chapter 5, 5.1.1

6 4.3.1 2.2 6.1 6.3.1 6.4.1

1.7

1.8 1.9

1.1.2 2.2 2.3 6.1.2 6.2 6.2 7 7.1 1 5.1.1.1 5.1.1.2 6.6 General

2.0 2.1 2.1 5.2 2.2 2.3

5 5

2.4

7

2.5

Supplement / Correction Authored Correction (wire colors) New module 56605 FE Use of cross-circuit unprotected lines Correction of connector assignment Warning notes p.4 New Note: Circuit-breaker in Warning box Note: Circuit-breaker in Warning box Danger note p.4 Warning after danger p.5 Warning after danger Warning after danger and text Warning after danger and 13849 New Art. No. and danger note New chapter Technical Data Response time Ethernet / IP Tab 5-2 & Tab 5-3 Socket, 5-pin (figure) Overview of HDB Ethernet / IP All notes "Safety Category 3" changed to "Safety Category 3 PL d" "Power supply" changed to "Power supply unit" in note. Change of danger note: Function test and inspection Change of name Amendments 13849-1 Amendments to fault exclusions MTTF value added to Technical Data New module 5665003

Date/Name 23.05.05 M.H. / Wei / Ba 16.03.06 M.H. / Wei. 03.08.06 M.H. / Wei. 27.10.06 M.H. / Wei. 08.03.07 M.H./Kug 16.08.07 sb/gro 24.10.07 / vk/ri

06.02.08 / vk

07.11.2008 / vk 13.11.2008 / csc/ ri

06.07.2009 / vk/ri

26.11.2009 vk/ri

25.01.2010 vk/ri 26.04.2010 vk/ri 01.06.2010 vk/ri 04.04.2011 vk/st

Notes:

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1 About This Instruction Manual This instruction manual is intended to support the safe switchoff of nonfunctional protected Cube67 modules made by Murrelektronik (Articles Nos. 56605, 56650 and 5665003). These modules are also referred to as passive safety modules in this document. In contrast to standard modules, they are equipped with a safe separation between the protected switched-off voltage and all other modules (not on module 56650 and 5665003. These modules has only one common ground. The positive potentials of actuator voltages UA1-UA4 are safely interprotected and also protected against US). It is important you read this instruction manual before you start up nonfunctional protected Cube67 modules connected to a fieldbus network. The instruction manual should be kept in a place that is accessible to all users at all times. We refer you to the relevant manuals that describe the standard functions of the Cube67 module. The manuals of the Cube67 series are divided into 4 parts: Cube67 System Manual Art. No. 56 970 Cube67 Technical Data Art. No. 56 971 Cube 67 Safe Switchoff of Nonfunctional Protected Modules Art. No. 56972 Cube67 Bus System Manual

Profibus Art. No. 56 980 DeviceNet Art.No. 56 981 CANopen Art.No. 56 982 Ethernet / IP Art.No. 56 983 DeviceNet V2 Art.No. 56 984 Profinet Art.No. 56 985

The texts, figures, charts, and examples used in this instruction manual are simply intended for the explanation, operation, and application of Cube 67 Series modules. If you have any queries that are not handled in this document, please contact us. We are at your disposal at all times. Murrelektronik GmbH

Postfach 1165 Falkenstrasse 3

71567 Oppenweiler 71570 Oppenweiler

Phone ++49 7191 470 Fax ++49 7191 47 130

Internet : http://www.murrelektronik.com Murrelektronik retains the right to make technical changes or amend this instruction manual at any time without prior notice.

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1.1 Explanation of Symbols 1.1.1 Use of Notes Notes indicating important information are marked specifically. They are displayed as follows: Note text…..

1.1.2 Use of Hazard Warnings Hazard warnings are also placed in a border.

CAUTION If you fail to comply with safety precautions, it may result in possible damage to devices and other assets.

WARNING If you fail to comply with these safety precautions, you may be placing your own life and health at risk.

1.1.3 Use of Numbers in Figures Numbers in figures are displayed by white characters in round black borders. Example: Text 1...... Text 2...... Text 3...... The explanations are presented in charts of the same number in direct relationship to the previous figure.

1.1.4 Use of Action Instructions An action instruction describes the sequence of operations for assembly, startup, operation, and servicing. It is essential to maintain the sequence of operations. Numbering is consecutive, ascending, and is denoted by black numerals in round white fields. Example: Instruction 1........ Instruction 2........ Instruction 3........

1.1.5 Use of Footnotes 1)

Additional information is indicated by raised numerals (Example: Text ). They are explained in the form of footnotes placed below tables or as running text at the bottom of the page.

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2 Safety Instructions 2.1 Intended Purpose The devices described in this Instruction are intended as decentralized input/output modules for connection to a fieldbus network. The devices were developed, produced, tested, and documented in compliance with valid European standards and directives. Under normal circumstances, the products harbor no danger to persons or assets, provided compliance is ensured with the regulations and safety instructions described for configuration, assembly, and operation conforms with the intended purpose of these products. The devices meet the requirements contained in the standards and specifications listed in the datasheet. The safe, troublefree functioning of the product requires proper transportation, storage, mounting, and installation, and careful operation. Operating the device in accordance with its intended purpose is only assured when the housing is fully mounted.

CAUTION The power supply unit must comply with SELV1 or PELV2. Power supply units in accordance with EN 61558-2-6 (transformers) or EN 60950-1 (switched-mode power supply) meet these requirements.

WARNING The actuator supply voltages must be applied based on the principles of safe electrical separation3. Only qualified, trained electricians knowledgeable in the safety standards of automation systems may configure, install, set up, service, and test the devices. Current safety and accident prevention laws valid for the specific application must be observed for the configuration, installation, setup, servicing, and testing of the devices. Only use cables and accessories that meet the requirements and regulations for safety, electromagnetic compatibility, and, if necessary, the specifications for telecommunications terminal equipment. Please request your local Murrelektronik office for information on what cables and accessories are approved for installation, or refer to the descriptions in this manual.

CAUTION Our devices are resistant to chemicals and oils. If other aggressive media are used, check their material resistance depending on the application.

1

- Safety Extra Low Voltage - Protective Extra Low Voltage 3 - Safe electrical separation for voltage cables must be routed to exclude the possibility of cross-circuits by safe routing and safe air and creepage paths. 2

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2.2 Applicable Standards EN ISO 13849-1 Safety of Machinery - Safety-related parts of control systems Categories (1 to 4) describe the necessary response of safety-related parts in a control system with regard to their resistance to possible dangerous faults (fault detection, fault handling). Categories 1 to 4 are supplemented by a Performance Level (PL) that provides additional failure probability calculations. EN 954-1 Safety of Machinery EN 50178 Electronic equipment for use in power installations EN 60204-1 Electrical equipment of machines EN 61496-1:2009 Safety of Machinery – Electro-sensitive protection equipment IEC 60664 Insulation coordination for equipment within low-voltage systems IEC 61140 Protection against electric shock SN 29500 Siemens Norm – Failure rates of components EN 61131-2 Programmable controllers

2.3 Qualified Personnel The requirements concerning qualified personnel are dependent on the requirements profiles described in ZVEI and VDMA publication "Weiterbildung in der Automatisierungstechnik" (Further training in automation systems) Publishers: ZVEI and VDMA Maschinenbau Verlag P.O. Box 71 08 64 60498 Frankfurt Only electricians who know the contents of this manual may install and maintain the products described here. These are electricians who are capable of assessing the work executed and any possible dangers arising from their work due to their professional training, knowledge, experience, and their knowledge of the pertinent standards. or who have a level of knowledge equivalent to professional training due to their many years of activity in a comparable field.

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Only Murrelektronik technical personnel are allowed to execute work on the hardware and software of our products, provided they are devices not described in this manual.

WARNING Unqualified tampering with the hardware or software, or failure to observe the warnings cited in this manual, may result in severe personal injury or damage to property.

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3 Advantages of/Differences in Passive Safety Modules Based on a standard module, there are passive safety modules with identical functions. This chapter describes the advantages of passive safety modules.

3.1 Cube67 Art.No. 56 650 DO16 C Valve K3 (compared with standard Cube67 Art.No. 56 651xx DO16 E Valve): The table below shows the differences: Passive Safety Module 500 mA / Output 4 actuator power supplies, each with 4 outputs and individual switchoff Actuator warning diagnostic

Standard Module 100 mA / Output 1 actuator power supply for all outputs No actuator warning diagnostic

3.2 Cube67 Art.No. 56 65003 DO8 C Valve CPV(9) K3 (compared with standard Cube67 Art.No. 56 65501 DO8 E Valve CPV(9)): The table below shows the differences: Passive Safety Module 500 mA / Output 4 actuator power supplies, each with 2 outputs and individual switchoff Actuator warning diagnostic Compact module

Standard Module 100 mA / Output 1 actuator power supply for all outputs No actuator warning diagnostic Extension module

3.3 Cube67 Art.No 56 605 DO6 (DO6) E 6xM12 K3 (compared with Cube67 Art.No. 56 601 DIO16 E 8xM12): The table below shows the differences: Passive Safety Module 12 outputs 2 actuator power supplies each with 6 outputs, with individual switchoff Safe electrical separation of actuator power supplies max 4 A for each actuator power supply Actuator power supply expandable 2 A (Σ3.2 A per socket) / output

12

Standard Module 16 inputs/outputs 1 actuator power supply for all outputs No safe electrical separation of actuator power supplies max. 4 A Actuator power supply not expandable 0.5 A / output

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4 Installation The Cube67 module can be mounted on the machine without a switch cabinet.

4.1 Terminal Overview 4.1.1 Terminal Overview of DO6 (DO6) E 6xM12 K3 – Art. No. 56605

In

U

Out

A1

In

A2

U

U

P Out

0

1

0

0

1

1

0

1

2

0

1

0

1

3

0

1

4 5

Figure 4-1: Connections of Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

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Connection of internal system connection (incoming) Connection of internal system connection (outgoing) Connection of 2x actuator power supplies galvanically separated (incoming) Connection of 2x actuator power supplies (outgoing) Connection of 12x actuators

13


4.1.2 Terminal Overview of Cube67 DO16 C Valve K3 – Art. No. 56650; Cube67 DO8 C Valve (9) K3 – Art.-Nr. 5665003 The Cube67 module can be mounted on the machine without a switch cabinet. It has two incoming connectors (internal system connection and power supply) and one outgoing cable (length approx. 50 cm) fitted with a connector to receive a Festo CP Series valve terminal.

Figure 4-2: Connections of Cube67 Valve K3 – Art. No. 56650 and 5665003

Connection of internal system connection (incoming) Connection of 4x actuator power supplies Connection for FESTO CP valve terminal

4.2 Internal System Connection The green system cable is a shielded hybrid cable for - communication between bus node and module, - to transfer the sensor power supply, - to transfer the actuator power supply (optional).

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Only use our preterminated cables for the internal system connection.

Connector

Assignment

Contact No. 1 2 3 4 5 6

Meaning Actuator power supply (optional) Sensor power supply / internal module power supply Ground Internal system connection Internal system connection Ground

Figure 4-3: Pin assignment of system connection

Length

Art.No. straight - straight 0.3 m 7000-46041-8020030 0.6 m 7000-46041-8020060 1.0 m 7000-46041-8020100 1.5 m 7000-46041-8020150 2.0 m 7000-46041-8020200 2.5 m 7000-46041-8020250 3.0 m 7000-46041-8020300 3.5 m 7000-46041-8020350 4.0 m 7000-46041-8020400 4.5 m 7000-46041-8020450 5.0 m 7000-46041-8020500 5.5 m 7000-46041-8020550 6.0 m 7000-46041-8020600 6.5 m 7000-46041-8020650 7.0 m 7000-46041-8020700 7.5 m 7000-46041-8020750 8.0 m 7000-46041-8020800 8.5 m 7000-46041-8020850 9.0 m 7000-46041-8020900 9.5 m 7000-46041-8020950 10.0 m 7000-46041-8021000 Table 4-1: Overview of system connection article numbers

angled - angled 7000-46061-8020030 7000-46061-8020060 7000-46061-8020100 7000-46061-8020150 7000-46061-8020200 7000-46061-8020250 7000-46061-8020300 7000-46061-8020350 7000-46061-8020400 7000-46061-8020450 7000-46061-8020500 7000-46061-8020550 7000-46061-8020600 7000-46061-8020650 7000-46061-8020700 7000-46061-8020750 7000-46061-8020800 7000-46061-8020850 7000-46061-8020900 7000-46061-8020950 7000-46061-8021000

4.2.1 Current Load Rating of Internal System Connection The modules connected to the bus node are supplied with two voltages over the internal system connection. Current load rating Sensor power Internal actuator power supply

4A 4A

Power supply to

Module electronics and sensors Unprotected actuators

Table 4-2: Current load rating

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CAUTION Make absolutely sure under all circumstances that you prevent any feedback of the sensor power supply by an external power supply to the Cube67 System.

4.3 External Actuator Power Supplies The Murrelektronik passive safety modules have 1 to 4 actuator power supplies that are switchable via 1 to 4 safety relays. In each case, the number of safety relays used is dependent on the required number of emergency-stop circuits.

4.3.1 External Actuator Power Supply for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

Connector

The left and right rows of M12 sockets are fed by the two actuator power supplies UA1 and UA2. The external actuator power supplies must be connected in order to use the outputs on these sockets. Assignment Contact No. 1 2 4 3 5 3 2 1 4 5

Meaning UA1 actuator power supply + 24 V DC 0V UA2 0V UA1 UA2 actuator power supply + 24 V DC FE

Figure 4-4: Connection assignment of external actuator power supply for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

4.3.2 External Actuator Power Supply for Cube67 DO16 C Valve K3 – Art. No. 56650; Cube67 DO8 C Valve (9) K3 – Art.-Nr. 5665003

Connector

The four channels (UA1, UA2, UA3, UA4) are powered by the external actuator power supply. The external actuator power supplies must be connected in order to use the outputs on these channels. Assignment Contact No. 1 2 3 4 5 6

Meaning UA1 actuator power supply + 24 V DC UA2 actuator power supply + 24 V DC Ground UA3 actuator power supply + 24 V DC UA4 actuator power supply + 24 V DC Ground

Figure 4-5: Connection assignment of external actuator power supplies for Cube67 DO16 E Valve K3 – Art. No. 56650

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4.3.3 Connection of Actuators for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 Pin

Assignment

1

n.c.

2

DO: 1x(0,2,4)(1,3,5)

3

0V UA1 / 0V UA2

4

DO: 0x(0,2,4)(1,3,5)

5

FE

Socket (on module) 2

1

View Connector (on cable) 2 5

5 4

1

3

3

4

Figure 4-6: Connection assignment of actuators for Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

A current of only 2 A may be applied to each output. Each socket is restricted to max. 3.2 A.

4.3.4 Connector for FESTO CP Valve Terminal DO16 C Valve K3 Art. No. 56650

U A1

Out 1 0.0 Out 2 0.1 Out 3 0.2 Out 4 0.3 Out 5 0.4 Out 6 0.5 Out 7 0.6 Out 8 0.7 Out 9 1.0 Out 10 1.1 Out 11 1.2 Out 12 1.3 Out 13 1.4 Out 14 1.5 Out 15 1.6 Out 16 1.7 GND GND Table 4-3: Connector assignment of CP valve control 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 24 25

Channe l

U A2

Byte x. Bit x

U A3

Function

U A4

DSub

Only use preterminated cables with permanently mounted connectors for Festo CP valve terminals. The module is designed to activate 16 valves (maximum current 0.5 A per valve) which are powered by 4 external independent voltages and grouped in 4 groups of 4 valves each.

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4.3.5 Connector for FESTO CP Valve Terminal DO8 C Valve K3 Art.No. 5665003 UA1

Kanal

UA2

Byte x. Bit x 0.0 0.1 0.4 0.5 1.0 1.1 1.4 1.5

UA3

Funktion Out 1 Out 2 Out 3 Out 4 Out 5 Out 6 Out 7 Out 8 GND

1 2 3 4 5 6 7 8 9

UA4

DSub

Only use preterminated cables with permanently mounted connectors for Festo CP valve terminals.

The module is designed to activate 8 valves (maximum current 0.5 A per valve) which are powered by 4 external independent voltages and grouped in 4 groups of 2 valves each.

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5 Diagnostics 5.1 LED Displays 5.1.1 Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

0 1

2 3

4 5

Figure 5-1: Position of the US

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LED Designation

4

LED Display

Response

State

US

lights continuously

up

US

flashing

No data exchange

US

off

No communication

Data transfer:

5

6

Table 5-1: Status of system communication

5.1.1.1 External Actuator Power Supply (Power IN) Display

0 1

2 3

4 5

Figure 5-2: Position of UA

4

The color of the display indicates the voltage state. Communication is interrupted in at least one line. 6 The module has no sensor power supply. 5

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LED Designation

LED Display

Response

UA1

green

UA1

off

UA2

OK (> 18 V) not available (< 15 V)

green

UA2

State

off

OK (> 18 V) not available (< 15 V)

Table 5-2: Status of external actuator power supply (Power IN display)

5.1.1.2 M12 Sockets – LED Diagnostic Display

In

O ut

In U

P

U

O ut

0

1

0

0

1

0

1

0

1

1

0

1

2 3

0

1

4 5

Figure 5-3: Position of LED diagnostic display (M12 sockets)

7

LED Display

Voltage at Channels 00 to 05

Voltage at Channels 10 to 15

Diagnostic at Channels 00 Diagnostic at Channels 10 to 05 to 15

0V

0V

-

Actuator disable

0V

24 V

-

Actuator warning

0V

0V

Actuator disable

-

24 V

0V

Actuator warning

-

Table 5-3: M12 sockets – LED diagnostic display

7

All diagnostic displays are red.

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5.1.1.3 Correlation Between Signal – Logic Display and LED Response A separate status display is assigned to every channel. They are labeled with '00 to 05’ and '10 to 15’. The displays are located directly next to the corresponding M12 socket. This makes it easy to identify the status of peripheral components, such as sensors and actuators.

Output

Logic Value

Voltage at output

0

0V

1

24 V

LED Display off yellow

Table 5-4: Correlation between signal – logic display and LED response

5.1.2 Cube67 DO16 C Valve K3 Art. No. 56650; Cube67 DO8 C Valve K3 Art.-Nr. 5665003 5.1.2.1 Diag – LED Display

US

UA

In

Diag

Diag

++49(0)719147-0

Cube67 DO16 E Valve Art.-No. 56651

Figure 5-4: Position of UA

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LED Display

Diagnostic

off

No diagnostic

red

Short-circuit at min. one output

red

Actuator warning at min. one output

Table 5-5: Diag – LED display

5.1.2.2 US – LED Display

US

UA

US

In

UA

In

Out

Diag

++49(0)719147-0

Cube67 DO16 E Valve Art.-No. 56651

Figure 5-5: Position of US and UA LEDs

LED Designation

LED Display

Response

State

US

green

OK (> 18 V) and data exchange

US

red

Sensor power undervoltage

US

blinking: red No data exchange or green

or US

off

supply

No communication

Table 5-6: Status of system power supply at module

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5.1.2.3 UA – LED Display LED Designation

LED Display

Response

State

UA

green

All 4 actuator power supplies > 18 V

UA

red

Undervoltage in one actuator power supplies

UA

off

One or supplies < 12.5 V

several

or

actuator

several power

Table 5-7: Status of actuator power supplies on module

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6 Startup in a Safety Network 6.1 General Principles CAUTION Cables and connectors must be routed safely and separately (compliant with EN 60204-1). If it is not possible to assure safe routing, cross-circuit-proof cables must be used. Module 56650 and 5665003: If voltages UA1-UA4 must be switched to more than one safety relay, a cross-circuitproof cable must be used. Module 56650 respectively 5665003 can only achieve Category 3 or PLd since only a single ground is used.

WARNING The external power supply must always be switched off on two poles in order to avoid any violation of the safe electrical separation principle. If switch-off only uses a single pole, it is prohibited to use the device in a safety function.

6.1.1 Integrated Safety Functions CAUTION Our products are designed to prevent external voltages from accessing the safely switched-off voltage. This is achieved by maintaining secure air and creepage distances and employing optocouplers with appropriate high galvanic isolation. The safe state is deenergized (0). Fault exclusions are used for the printed-circuit board, connectors, terminals, and optocouplers. All other faults in the fault models result in a safe state, or result in a functional fault that has no impact on the safety function. Owing to the use of fault exclusions, the product attains an MTTFd value equal to infinity and is not included in DCavg calculations. In the case of a single-channel safety function, only Category 3 PLd is achievable in a product that is based only on fault exclusions. A two-channel safety function can achieve Category 4 PLe, depending on the architecture of the safety function. Category 4 or PLe is only achievable if the two safety function channels are not switched via the same group, i.e. they are switched either via 2 separate modules, or else Channel 1 is routed to the same module via UA1, and the second channel is routed via UA2 (this is not implemented in Module 56650 and 5665003). If the specifications of EN 954-1 are applied, the maximum category achievable is Category 3.

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6.1.2 Fuse Protection CAUTION The actuator power supply(ies) must be protected against excess total current by a suitably dimensioned prefuse.

CAUTION Module 56650 and 5665003: A maximum of 4 safety relays can be used in connection with this module to produce 4 separate emergency-stop circuits. The total current of 8 A (4A with 5665003) must be protected by suitable fuses. A maximum of 4 A (2A) is permitted for each actuator voltage. This current must be protected by means of individual fuses if several safety relays are used.

6.1.3 Schematic Diagram of a Safety Relay CAUTION If only one fuse is used to protect the two external power supplies, it may only be designed for the total current of a supply voltage. If the total current of the two supply voltages is used, protection must be provided by two fuses that are switched between the safety relay and the safety module.

Figure 6-1 Schematic diagram of UA1 and UA2 and supply via a safety relay

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6.1.4 Schematic Diagram with Supply via Two Safety Relays 6.1.4.1 Variant with one power supply unit

Figure 6-2 Schematic diagram of UA1 and UA2 with power supply via two safety relays and one power supply unit

6.1.4.2 Variant with two power supply units

Figure 6-3 Schematic diagram of UA1 and UA2 with pwer supply via two safety relays and two power supply units V 2.5

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6.2 Required Tests The machine on which the Murrelektronik passive safety modules are mounted may only be started up when proper tests have been performed. These tests must comply with EN 60204-1:2006 (e.g. Chapter 18) or the product standard applicable to the machine. Here is an excerpt from EN60204-1:2006 Chapter 18: The extent of verification will be given in the dedicated product standard for a particular machine. Where there is no dedicated product standard for the machine, the verifications shall always include the items a), b) and f) and may include one or more of the items c) to e): a) Verivication that the electrical equipmentcomplies with its technical documentation; b) In case of protewction against direct contact by automatic disconnection the effectiveness of the protective bonding circuit shall be veryfied according to 18.2; c) Insulation resistance test (see 18.3) d) voltage test (see 18.4); e) protection against residual voltage (see 18.5); f) functional tests (see 18.6). When these tests are performed, it is recommended that they follow the sequence listed above. The results of the verification shall be documented.

CAUTION The actuator voltage switchoff by an upstream safety relay must be verified and documented before the machine is started up. This verification should be conducted at regular intervals (at least once a year) and the result must be documented. If the safety function has a malfunction, the fault must be located and rectified. Startup is not permitted until the fault is rectified.

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6.3 Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605

Figure 6-4: Connection of module 56605

The module is connected via the internal system connection to a bus node that permits communication to the PLC. The power for the module electronics is supplied via the internal system connection. The power supplies for the actuators are fed over a separate M12 connector. Two independent actuator voltages can be fed over this cable.

The user can set up two "emergency stop" circuits. Connection to the safety relay must have a cross-circuit-proof design (refer to 6.3.1 connecting wire for actuator voltage).

6.3.1 Connecting Wire for Actuator Voltage Two separate actuator voltages can be supplied. Each actuator voltage can power six actuators. This then results in two groups of six outputs each, i.e. 12 connectable actuators. There is the possibility of looping though the two actuator voltages to a further 56605. Looping-through external actuator voltages is only supported from a safety module 56605 to another safety module 56605. When looping-through from one safety module to another, make sure that only a maximum total current of 4 A flows through each PIN. This must be ensured by an upstream fuse.

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6.3.1.1 Safe Wiring of 5-pin M12 Safe (protected) wiring compliant with EN 60204-1:2006 Excerpt (EN 60204-1 Section 13.4): “Flexible cables of machines shall be so installed or protected as to minimize the possibility of external damage due to factors that include the following cable use or potential abuse: • being run over by the machine itself; • being run over by vehicles or other machines; • coming into contact with the machine construction during movements; • running in and out of cable baskets or on or off cable drums; • acceleration forces and wind forces on festoon systems or suspended cables; • excessive rubbing bycable collector; • exposure to excessive radiated heat The cable sheath shall be resistant to the normal wear that can be expected from movement and to the effects of atmospheric contaminants (e.g. oil, water, coolants, dust).” Bending radii: Compliance must be ensured with the bending radii contained in EN 60204-1 Table 8. The straight section between 2 bends in an S shape or a deflection to another level must be at least 20 times the cable diameter. Excerpt (EN 60204-1 Section 13.5): “All sharp edges, flash, burrs, rough surfaces, or threads with which the insulation of the conductors can come in contact shall be removed from ducts and fittings. Where necessary, additional protection consisting of a flame-retardant, oil-resistant insulation material shall be provided to protect conductor insulation. … Ducts and cable trays shall be rigidly supported and positioned at a sufficient distance from moving parts and in such a manner so as to minimize the possibility of damage or wear. In areas where human passage is required, the ducts and cable trays shall be mounted at least 2 m above the working interface.” Objective: The objective is to achieve a high degree of operating safety. In order to provide protection against parasitic voltage, the various voltages in a cable or equipment must be insulated against the highest occurring voltage (Protection against electric shock, IEC 61140 - Cable insulation between two conductors of different potentials). Insulation test: In order to test the dielectric strength of the actuator cable, the routed cable must be tested before starting up the machine. In this test, the two cable ends must be open to avoid damage to the electronic components. This test should be included in the time intervals of the machine inspections. The dielectric strength of the insulation must be strong enough to resist a test voltage of 500 VAC for 5 minutes. In order to detect a cross-circuit between safety relay 1 and safety relay 2, conduct a dielectric strength test between the two safety relays. Always provide sufficient protection to avoid mechanical damage of the connectors (EN 60204-1).

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6.3.1.2 Use of a cross-circuit-proof cable in rugged environments If it is impossible to route a cable safely, then use a cross-circuit-proof cable. This cable must have a grounded shield around voltages UA1 and UA2 that must be separated. In case of a fault (cross-circuit), the shield short-circuits the voltage and provides a safe state as a result.

6.3.2 Connecting Actuators Always provide sufficient protection to avoid mechanical damage of the connectors (EN 60204-1).

Actuators are connected to the module by means of standard I/O cables terminated with M12 5-pin connectors (see PIN assignment on page 6.5.1). Module 56605 detects a short-circuit to ground in the cable or the actuator and this disables the actuator power supply of the affected actuator. A cross-circuit between the module actuator power supplies is excluded by the safe separation of the actuator power supplies and maintenance of safe air and creepage paths. The module detects a voltage at a disabled output and feeds back the fault message "Actuator warning". This may not be evaluated as safety-related information since the software in the µC is not part of the safety test. The voltage is disabled by a safety relay. After the voltage is switched off, no voltage may be present on the disabled path, even if a fault occurs in the system (single-fault analysis). The software and the communication over the fieldbus are not included in the safety analysis. Fault exclusion is described. A safe state is always defined as deenergized (0 V). The software is not part of the safety analysis Fault messages are generated by the software and are not part of the safety analysis.

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6.4 Cube67 DO16 C Valve K3 Art. No. 56650 and Cube67 DO8 C Valve(9) K3 Art,.Nr. 5665003 Bus

kn o

ten

24V UA1

24V UA2

0V

24V UA1 braun

24V UA2 schwarz

0V Sicherheitsschaltgerät

hlu sc An

24V UA3 rosa

er Int ss ne

S ys

te mv

g n d un e rb i

s h lus Ansc nun g rspa n Akt o

24V UA4 24V UA3 gra u

24V UA4

ß we i u bl a schir m

GND

Schirm muss auf GND gelegt werden!

el til in s n e V sel er ti lin teck Venl usss scg an

Figure 6-5: Connection of module 56650 respectively 5665003

The module is connected via the internal system connection to a bus node that permits communication to the PLC. The power for the module electronics is supplied via the internal system connection. The power supplies for the valve terminal is fed over a separate M12 connector. Four independent actuator voltages can be fed over this cable. The internal system connection and the actuator voltages have a common ground and are not galvanically separated.

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The use may set up four "EMERGENCY STOP" circuits for one valve terminal. Connection to the safety relay must have a cross-circuit-proof design (refer to 5.1.1 Connecting wire for actuator voltage).

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6.4.1 Connecting Wire for Actuator Voltage Four separate actuator voltages can be supplied. Each actuator voltage can power four (two with 5665003) valves. This then results in four groups of four outputs each, i.e. 16 connectable actuators respectively four groups of two outputs each, i.e. 8 connectable actuators with 5665003. Murrelektronik cables Art.No. 7000-15101-1380500 (5.0 m), Art.No. 7000-151011381000 (10 m), Art.No. 7000-46045-1380300, Art.No. 7000-46045-1380500, and Art.No. 7000-46045-1381000 are recommended to produce a simple connection of the safety relay and for troublefree startup.

CAUTION Make sure you provide suitable protection. The maximum current per actuator voltage is 4 A (2A with 5665003). The total current for the module may not exceed 8 A (4 A) (2xGND of 4 A each).

6.4.1.1 Use of Murrelektronik cables (yellow, cross-circuit-proof) Art.No. 7000-15101-1380500 (5.0 m), Art.No. 7000-15101-1381000 (10 m) Art.No.7000-46045-1380300 (3.0 m), -1380500 (5.0 m) and -1380100 (10 m) The four conductor wire that carry the actuator power supply (brown, black, pink, gray) are surrounded by a shield at ground potential (GND). If the cable is crushed, this then prevents one actuator voltage from crossing over to the other. The shield short-circuits the actuator voltage to GND and ties it to 0 V. This is then diagnosed in the module.

CAUTION The shield must be tied to GND to prevent the actuator voltage from crossing over to another actuator voltage in case of a cross-circuit.

6.4.1.2 Use of a Standard Cable (not cross-circuit-proof) WARNING A non cross-circuit-proof cable may be used if all 4 actuator voltages are only switched via one safety relay.

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6.4.2 Safe (Protected) Wiring Compliant with EN 60204-1 Excerpt (EN 60204-1 Section 13.4): Flexible cables of machines shall be so installed or protected as to minimize the possibility of external damage due to factors that include the following cable use or potential abuse: • being run over by the machine itself; • being run over by vehicles or other machines; • coming into contact with the machine construction during movements; • running in and out of cable baskets or on or off cable drums; • acceleration forces and wind forces on festoon systems or suspended cables; • excessive rubbing bycable collector; • exposure to excessive radiated heat The cable sheath shall be resistant to the normal wear that can be expected from movement and to the effects of atmospheric contaminants (e.g. oil, water, coolants, dust). Bending radii: Compliance must be ensured with the bending radii contained in EN 60204-1 Table 8. The straight section between 2 bends in an S shape or a deflection to another level must be at least 20 times the cable diameter. Excerpt (EN 60204-1 Section 13.5): All sharp edges, flash, burrs, rough surfaces, or threads with which the insulation of the conductors can come in contact shall be removed from ducts and fittings. Where necessary, additional protection consisting of a flame-retardant, oil-resistant insulation material shall be provided to protect conductor insulation. … Ducts and cable trays shall be rigidly supported and positioned at a sufficient distance from moving parts and in such a manner so as to minimize the possibility of damage or wear. In areas where human passage is required, the ducts and cable trays shall be mounted at least 2 m above the working interface. Objektive: The objective is to achieve a high degree of operating safety. In order to provide protection against parasitic voltage, the various voltages in a cable or equipment must be insulated against the highest occurring voltage (Protection against electric shock, IEC 61140 - Cable insulation between two conductors of different potentials). Insulation test: In order to test the dielectric strength of the actuator cable, the routed cable must be tested before starting up the machine. In this test, the two cable ends must be open to avoid damage to the electronic components. This test should be included in the time intervals of the machine inspections. The dielectric strength of the insulation must be strong enough to resist a test voltage of 500 VAC for 5 minutes. In order to detect a cross-circuit between safety relay 1 and safety relay 2, conduct a dielectric strength test between the two safety relays. Always provide sufficient protection to avoid mechanical damage of the connectors (EN 60204-1).

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6.4.3 Connecting Wire for Valve Terminal The four cable harnesses comprising various actuator voltages are jacketed by a shield that is tied to ground potential (GND). If the cable is crushed, this then prevents one actuator voltage from crossing over to the other. The shield short-circuits the actuator voltage to GND and ties it to 0 V. This is then diagnosed in the module. Only use preterminated cables with permanently mounted connectors for Festo CP valve terminals.

6.4.4 Connecting Wire for Valve Terminal Always provide sufficient protection to avoid mechanical damage of the connectors (EN 60204-1).

Module 56650 detects a short-circuit to ground in the connector and this disables the actuator power supply of the affected actuator group. A cross-circuit between the actuator voltages is excluded by maintaining air and creepage paths. The module detects a voltage at a disabled output and feeds back the fault message "Actuator warning". This may not be evaluated as safety-related information since the software in the µC is not part of the safety test. The voltage is disabled by a safety relay. After the voltage is switched off, no voltage may be present on the disabled path, even if a fault occurs in the system (single-fault analysis). The software and the communication over the fieldbus are not included in the safety analysis. The fault exclusion is described. A safe state is always defined as deenergized (0 V). The software is not part of the safety analysis. The individual voltages are switched on by additional separate FETs that are only enabled when the µC sends a pulsing signal to a capacitively separated FET output stage. This ensures troublefree operation of the µC. The manual provides a detailed function description. Fault messages are generated by the software and are not part of the safety analysis.

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6.5 Component Description 6.5.1 Pin Assignment of Cube67 DO6 (DO6) E 6xM12 K3 – Art. No. 56605 Internal system connection 1 – 24 V (NC) 2 – 24 V (System) 3 – GND 4 – internal system connection 5 – internal system connection 6 – GND Actuator power supply 1 – UA1 2 – 0V UA2 3 – 0V UA1 4 – UA2 5 – FE

In

Out

In U

P

U

Out

0

1

0

0

1

0

1

1

UA1

Soc 0 Pin 2 Pin 4 Soc 2 Pin 2 Pin 4 Soc 4 Pin 2 Pin 4

UA1

0

1

2

UA2

3

0

1

4

UA2

0

1

Soc 1 Pin 2 Pin 4 Soc 3 Pin 2 Pin 4 Soc 5 Pin 2 Pin 4

5

M12 (UA1, UA2): 1 NC 2 – DO:1x (Soc 0,2,4) (Soc 1,3,5) 3 – 0V UA1 / 0V UA2 4 – DO: 0x (Soc 0,2,4) (Soc 1,3,5) 5 – FE

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6.5.2 Pin Assignment of Cube67 DO16 C Valve K3 – Art. No. 56650 Internal System Connection 1 – 24 V (NC) 2 – 24 V (System) 3 – GND 4 – internal system connection 5 – internal system connection 6 – GND Actuator power supply

V 25 Connector OUT

UA1

UA2

UA3

UA4

PIN 1 PIN 2 PIN 3 PIN 4

OUT 1 OUT 2 OUT 3 OUT 4

white brown green yellow



gray pink blue red



black purple gray/pink red/blue



white/green brown/green white/yellow yellow/brown

PIN 17 NC PIN 18 NC PIN 19 NC PIN 20 NC PIN 21 NC PIN 22 NC PIN 23 NC PIN 24 GND PIN 25 GND

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1 – UA1 2 – UA2 3 – GND 4 – UA3 5 – UA4 6 – GND Shield must be tied to GND.

auxiliary conductor shield

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6.5.3 Pin Assignment of Cube67 DO8 C Valve(9) K3 – Art.-Nr. 5665003 Internal System Connection 1 – 24V (N.C.) 2 – 24V (System) 3 – GND 4 – internal system connection 5 – internal system connection 6 - GND Actuator power supply

9p Connector OUT

UA1

PIN 1 PIN 2

OUT 1 OUT 2

white brown

UA2

PIN 3 PIN 4

OUT 3 OUT 4

grey pink

UA3

PIN 5 PIN 6

OUT 5 OUT 6

black purple

UA4

PIN 7 PIN 8

OUT 7 OUT 8

white/green brown/green

PIN 9 GND

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1 – UA1 2 – UA2 3 – GND 4 – UA3 5 – UA4 6 – GND Shield must be tied to GND!

auxilary connector /shield

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6.6 Handling in Various Fieldbus Systems Please refer to the associated manual for information on module startup in the various fieldbus systems.

Cube67 System Manual Art. No. 56 970

Cube67 Technical Data Art. No. 56 971 Profibus Art.No. 56 980 DeviceNet Art.No. 56 981, Cube67 Bus System Manual

CANopen Art.No. 56 982 Ethernet / IP Art.No. 56 983 DeviceNet V2 Art.No. 56 984 Profinet Art.No. 56 985

Cube67 "Safe switchoff of nonfunctional protected modules “ Art. No.56 972

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7 Technical Data 7.1 56605 Cube67 DO6 (DO6) E 6xM12 K3 EMC EN 61131-2 Product norm EN 61000-4-2 ESD EN 61000-4-3 RF Field & GSM EN 61000-4-4 Burst EN 61000-4-5 Surge EN 61000-4-6 HF-asymmetric EN 61000-4-8 Magnetic field 50 Hz EN 55011 Emission

Contact ± 4 kV, Air ± 8 kV 10 V/m ± 2 kV asym./symm. ± 500 V (supply) asym. ± 1 kV (Signals/Bus) 10 V 30 A/m QP 40 dBµV/m (30 - 230 MHz) QP 47 dBµV/m (230 - 1000 MHz) (Cl. A)

Ambient conditions Operating temperature Storage temperature Protection class to EN 60529 Vibrations to EN 60068 Part 2-6 Shock to EN 60068 Part 2-27

0°C ... +55°C -25°C ... +70°C IP 67 5 – 150 Hz, 1g Amplitude 15 g, 11 ms Duration

Connection options Internal system connection IN Internal system connection OUT Safety supply IN Safety supply OUT Actuator

M12 6-pin connector M12 6-pin socket M12 5-pin connector M12 5-pin socket 6x M12 5-pin socket

Dimensions and Weights Dimensions (LxWxH) in mm Fixing dimensions in mm Weight

126x50x34.5 mm 75± 0.5mm approx. 220 g

Internal Bus Protocol Transmission rate Addressing

internal system 1 MBaud auto

Power Supply Supply voltage UB 24VIN 2 actuator power supplies Voltage range Module power consumption Connection Reverse-connect protection

24 V DC (must be connected) 24 V DC each 18 to 30 V DC