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User Manual - GS Global Resources

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1. 50 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Failure modes The following tables have information about the actions taken by the IQAN MC3 when certain failure causing conditions occur Failure modes for single inputs NOTICE Q For safety functions VIN is the only input type that may be used without another input as comparison Sensor failure modes are not included in these tables Key to symbols detection leads to error status on input See IQANdesign user manual VIN error detection limits are application dependent and must be used for safety functions See IQANdesign user manual Use a secondary diagnostic channel for error detection Voltage input Failure mode Detected Comment VIN open N Detection only if valid signal range is limited VIN short circuit to BAT N Detection only if valid signal range is limited VIN short circuit to signal high error N Detection only if valid signal range is detection voltage limited VIN short circuit to signal within error Incorrect input detection limits VIN short circuit to signal low error N Detection only if valid signal range is detection voltage limited VIN short circuit to BAT Detection onl
2. 43 9 Diagnostics and troubleshooting 44 Diagnostic interfaces 44 CAN diagnostics connection 44 Bypass application 44 Appendix A 2 else fat 34 ae eee ea ie am RE 45 IQAN MC3 Technical Overview 45 Appendix B 2e eR eR EMEN ERU T RAN MEE 50 Error codes messages and actions 50 Failure modes 24 0205 XE dR E aR R RR HRA RN KRL RRR RPG RE S 51 Failure modes for single inputs 51 Voltage Input iis vu Rey rr PIG Pewee blade die adds E 51 Digital Input 225 porran eE renr E ERPEIFES HEU ES dE EFE p 51 Frequency input X 0 niknik KRL eee 52 Directional frequency input 52 Failure modes for external wiring faults on power drivers COUT 53 Current output 2 s nuron RR ad R R RR rne 53 Failure modes for external wiring faults on power drivers DOUT 56 Digital output xiu pue eem E ERE eee ee EEG ede eb ERR eee 56 Appendix C Qiies Lu memes ee Ae re XEM ERR t EAR EE mm 60 Dimensioning of the IQAN MC3 module 60 Appendix D 22 2 ceteris KERE xr ERU ax RI ees 61 Safety manual requirements 61 SMR Safety Manual Requirement 61
3. Emergency stop Alternatively the emergency stop may also shut off the diesel engine or a dump valve and with that depressurize the hydraulic system 41 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Start up procedures 8 Start up Prepare for system start N WARNING Make sure no one is in dangerous proximity to the vehicle to avoid injuries when it starts Prepare for the initial system start as follows The engine for the hydraulic system s pump shall be in off position Make sure that all connectors are properly connected Turnon the control system Make sure that voltage is being supplied to all modules the green diode shall be illuminated on all modules Also make sure that master is in contact with all mod ules by checking the master s status LED Error codes are blinked if the master is not in contact with one or more of the modules Make sure the emergency stop is functioning properly Start the system Start the system as follows Start the engine for the hydraulic system s pump assuming that the above men tioned inspections have been carried out and shown correct values e Calibrate and adjust input and output signals according to the instructions related to the master menu system and check each and every output func
4. 32 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Directional frequency inputs 7 VO functionality Simple directional frequency sensor The positive terminal of the directional frequency sensor is connected to the VREF and the negative terminal to the VREF respectively The sensor signals are connected to the DFIN and DFIN positions EXAMPLE Connect the positive and negative terminals of the frequency sensor to VREF and VREF respectively Then connect the sensor signals to DFIN and DFIN IQAN MC3 Directional frequency sensor Connecting of directional frequency sensor to DFIN and DFIN NOTICE o The negative terminal of the sensor must not be connected to the chassis Maximum load for VREF position see Appendix A on page 45 Using directional frequency inputs in safety functions The following addional information applies when the inputs are used in safety functions where an incorrect input signal can lead to an immediate increase of the risk MC3 SMR 011 A Use of DFIN inputs in pairs When directional frequency inputs are used in safety functions the application shall be designed so that the input signals are compared to an additional signal to ensure that it is correct 33 GLOBAL GS Global Resources 1 800 261
5. Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Off Failure mode Detected Comment DOUT open N DRET open N DOUT short circuit to DRET No influence on function in this state DOUT short circuit to BAT Reverse feed No influence on function in this state DOUT short circuit to BAT Detected or fuse blows DRET short circuit to BAT Reverse feed No influence on function in this state DRET short circuit to BAT Current through load 100 ms DOUT short circuit to 2 DOUT active No influence on function in this state passive DOUT short circuit to 2 COUT active i DOUT short circuit to 2 COUT No influence on function in this state passive DOUT short circuit to 21 CRET active No influence on DOUT error detected on 2 COUT DOUT short circuit to 2 7 DRET active Detected or fuse blows DOUT short circuit to 2 CRET DRET No influence on function in this state passive DRET short circuit to 2 DRET active DRET short circuit to 2 CRET DRET No influence on function in this state passive 57 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B On under current detect
6. Deutsch crimping DT 20 00 tool reference Prototype cable Parker no 5030218 a Kit contains parts for all 4 connectors C1 C4 Symbol Pin In Function No Out VREF B 1 Voltage reference for external sensors Return OV VREF B 2 Voltage reference for external sensors Sourcing 5V DIN A 3 l DIN FIN DFIN PCN DPCN signal input DIN B 4 l DIN FIN DFIN PCN DPCN signal input DIN C 5 l DIN FIN DFIN PCN DPCN signal input DIN D 6 DIN FIN DFIN PCN DPCN signal input DIN E 7 l DIN FIN DFIN PCN DPCN signal input DIN F 8 l DIN FIN DFIN PCN DPCN signal input DIN G 9 l DIN FIN DFIN PCN DPCN signal input DIN H 10 l DIN FIN DFIN PCN DPCN signal input DIN I 11 l Digital signal input DIN J 12 l Digital signal input DIN K 13 l Digital signal input DIN L 14 l Digital signal input DIN M 15 l Digital signal input DIN N 16 l Digital signal input DIN O 17 l Digital signal input DIN P 18 l Digital signal input 22 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Connectors C1 C4 6 Installation Connector C4 pin assignments Connector kit Parker no 5035016 Housing Deutsch no DT16 18SDK004 Pin types 1062 16 0644 Cables 0 75 mm 18 A
7. GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Dimensioning of the IQAN MC3 module Appendix C Appendix C Dimensioning of the IQAN MC3 module Rs os A zo 60960 on eae e e e em 19 B 76 6 or n n lae o o o o 10 os S 76 ox n n cle e o e o ouf Unit mm 60 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety manual requirements Appendix D Appendix D Safety manual requirements This appendix contains a list of the mandatory safety requirements that must be fulfilled in order for the unit to be used up to its specified safety integrity level SMR Safety Manual Requirement MC3 SMR 001 A Use within specification sss ese eee eee eee 3 MC3 SMR 002 A No field repair a MC3 SMR 003 A Safe state 7 MC3 SMR 004 A System cycle time 9 MC3 SMR 005 A Only use an official release of IQANdesign 10 MC3 SMR 006 A CAN communication 13 MC3 SMR 007 A Limits on VIN signal range 28 MC3 SMR 008 A Tolerances on VIN 29 MC3 SMR 009 A Use
8. IQAN MC3 Instruction book Publ no HY33 8001 IB UK Edition 2013 05 17 Darker ENGINEERING YOUR SUCCESS GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Contents 1 Introduction 2 2 REI ee ikke each or exor E SCR UR RR X 1 lU CH OT 1 Mandatory Safety Requirements 1 Overview of relevant documentation 2 2 Precautions 2 2 terie ises x eee ae RR memes aes eee 3 Read M Se 3 Design of control system 3 Start up maintenance and diagnostics 4 3 Product description 5 IQAN MG3 2 25 ce ae ds deed Se be D S nat wee Ka tos ER 5 VO overview 5 Communication iis cse i aR 0 9 K RR E KR R bene ee RR NT 6 CAMBIO ptt 7 Safety concept lt e RRR K RRR a RT R e RR R RR RRR RR RRR hne 7 Sal State ceo dee Ee T TETE Roca rater lela ceed aes 7 Maximum achievable SIL and PL 7 System boundaries ees 8 Architecture for a complete safety function ranana 9 Local physical inputs used as part of input subsystem in safety functions 11 CAN communication ren 12 Outputs zu i
9. System TA 40 to 85 C unless otherwise specified Safety integrity level up to SIL2 System capability SC2 Element complexity Type B PFHp 2x10 SFF 98 HFT 0 Diagnostic test interval 100 ms Tsc lt 75 ms Lifetime 10 years or 20 000 hours Periodic proof test No Sensor supply VREF Number of VREF 2 Output voltage 5 V 150 mV 40 to 85 C Output voltage temperature drift 0 25 mV C 40 to 85 C Maximum load current 140 mA on each VREF Protection overload SCB SCG Diagnostics over under voltage Under over voltage threshold 150 mV from nominal value Signal input VIN Number of VIN 16 VIN full scale 5000 mV 100 mV VIN resolution 12 bits 1 22 mV Input impedance 36 kohm in parallel with 10 nF Accuracy with external sensor supply with VREF sensor supply 0 8 5 mV 0 2 5 mV Sample rate same as system cycle time Maximum continuous voltage 5 5 V Protection SCB SCG Diagnostics ADC scale error lt 3 Signal input DIN Number of DIN 16 configuration may reduce number Logic levels low high hysteresis lt 1V gt 4V gt 0 1 V Input impedance 6 8 kohm in parallel with 10 nF Sample rate same as system cycle time Tsc Maximum continuous voltage 32 V Diagnostics Defined in application Signal input FIN DFIN Number of
10. GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Warnings 1 Introduction 1 Introduction These instructions are to be used as a reference tool for the vehicle manufacturer s design production and service personnel The user of these instructions should have basic knowledge in the handling of electronic equipment Warnings Sections marked with a symbol in the left margin must be read and understood by everyone using the system carrying out service work or making changes to hardware and software The different symbols used in this manual are defined below WARNING Sections labeled WARNING with a caution symbol in the left margin indicate that a hazardous situation exists We use warnings marked with the warning symbol in two ways Asastrong recommendation about work practices when using the product in the machine e g routines when updating an application This use is common to the term hazardous situation that a person is exposed to a hazard As a way of pointing out important information for the machine designer that in some way relates to safety This includes the design of the physical machine and also the application program being developed for the control system Not all document sections that contain information about safety are marked with
11. Product description Programmable controller for use in mobile machinery applications intended for implementation of safety functions Certification The product described above fulfils the requirements for SIL 2 of the standard IEC 61508 2010 Functional safety of electrical electronic programmable electronic safety related systems part 1 7 for a safety related control system The certification is based on a functional safety assessment according to IEC 61508 described in SP report PX20818 A dated 27 March 2013 supplemented by a separate evaluation of Parker Hannifins development tool IQANdesign and service tool IQANrun for use together with MC3 control system described in SP report PX20818 B dated 27 March 2013 and instruction book IQAN MC3 in the currently valid revision Tolerance complexity Safety integrity 4 PFHp a rea level Sug ET 2x10 Fu Safe failure SEF 98 Systematic sc2 fraction capability Hardware Fault HFT 0 Element TypeB Diagnostic DC 97 Diagnostic test G coverage interval Lifetime 10 years or 20 000 Periodic proof test hours No Marking Each sample that conforms in all respects with the original item certified may display the text Type examined by SP When this marking is applied the marking shall also contain reference to the standard IEC 61508 2010 the reached SIL Safety Integrity Level of the item the number of this certificate and
12. 35 M lnlycke SWEDEN Declare that the products declared herein fulfil all relevant safety component requirements of EC Machinery Directive 2006 42 EC Trade Name n Product since year of manufacture Electrohydraulic Control System IQAN MC3 2010 Harmonized standard EN 62061 2005 AC 2010 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems Other standards IEC 61508 edition 2 Functional safety of electrical electronic programmable electronic safety related systems EC Type examination SP Sveriges Tekniska Forskningsinstitut Notified body no 0402 Certificate no SC0534 13 The products referred in this declaration of conformity also fulfil the relevant provisions of EMC Directive 2004 108 EC fd p Signature T2 Printed name H kan Jisland Position Operations Manager Executed on May 13 2013 at M lnlycke Sweden Publ no HY33 8001 DC UK Ed 05 2013 18 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 5 Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Mounting the module 5 Mounting 5 Mounting Mounting the module The IQAN MC3 module should be mounted according to the following instructions Locate the module eliminating the risk for the cabling to be folded crushed or dam aged in any way Ensure
13. A on page 45 Frequency To obtain the best performance from proportional valves the IQAN MC3 produces a current mode closed loop output signal The units have an adjustable frequency which can be changed using IQAN software The table below shows the MC3 frequency possibilities Any frequency may be entered in your application and is translated according to this table The bold values are the actual frequencies in Hz output by the MC3 for proportional valve control Frequency Hz Frequency Hz entered in appl output by MC3 76 71 77 82 77 83 90 83 91 99 91 100 110 100 111 124 111 125 142 125 143 166 143 167 199 167 200 249 200 250 332 250 333 333 55 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Proportional outputs 7 VO functionality Connecting loads to proportional outputs The current outputs are high performance outputs with closed loop current control designed to drive proportional electrohydraulic valves For COUT and load characteristics please see Appendix A Connecting a load e g one proportional valve section to the current mode or PWM mode outputs is done by using the COUT CRET paired positions When a COUT is used with a just single solenoid connected e g a hydraulic motor the application file must be
14. GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED IQAN MC3 Technical Overview Appendix A Appendix A IQAN MC3 Technical Overview Absolute Maximum Ratings Ambient temperature 40 to 85 C Storage temperature 40 to 100 C Voltage supply on BAT 6 to 36 Vdc Voltage on any pin with respect to BAT 36 Vdc Power driver load Total load on power drivers lt 20A a The Absolute Maximum Ratings table lists the maximum limits to which the device can be subjected without damage This doesn t imply that the device will function at these extreme conditions only that when these conditions are removed and the device operated with in the Recommended Operating Conditions it will still be functional and its useful life wonit have been shortened Environmental ratings Climate environment Enclosure water amp dust protection Salt mist Damp heat cyclic Damp heat steady state Heat operation Heat storage Cold Change of temperature IEC 60529 2001 IP67 DIN 40050 Part 9 1993 IP6K9K IEC 60068 2 52 1996 Kb 72 h IEC 60068 2 30 2005 Db 55 C 95 RH 6 cycles IEC 60068 2 78 2001 Cab 40 C 93 RH 21 days IEC 60068 2 2 2007 Bb 85 C 72 hours IEC 60068 2 2 2007 Bb 100 C 72 hours IEC 60068 2 1 1993 Ab 4
15. IQAN MC3 module and output diagnostics There is also a common high side switch that supply all outputs that is used as an additional shutdown path Because of the built in diagnostics and redundant switches the architecture of the output subsystem can be selected independent of any constraints set by the unit Internal diagnostics The concept of the IQAN MC3 is that the primary CPU is monitored by a second independent CPU and they in turn are monitored by a completely separate safety ASIC The safety ASIC provides an independent alternate path to bring the system into a safe state via a safe path switch that cuts power to all of the power drivers To achieve good diagnostics the IQAN MC3 executes a high number of self tests on the processor memory and peripherials both during start up and cyclically during operation Peripheral testing MC3 internal diagnostics 14 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Certificates 4 Safety Certificates l MW MM I SP CEDTIFIVAT Type Examination Certificate No SC0064 11 Parker Hannifin IQAN MC3 control system Holder Issued for Manufacturer Parker Hannifin Manufacturing Sweden AB M lnlycke Fabriker 14 SE 435 35 M lnlycke Sweden Reg number 556045 9470 Product name IQAN MC3
16. It is not allowed for DIN FIN or DFIN input used in safety functions The structure depends largely on how the input is used by the application to view the inputs as two redundant channels they must lead to a safe state independent of each other EXAMPLE An overload safety function that uses two separate pressure sensors to initate stopping of a hazardous movement may have true redundancy if the highest of the two signals is used for the overload and the signals are compared with each other as a diagnostic measure Implemented in IQANdesign with 2 VIN channels the method MaxOf and with AAC Analog Analog Comparator If the same overload function only uses one of the signals and compares with the other for diagnostics that lead to a safe state that is not true redundancy but may be interpreted as a single structure with monitoring by separate signal Implemented in IQANdesign with 2 VIN channels and with AAC IQAN MC3 VIN primary VIN secondary Connecting pairs of signals The wiring is the same for both alternatives CAN communication The IQAN MC3 has built in support for safe connection to other IQAN MC3 units For more information see the IQANdesign user manual 12 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety con
17. Module prevented from starting 53 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Off Failure mode Detected Comment COUT open s CRET open N COUT short circuit to CRET No influence on function in this state COUT short circuit to BAT Reverse feed No influence on function in this state COUT short circuit to BAT CRET short circuit to BAT Reverse feed No influence on function in this state CRET short circuit to BAT CRET short circuit to CRET No influence on function in this state COUT short circuit to 2 COUT No influence on function in this state COUT short circuit to DOUT active COUT short circuit to DOUT passive No influence on function in this state COUT short circuit to 2 CRET DRET active No influence on COUT error detected on 2 4 COUT DOUT COUT short circuit to 27d CRET DRET passive No influence on function in this state CRET short circuit to 21 CRET DRET active CRET short circuit to 2 CRET DRET passive No influence on function in this state 54 RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne
18. a warning symbol there would be warnings everywhere Failure to comply with the recommendations can cause unintentional and unexpected behavior of the control system This can potentially cause death serious injury or property damage NOTICE Sections labeled NOTICE with a notice symbol in the left margin indicate there is important information about the product Ignoring this could result in less than optimal performance or damage to the product Mandatory Safety Requirements The requirements shown in boxes and labeled SMR contain important information about the use of the product in safety related applications If these requirements are not fulfilled the safety integrity level on the product is not valid The SIL claim on the product assumes that the user will follow these requirements MC3 SMR 00x A Safety Manual Requirement Boxed sections labeled as SMR contain important safety information All SMR s are tagged and numbered for easy access In some cases we put a warning next to a SMR This is done where there is a need to emphasize that the safety information is just as important when the module is used for normal non safety related functions GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Overview of relevant documentation 1 Introduction Cont
19. configured so that the COUT is not bidirectional otherwise an open load will be detected EXAMPLE Positive direction Connect the proportional valve to the COUT and the CRET respectively Negative direction Connect the proportional valve to the COUT and the CRET respectively IQAN MC3 Directional Valve Connecting a load to a proportional output NOTICE DO NOT install diodes across coils Proportional outputs in PWM mode It is possible to configure the proportional outputs for PWM mode and control the output directly with the modulation ratio instead of closed loop current control In PWM mode the current is not measured and diagnostics are limited NOTICE Q The PWM outputs on an IQAN MC3 can not be used to drive Pulsar valves select another IQAN module to do that COUT mode output diagnostics The COUT is capable of detecting internal faults as well as wiring faults The fault will be identified as one of the following status values in IQANdesign Over load e g over current Open load e g open circuit or under current Error internal error in the IQAN MC3 power driver The reported status is describing the most likely fault condition but in certain cases the status will not match the actual fault For details on failure modes see Appendix B on page 50 36 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Fo
20. load 1500 mA load typ 0 45 V saturation typ 0 90 V saturation Maximum COUT saturation typ Command 25 Absolute accuracy 2 15 mA 40 to 85 C Dither frequency Forty 71 77 83 90 100 111 125 167 200 250 333 Hz Leakage current in OFF state 100 uA Supply rejection 2 mA Var change 9 to 18V or 18 to 32V Load rejection 2 mA load change 50 Maximum load VBAT 14V and FDITH 2 200 Hz VBAT 14V and FDITH 2 200 Hz VBAT 14V and FDITH 2 200 Hz VBAT 14V and FDITH 2 200 Hz 5 ohm 10 mH 5 ohm 20 mH 10 ohm 30 mH 20 ohm 60 mH GLOBAL RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED 47 IQAN MC3 Technical Overview Appendix A Power driver COUT Maximum allowable load inductance 1 0 A load 500 mH 1 5 A load 200 mH 2 0 A load 50 mH Protection SCB SCG Diagnostics Operational ON under current SCG SCB Operational OFF open load SCG Open load threshold gt 50 kohm when COUT is OFF Under over threshold MaxOf 100 mA and 25 Power driver PWMOUT Number of PWMOUT 4 dual outputs PWMOUT range 0 to 100 200us PWMOUT resolution 1 us Power driver voltage drop typ 0 8 V 1 5 A load Dither freq
21. operate in 2 modes Speed which is frequency and position which is a pulse count For the frequency ranges and trigger levels see Appendix A on page 45 Simple frequency sensor The positive terminal of the frequency sensor is connected to the VREF and the negative terminal to the VREF respectively The sensor signal is connected to the FIN position EXAMPLE Connect the positive and negative terminals of the frequency sensor to VREF and VREF respectively Then connect the sensor signal to a FIN IQAN MC3 Frequency sensor Connecting of frequency sensor to FIN NOTICE o The negative terminal of the sensor must not be connected to the chassis Maximum load for VREF position see Appendix A on page 45 Using frequency inputs in safety functions The following addional information applies when the inputs are used in safety functions where an incorrect input signal can lead to an immediate increase of the risk MC3 SMR 010 A Use of FIN inputs in pairs When frequency inputs are used in safety functions the application shall be designed so that the input signals are compared to an additional signal to ensure that it is correct Directional frequency inputs Connecting sensors to the directional frequency inputs Directional frequency inputs can operate in 2 modes Speed which is frequency and position which is a pulse count For the frequency ranges and trigger levels see Appendix A on page 45
22. the serial number or equivalent of the item Certificate No SC0064 11 dated 2 May 2013 page 1 2 Lf SP Technical Research Institute of Sweden Postal address Phone Fax Reg number E mail Internot This certificate may not be reproduced other than in full Box 857 46105165000 5564646874 inlo sp se except with the prior written approval by SP SE 501 15 Bor s 46 33 13 55 02 www 350 39 SWEDEN 15 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 RESOURCES Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Certificates 4 Safety M MM Wl T T xamination Certificate No SC0064 11 c IR gt N 10 x inm wo m 11 Type Validity This certificate is valid until not later than 27 January 2016 Miscellaneous Other terms and conditions arc set out in SP s certification rules for type examination SPCR 123 This is the second edition of this certificate The certificate was originally issued on 27 January 2011 Boras 2 May 2013 fe SP Techni earch Institute of Sweden Ce X L y 4 LS Te CELT WKennart Aronsson L Susanne H VProduct Certification Manager Certification Certificate No SC0064 11 dated 2 May 2013 page 2 2 SP Technical Research Institute of Sweden Postal address Phone Fax Hog number Emol internet This certificate may not be reprod
23. tolerance with a diagnostic function or type D single fault tolerance with a diagnostic function Alternatively it can be used for connection to an input subsystem communication over CAN for up to SIL2 or PLd Logic subsystem IQAN MC3 and application software The logic subsystem consists of the IQAN MC3 and the application software The hardware and embedded software of the IQAN MC3 allows it to be used to implement safety functions of up to SIL2 or PLd In order to achieve this the application software must be designed up to the same level The application software can be designed using the generic standard for functional safety IEC 61508 However it is recommended that a standard for the functional safety of machinery is applied either EN ISO 13849 1 or EN IEC 62061 Use IQANdesign to develop the application software It is not necessary for all development of the application to be made using an official release of IQANdesign a beta version may be used for prototyping However before the safety integrity of the module can claimed the application must be upgraded to an official release of IQANdesign Output subsystem The output subsystem is the output power elements e g valves which control the machine actuators The outputs of the IQAN MC3 control the valves Each DOUT or COUT output on the IQAN MC3 is individually safe meaning that the unit does not place any restriction on the possible architecture for the output subsyst
24. 0 C 16 hours IEC 60068 2 14 1984 Nb 30 C to 70 C 100 x 4 hours Mechanical environment Random vibration Bump IEC 60068 2 64 2008 Fh 10 1000 Hz 11 6 Grms 3x 10h IEC 60068 2 27 2008 Ea 40 g 6 ms 1000 6 dir EMC Radiated emission Conducted emission Conducted susceptability Radiated susceptability Conducted transients susceptability ESD operation ISO 13766 ISO 14982 EN 55025 2003 0 15 108 MHz Class 1 ISO 11452 4 2005 1 200 MHz 1 kHz 80 AM 100 mA ISO 11452 2 2004 200 2000 MHz 1kHz 80 AM 100 V m ISO 7637 2 2004 Pulse 1 2a 2b 3a 3b 4 5 Level 3 ISO 7637 3 2007 Level 3 ISO 10605 2008 8kV contact 15kV air ESD handling ISO 10605 2008 8kV contact System Ta 40 to 85 C unless otherwise specified Weight 1 1 kg Ambient temperature TRoc 40 to 85 C Voltage supply on BAT Vpar 9 to 32 Vdc Current supply Vgar 14V typ 250 mA Vaar 28V typ 170 mA Start up time typ 1000 ms with a small application System cycle time Tsc 10 to 100 ms Application flash memory 1 5 MB Application RAM memory 1 5 MB Data log memory typ 80 000 records GLOBAL RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED 45 IQAN MC3 Technical Overview Appendix A
25. 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Voltage inputs 7 VO functionality NOTICE The negative terminal of the sensor must not be connected to the chassis Maximum load for VREF position see Appendix A on page 45 Selection of sensors The voltage inputs are designed for potentiometer type sensors and for 5V hall effect sensors Sensors with padding at the min and max limits of the signal range will ensure that the most common i e short circuits broken wires wiring errors are detected For potentiometer type sensors with a 0 5 4 5 V range we recommend that the potentiometer resistance is 1000 Ohm Using voltage inputs in safety functions The following addional information applies when the inputs are used in safety functions where an incorrect input signal can lead to an immediate increase of the risk Limits on signal range By limiting the normal operating range of voltage input signals several faults can be detected For this check to be effective the signal range must not be too wide Calibration Limits e Min voltage 22200 mV Max voltage 24800 mV MC3 SMR 007 A Limits on VIN signal range When voltage input signals are used in safety functions the active signal range shall be limited within 200 4800 mV and the limits shall be implemented in IQANdesign VREF usage
26. 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Reference voltage VREF 7 VO functionality Reference voltage VREF The IQAN MC3 is internally equipped with voltage regulators to generate the reference voltage VREF The standard 5V reference voltage will feed different kinds of sensors There is a VREF connection in both the C2 connector and the C3 connector Having multiple VREF supplies allows you to distribute power to the sensors in the vehicle according to installation zones or some other configuration IQAN MC3 VREF VREF VREF positions NOTICE It is strongly recommended to use the module s VREF and VREF to all sensors and potentiometers that are connected to the module inputs This will reduce bad measurement based on potential fault i e different ground points for other supplies in relation to the MC3 ground BAT Maximum load for the VREF supply see Appendix A on page 45 34 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Outputs 7 VO functionality Outputs Proportional outputs The current PWM outputs control proportional valves and devices For the current range and loads see Appendix
27. AT positions C1 13 C1 14 and BAT positions C1 1 C1 2 Protect the module by using a fuse Requisite fuse level should be max 20 A fast F IQAN MC3 Emergency Stop CD ei Symbol for disconnecting Switch for battery ignition lock and other fuses Connecting the emergency stop and voltage supply NOTICE Do not use the chassis as the negative terminal Reverse feed N WARNING Risk of inadvertently supplying power to the module If any of the outputs are shorted to battery voltage the module will be powered by reverse feed of voltage even when the connection to module power is off The IQAN MC3 is capable of detecting if outputs are shorted to battery voltage at start up and will prevent the application from starting If the same short circuit occurs while the module is already powered it may also be detected by the module but shutdown will be limited to the specific output see Appendix B on page 50 for details It is highly recommended that this failure mode is considered when designing the electrical system so that the risk of inhibiting the emergency stop shutdown is minimized IQAN MC3 addressing terminating Use of an ID Tag Each IQAN MC3 module must be configured by using an D tag The value of the ID tag will give the MC3 an address to differentiate it from other MC3 units on the same bus The desired functionality is built into the application file using IQANdesign software For more informa
28. C1 C4 Symbol Pin In Function No Out BAT 1 Power supply GND BAT 2 E Power supply GND CAN A L 3 CAN low voltage bus line will be LOW in dominant state CAN A H 4 E CAN high voltage bus line will be HIGH in dominant state CAN B L 5 CAN low voltage bus line will be LOW in dominant state CAN B H 6 CAN high voltage bus line will be HIGH in dominant state ADDR L T IdTag interface Low side to address tag Return signal ADDR H 8 IdTag interface High side to address tag Sourcing 5V CAN C L 9 CAN low voltage bus line will be LOW in dominant state CAN C H 10 CAN high voltage bus line will be HIGH in dominant state CAN D L 11 CAN low voltage bus line will be LOW in dominant state CAN D H 12 CAN high voltage bus line will be HIGH in dominant state BAT 13 Power supply 12 24 Vdc BAT 14 Power supply 12 24 Vdc DOUT D 15 O DOUT power driver type B high side DRET D 16 O DOUT power driver type B low side DOUT E 17 O DOUT power driver type B high side DRET E 18 O DOUT power driver type B low side 20 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Connectors C1 C4 6 Installation Connector C2 pin assignments Connector kit Parker no 5035016
29. CES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Failure modes for external wiring faults on power drivers DOUT NOTICE o Failure modes for internal faults are included in the total PFHd for the module Key to symbols and conditions detection leads to the power driver being disabled Restart conditions are applicaton specific Start up When module is started all DOUT and DRET are off a test pattern is applied to detect faults Off When power driver is off DOUT is on and DRET is off On When power driver is on DOUT is on and DRET is on Disabled After an error is detected both DOUT and DRET are off No diagnostic is performed until there is an attempt to reactivate the output Restart condtions are application specific Reverse feed of the module Ability to shut down module via BAT inhibited Ability to shut down in the event of an internal error reduced Detected at next start up Digital output Start up Failure mode Detected Comment DOUT short circuit to BAT at start up Module prevented from starting DRET short circuit to BAT at start up Module prevented from starting 56 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151
30. Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B On active CRET Failure mode Detected Comment COUT open s CRET open N COUT short circuit to CRET active N COUT short circuit to CRET passive No influence on function in this state COUT short circuit to BAT Reverse feed No influence on function in this state COUT short circuit to BAT s CRET active short circuit to BAT N Detection is limited to this output Reverse feed is not detected CRET active short circuit to BAT CRET short circuit to CRET COUT short circuit to 2 COUT N COUT short circuit to 27 DOUT S COUT short circuit to 2 CRET DRET No influence on COUT error detected active on 2 4 COUT DOUT COUT short circuit to 274 CRET DRET No influence on function in this state passive CRET short circuit to 2 CRET active e CRET short circuit to 2 CRET No influence on COUT error detected passive on 2 4 COUT DOUT Insufficient voltage on BAT current saturated 75 to 100 Insufficient voltage on BAT current N saturated lt 75 On passive CRET Failure mode Detected Comment CRET open CRET short circuit to BAT Reverse feed No influence on function in this state CRET short circuit to BAT CRET short circuit to 27d CRET No influence on function in this state passive 55 RESOUR
31. FIN DFIN 8 4 configuration may reduce number Frequency range FIN DFIN 1 to 20 000 kHz 50 duty cycle 1 to 20 000 kHz 50 duty cycle GLOBAL RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED 46 IQAN MC3 Technical Overview Appendix A Signal input FIN DFIN Minimum pulse width 10 us for 5 V signal Step response 400 ms 10 to 90 step Logic levels low high hysteresis 1V gt 4V gt 0 3 V Input impedance 6 8 kohm in parallel with 10 nF Sample rate same as system cycle time Tsc Maximum continuous voltage 32V Diagnostics Defined in application Signal input PCNT DPCNT Number of PONT DPCNT 8 4 configuration may reduce number Frequency range PCN DPCN 0 to 20 000 kHz 0 to 20 000 kHz Minimum pulse width 10 us for 5 V signal Logic levels low high hysteresis 1V gt 4V gt 0 3 V Input impedance 6 8 kohm in parallel with 10 nF Sample rate same as system cycle time Tsc Maximum continuous voltage 32 V Diagnostics Defined in application Power driver COUT Number of COUT 4 dual outputs COUT range low 100 mA high 2000 mA COUT resolution 1 mA Power driver voltage drop 750 mA
32. Housing Deutsch no DT16 18SBK004 Pin types 1062 16 0644 Cables 0 75 mm 18 AWG Plugs empty pos Deutsch no 114017 Deutsch crimping DT 20 00 tool reference Prototype cable Parker no 5030217 a Kit contains parts for all 4 connectors C1 C4 Symbol Pin In Function No Out VREF A 1 Voltage reference for external sensors Return OV VREF A 2 Voltage reference for external sensors Sourcing 5V VIN A 3 l Voltage signal input VIN B 4 Voltage signal input VIN C 5 l Voltage signal input VIN D 6 l Voltage signal input VIN E 7 l Voltage signal input VIN F 8 l Voltage signal input VIN G 9 l Voltage signal input VIN H 10 l Voltage signal input VIN I 11 l Voltage signal input VIN J 12 l Voltage signal input VIN K 13 l Voltage signal input VIN L 14 Voltage signal input VIN M 15 l Voltage signal input VIN N 16 l Voltage signal input VIN O 17 l Voltage signal input VIN P 18 l Voltage signal input 21 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Connectors C1 C4 6 Installation Connector C3 pin assignments Connector kit Parker no 5035016 Housing Deutsch no DT16 18SCK004 Pin types 1062 16 0644 Cables 0 75 mm 18 AWG Plugs empty pos Deutsch no 114017
33. It is recommended that the connected sensors shall use one of the VREF s from the IQAN MC3 especially when voltage inputs are used in safety functions If an external 5 V reference is used it is up to the application to ensure that the reference voltage is correct IQAN MC3 VIN primary VIN secondary Using a common VREF Pairs of inputs may use a common VREF 28 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Voltage inputs 7 VO functionality Tolerances on voltage inputs in safety functions The unit has automatic monitoring of the internal analog to digital converter that is capable of detecting gain errors of 3 or higher An internal error causing a smaller signal drift than 396 is not detected by the check MC3 SMR 008 A Tolerances on VIN When voltage inputs are used in safety functions the application shall be designed so that it can tolerate a gain error of 3 on the voltage inputs and still be in a safe state EXAMPLE For a safety related hold to run function controlled by a proportional lever the function is in a safe state when the lever is in its neutral position corresponding to an output signal of 2500mV To ensure that the function does not get activated when the lever is in its neutral a deadband is needed With a lev
34. New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety Average probability of dangerous EN 13849 1 PL EN 62061 SIL IEC61508 SIL failure per hour 1 h 210 to lt 10 a d 23 108 to lt 10 b 1 1 210 to lt 3 106 c 1 1 2107 to lt 10 d 2 2 210 to lt 107 e 3 3 Z 4 For the IQAN MC3 the maximum achievable Performance Level and Safety Integrity Level is shown in the following table Maximum achievable Performance Level EN ISO 13849 1 PLd Maximum achievable Safety Integrity Level EN IEC 62061 SIL2 Maximum achievable Safety Integrity Level EN IEC 61508 SIL2 System boundaries The safety integrity of the IQAN MC3 covers e All inputs VIN DIN FIN DFIN All sensor supplies VREF s All outputs COUT DOUT Core electronics processor memory power supply CAN For the functions above the following restrictions apply e UO must be installed and used in accordance with this manual Information sent over CAN must also be protected by the high level protocol The following internal diagnostic information is used for keeping the IQAN MC3 within the specified range and may not be used for implementation of safety functions Measurement of module supply voltage Measurement of module temperature The following built in functionality of the IQAN MC3 is seen as non safe
35. Overload threshold gt 4 A when DOUT is ON CAN Number of CAN buses 4 CAN specification 2 0A and 2 0B CAN bus speed 125 kbit to 500 kbit Protection SCB SCG 49 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 RESOURCES Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Error codes messages and actions Appendix B Appendix B Error codes messages and actions If one of the following error is detected a message will be presented with an error code on the module In some cases the module will turn off or at least shut down the outputs to increase safety WARNING N Do not use the machine if an error message or error code is activated LED indicator showing different MC3 modes Status Flash yellow Normal operation Application not loaded lee T No application available Lo P Waiting for restart O MM l1 FLHLbTL Error Error Primary Flash red Secondary Flash yellow code Error category Error description 1 1 Output 1 1 2 Input 1 1 3 VREF 1 2 1 Power Supply 2 2 Temperature 3 1 CAN error No contact 3 2 IDtag error J w Re ee 3 3 System mismatch omman NN 4 1 Internal error OSE TL 4 2 Critical Temperature 4 3 Critical Stop
36. WG Plugs empty pos Deutsch no 114017 Deutsch crimping DT 20 00 tool reference Prototype cable Parker no 5030219 a Kit contains parts for all 4 connectors C1 C4 Symbol Pin In Function No Out COUT A 1 O COUT power driver high side CRET A 2 O COUT power driver low side CRET A 3 O COUT power driver low side COUT B 4 O COUT power driver high side CRET B 5 O COUT power driver low side CRET B 6 O COUT power driver low side COUT C 7 O COUT power driver high side CRET C 8 O COUT power driver low side CRET C 9 O COUT power driver low side COUT D 10 O COUT power driver high side CRET D 11 9 COUT power driver low side CRET D 12 O COUT power driver low side DOUT A 13 O DOUT power driver type B high side DRET A 14 O DOUT power driver type B low side DOUT B 15 O DOUT power driver type B high side DRET B 16 O DOUT power driver type B low side DOUT C 17 O DOUT power driver type B high side DRET C 18 O DOUT power driver type B low side 23 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED VO configuration 6 Installation UO configuration BAT _ VREF Power supply Signal input T ADDR L_ h gian MC3 ADORN d OUTPUTS VIN Cor
37. act the manufacturer if there is anything you are not sure about or if you have any questions regarding the product and its handling or maintenance The term manufacturer refers to Parker Hannifin Corporation Overview of relevant documentation The following publications are relevant for users of this product The main documentation contains information that is not found elsewhere The additional documentation contains product information in a compact format for details on the information found in those documents consult this manual Main IQANdesign IQAN MC3 Instruction Book Mounting and Maintenance User Manual HY33 8001 IB Instruction Book this book HY33 8327 IB Documentation Compass IQAN MC3 IQAN MC3 IQAN MC3 Documentation Catalogue Datasheet Installation Sheet Electrical Schematic HY 33 8001 HY33 8001 IS HY33 8327 ES The IQAN MC3 module documentation system GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 5 Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Read This 2 Precautions 2 Precautions Work on the hydraulics control electronics may only be carried out by trained personnel who are well acquainted with the control system the machine and its safety regulations WARNING Make sure that you have sufficient knowledge before designing modifiying or servicing the c
38. application safety GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Read This 2 Precautions Start up maintenance and diagnostics For all personnel carrying out installation commissioning maintenance or troubleshooting WARNING Work on the hydraulics control electronics may only be carried out by trained personnel who are well acquainted with the control system the machine and its safety regulations Before you start Read section Start up on page 41 Additional information for service Mounting and maintenance instruction book Additional information for diagnosing the system Read section Diagnostics and troubleshooting on page 44 and see Appendix B on page 50 in this document Use the IQANrun software user manual as a reference GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED IQAN MCS3 3 Product description 3 Product description IQAN MC3 The IQAN MC3 is designed for controlling hydraulic systems in vehicles and machinery using 12 24 Vdc power supply IQAN MC3 is especially suited for applications with higher demands on functional safety where there is a need to prove t
39. be limited See IQANdesign user manual 38 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Digital outputs 7 VO functionality Digital outputs The IQAN MC3 has two types of digital outputs While all of the digital outputs are designed to drive coils for on off valves DOUT D E are also designed to drive indicators such as LED s For current ratings on the DOUT s see Appendix A on page 45 Connecting loads to digital outputs Connecting of loads to the digital outputs such as on off valves is done by using the DOUT DRET paired positions Protection against voltage transients A clamping diode must be placed between the digital output and return as close to the load as possible This reduces EMI it also helps in protecting the output against high voltage transients Use the diode 1N5408 3A 1000V Depending on the load other clamping diodes might be used instead EXAMPLE Connect the on off valve to the digital output using the DOUT and the DRET respectively IQAN MC3 Connecting a load to the digital output DOUT output diagnostics The DOUT is capable of detecting internal faults as well as wiring faults The fault will be identified as one of the following status values in IQANdesign Over load e g over current Open load
40. bs RE be 31 Connecting switches to the digital inputs 31 Using digital inputs in safety functions 31 Frequency inputs 32 Connecting sensors to the frequency inputs 32 Using frequency inputs in safety functions 32 Directional frequency inputs 32 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Contents Connecting sensors to the directional frequency inputs 32 Using directional frequency inputs in safety functions 33 Reference voltage VREF 2 34 O tputs cerae ware deal a Sew me daretur Cu oe ids 35 Proportional outputs 35 Use of COUT in safety functions 37 Digital outputs iles e ERR ERR LIRE R Rex ru ER RE ERE 39 Use of DOUT in safety functions 40 CEMELCIZUI MP 41 Start up procedures 41 Starting the control system 41 Prepare for system start 42 Start the system eren 42 Check list for electronics
41. cept 4 Safety Safe communication between IQAN MC3 units one CAN bus used CAN communication between multiple QAN MC3 master modules The IQAN MC3 can be used for connection to sensor subsystems over CAN assuming that the CAN protocol is suitable for safety related communication and that the diagnostic features in that protocol are able to be implemented on the IQAN MC3 Auxiliary Auxiliary ECU ECU Safe communication to other units one or two CAN buses used protocol dependent CAN communication between IQAN MC3 and other units with support for safe communication The diagnostic checks required by the protocol need to be implemented in the application MC3 SMR 006 A CAN communication When exchange of safety related data on CAN is done using a protocol that is not supported by IQANdesign the diagnostic features of that protocol shall be implemented in the application Outputs Each individual power driver of the IQAN MC3 uses a combination of high side and low side switches to control the load this makes it possible to have an alternative shutdown path if one would fail 13 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety Internal diagnostics 2 The
42. d at startup see Appendix B on page 50 MC3 SMR 017 A DOUT undetected wiring faults The application shall be designed so that undetected wiring errors on DOUT are safe GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Start up procedures 8 Start up 8 Start up Start up procedures This chapter contains instructions for action to be taken in connection with the initial start for example setting values calibrating and testing the system WARNING A Risk of injury If the control system is not fitted properly the machine could move uncontrollably The machine s engine shall not be started before the control system is completely fitted and its signals are verified Starting the control system Start the control system as follows Prior to start all modules and cables are to be fitted correctly Check fuses i e make sure that the supply voltage to the modules is equipped with the correct fuse Make sure that connections for supply voltage and return lines are correct in the cable s conductor joint Make sure that the ID tag is connected properly if used Make sure the emergency stop works The emergency stop should disconnect the supply voltage to all modules IQAN MC3 BAT Emergency stop CD OA u in BAT Dump valve
43. e microcontroller INPUTS and DIN Memory CANH CANL Supply voltage Before any installation of the IQAN system can take place make sure the ignition lock is turned off and the battery is disconnected Emergency stop The machine must always be equipped with an Emergency stop that stops all potentially hazardous movements by cutting the power supply to the actuators The recommended way of implementing this is by cutting the power to all IQAN modules and also to the actuators directly e g via a dump valve See below IQAN MC3 Emergency Stop gt ei Dump Valve B AT Emergency stop Since the IQAN MC3 is capable of implementing safety functions it may in some applications be tempting for the designer to implement the emergency stop as a function in the IOAN MC3 The IQAN MC3 does not have any built in emergency stop function but if it is implemented anyway it must be done with extreme caution Especially when application updates are performed e g during service or commissioning 24 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Heverse feed 6 Installation Connecting of Supply Voltage The supply voltage should be within the operating interval see Appendix A on page 45 Connect the supply voltage to B
44. e g open circuit or under current e Error internal error in the IQAN MC3 power driver The reported status is describing the most likely fault condition but in certain cases the status will not match the actual fault For details on failure modes see Appendix B on page 50 There are faults that are detected on startup and that will prevent the module from starting the application These are all faults where an output is connected to BAT on startup To detect these faults it is important that all connectors are plugged in before the module is started See section Start up on page 41 also see Appendix B on page 50 39 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Digital outputs 7 VO functionality Disabling DOUT under current detection It is possible to disable under current detection on individual DOUT s This may be useful when connection a DOUT to a high impedence load e g a relay When under current detection is disabled there are other failure modes that become undetectable as well For details on failure modes see Appendix B on page 50 Reset of faults The reset behaviour of the DOUT is configured in the application file see IQANdesign user manual Use of DOUT in safety functions DOUT safe state The DOUT is assumed to be in a safe state w
45. em 10 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety OUTPUT INPUT SUBSYSTEM SUBSYSTEM IQAN MC3 OUT 1 e g sensors i i i e g valve The IQAN MC3 module connected to output subsystem The IQAN MC3 is suitable for connection to output subsystems of category B 1 2 3 or 4 in accordance with EN ISO13849 1 up to PLd Local physical inputs used as part of input subsystem in safety functions This section describes the concept for how to use the IQAN MC3 inputs e g VIN DIN FIN DFIN as part of an input subsystem in a safety function Pairs of inputs All inputs used in the safety function where a fault can lead to a dangerous failure should be connected in pair with a separate signal For VIN the unit can accept a single analog signal without degradation of the safety integrity but DIN FIN and DFIN must always be used in conjunction with a separate monitoring signal For details see section I O functionality on page 27 WARNING A Although the IQAN MC3 can accept a single VIN as input to a safety function without 3 degradation of its own integrity IQAN MC3 the use will normally be restricted due to lack of diagnostics and redundancy on t
46. er that has a tolerance of 200 mV in the neutral position typically 10 in each direction the deadband in the application must be 1346 or more Deadband Connecting switches to the voltage inputs Connection of switches to voltage inputs will in most cases be restricted by the restriction of signal range on voltage inputs used in safety functions A voltage input may be connected to a switch but it shall use VREF the switch may not be connected to BAT NOTICE Q The VIN are designed for permanent connection to BAT but not for BAT transients Therefore VIN connection to BAT should be avoided 29 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Voltage inputs 7 VO functionality The switches are connected to VREF and VIN DIN respectively for 5V signal EXAMPLE Connect the positive and negative terminals of the switch to VREF and VIN respectively IQAN MC3 VREF VIN Connecting a switch to VIN and VREF NOTICE Maximum load for VREF position see Appendix A on page 45 30 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Digital inputs 7 VO functionali
47. ers see list 16 Voltage inputs VIN A thru VIN P and 8 Frequency inputs FIN A thru FIN H or DFIN A thru DFIN Dz and 8 Digital inputs DIN A thru DIN H Proportional outputs All of the outputs on the IQAN MC3 can be used for safety related signals There are 4 double proportional current outputs designed to drive proportional hydraulic valves These outputs can control 4 bi directional valve sections or 4 single solenoid devices ie proportional cartridge valves see below 4 double proportional outputs COUT A thru COUT D or 4 proportional outputs COUT A thru COUT D using single low side connections In order to increase the performance of the proportional outputs when controlling proportional valves the dither frequency can be adjusted Digital outputs All of the outputs on the IQAN MC3 can be used for safety related signals There are 5 digital outputs for driving on off solenoids Two of these are also intended to function as alarm outputs for e g LED lamps see below 5 digital outputs DOUT A thru DOUT E CAN related functions The IQAN MC3 uses a CAN bus CAN Controller Area Network to communicate with IQAN expansion modules and other systems The CAN bus is a robust communication protocol that is widely used and well proven within the automotive industry The unit has 4 CAN buses CAN A thru CAN D The buses may be configured using IQAN software to be ICP ICP 2 IQAN CAN Protoc
48. esigned so that the system is in a safe state when the controller is off If any critical fault within the IOAN MC3 is detected by its internal checks the controller will shut down all outputs including CAN Ifa fault on one output is detected that output will be shut off e fthis occurs the stop ramps on on the outputs will have no effect the outputs will shut off immediately Therefore the application must be designed so that a sudden stop on the outputs does not in itself lead to a hazardous situation Maximum achievable SIL and PL The IQAN MC3 is designed for use in safety functions of up to SIL2 IEC 61508 The IQAN MC3 in itself does not come with any safety function it needs to be put into a system and loaded with an application file It is recommended for the developer of the safety function to apply a standard written specifically for machine manufacturers when designing safety functions with the IQAN MC3 Suitable standards for machinery are EN ISO 13849 1 or IEC EN 62061 The following table shows the relationship between Performance Level PL and Safety Integrity Level SIL and also the corresponding average probability of dangerous failure per hour PFHd The PL and SIL are based both on quantifiable aspects and on non quantifiable aspects such as the development process used and the safety related software GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive
49. he safety integrity of each implemented safety function The IQAN MC3 is a SIL2 rated master module in the IQANdesign platform It can be used as a standalone controller as a single bus master or together with other IQAN master modules The MC3 has local I O for input output use and has 4 CAN busses that support ICP IQAN CAN Protocol SAE J1939 and Generic CAN As a bus master the MC3 is able to control other IQANdesign platform expansion units This product is designed for the outdoor environment and comes with an IP6K9K protection for applications where high pressure water and steam jet cleaning is used The IQAN MC3 module UO overview 4BAT VREF Power supply BAT and safe path control VREF Signal input ADDR L E idTag MC3 ADDR H 4 OUTPUTS VIN Core microcontroller INPUTS an DIN Memory GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED IQAN MC3 3 Product description Inputs All of the 32 inputs on the IQAN MC3 can be used for safety related signals when the inputs are configured in pairs On the unit there are 16 analog inputs for 0 5 V signals from e g hall effect or potentiometer sensors 8 digital inputs for e g switches and 8 frequency inputs for e g reading signals from quadrature encod
50. he source of the signal e g sensor Pairs of signals may be used either asafully redundant structure IN 1 OUTPUT IQAN MC3 SUBSYSTEM IN2 eg valves Fully redundant structure e or as a single channel that performs the safety function combined with a monitoring channel IN 1 OUTPUT IQAN MC3 SUBSYSTEM i IN 2 g valves Single structure with monitoring by separate signal 11 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety The fully redundant structure for input signals is recommended since it normally yields a higher performance level for the sensor arrangement The IQAN MC3 will accept any of the two structures above for all I O types The single channel structure illustrated below is only allowed for VIN but it is recommended to avoid this since it normally yieds a low performance level on the input subsystem IN 1 OUTPUT IQAN MC3 SUBSYSTEM Not recommended e g valves i Single structure with limited or no monitoring Avoid the single structure without monitoring in safety functions
51. hen the output is off in this state only the leakage current is delivered see Appendix A on page 45 Minimum current when using DOUT as power driver MC3 SMR 015 A Minimum current when using DOUT as power driver When the load connected to the DOUT is capable of initiating a hazardous movement it shall be designed so that it is only activated if the current is gt 50 mA This is to ensure that there is no movement when the output is off DOUT used as alarm driver in a safety function The safe state has to apply also when a DOUT is used as an alarm to inform the operator about a hazardous situation The IQAN MC3 can not guarantee that the alarm is working but when the DOUT is off it is capable of detecting if the load is connected This can be used by the application to activate another alarm or to shut down the power drivers or both to ensure a safe state MC3 SMR 016 A DOUT used as alarm drivers When DOUT is used to implement a safety related alarm function the application shall be designed so that it does not rely on a single alarm The application shall also be designed so that shutdown of the complete unit also inhibits the hazard that the alarm is intended to give a warning about You should also note that there are wiring errors that can only be detected on start up of the unit Undetected wiring faults There are DOUT wiring faults that are not detectable by the IQAN MC3 and there are faults that are only detecte
52. ia aee legs ird od eeu eorr eee a a 13 Internal diagnostics 14 Certificates is bei ERA eee Rara s eed a RP gea d 15 5 Mounting See wa wees erue EE e Emm E Exe xm ER Nes a 19 Mounting the module 19 6 Installation 4 2 R RR ERRER ERER fx RKR ee eee eee 20 Connectors C1 C4 ern 20 Connector C1 pin assignments 20 Connector C2 pin assignments 21 Connector C3 pin assignments 22 Connector C4 pin assignments 23 UG configuration 24 Supply voltage 24 Emergency stop 24 Connecting of Supply Voltage 25 Reverse teed sues sb Re Rea eR E x RE RE Rd Ra ERREUR a 25 IQAN MC3 addressing terminating 25 Use of an ID Tag 25 Terminating esee ek ey ub a wee e RR E RC E OR E E ER N 26 7 VOfunctionality 27 INPUIS 1 ius eG ee xA RR ARI RE Ede 2 a an dee dere dee 27 Voltage inputs 27 Using voltage inputs in safety functions sssaaa annee 28 Digital Inputs 2s 00 a0 eee eek eel eee due eee deed eee her he l
53. ion enabled Failure mode Detected Comment DOUT open DRET open DOUT A C short circuit to BAT Detection is limited to this output Reverse feed is not detected DOUT D E short circuit to BAT Reverse feed No influence on function in this state DOUT short circuit to BAT Detected or fuse blows DOUT short circuit to DRET Detected or fuse blows DOUT over current DRET short circuit to BAT Detected or fuse blows Detection is limited to this output Reverse feed is not detected DRET short circuit to BAT No influence on function in this state DOUT short circuit to 2 DOUT No influence on function in this state DOUT short circuit to 2 COUT No influence on function in this state DOUT short circuit to 2 9 CRET active No influence on DOUT error detected on 2 4 COUT DOUT short circuit to 2 DRET active DOUT short circuit to 2 CRET DRET passive No influence on function in this state DRET short circuit to 2 DRET active No influence on function in this state DRET short circuit to 2 4 CRET active No influence on DOUT error detected on 2 4 COUT DRET short circuit to 27d CRET DRET passive No influence on function in this state Insufficient voltage on BAT 58 RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresou
54. mits can lead to an unintentional change of speed of the output and must be safe in the application for which the IOAN MC3 is used MC3 SMR 013 A COUT error detection limits The application shall be designed so that changes of output current up to the undercurrent and overcurrent threshold are safe During normal operation when there is no fault the accuracy is significantly better than the error detection limits Undetected wiring faults There are COUT wiring faults that are not detectable by the IOAN MC3 see Appendix B on page 50 All types of wiring faults must be considered to ensure that the failures are safe in the application MC3 SMR 014 A COUT undetected wiring faults The application shall be designed so that undetected wiring errors on COUT are safe You should also note that there are wiring errors that can only be detected on start up of the unit 37 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Proportional outputs 7 VO functionality Limits on COUT adjustable parameters The COUT current range and slopes must be limited in the application file Due to the risks involved with modifying these adjustable values it is recommended that these limits are kept narrow Alternatively the access to modification of current range and slopes can
55. ng measuring accessing logs and otherwise checking the performance or troubleshooting your control system CAN diagnostics connection One of the 4 CAN buses of the IQAN MC3 may be dedicated for diagnostics Reserving a bus for diagnostics ensures that signals are not interrupted by other bus traffic A high speed CAN interface is needed to use this feature Contact Parker for information about supported CAN interfaces A termination resistor is usually required at the CAN interface on the PC Parker part number 5030182 or an equivalent 120 ohm resistor may be used A flying lead cable may be connected to the IQAN MC3 to provide a connector interface The connection from IQAN MC3 to diagnostic CAN interface can then be made quite easily It is recommended that the diagnostic connector be a sealed automotive type When not being used this connector should be protected from the environment with a cover or mating blank plug The recommended wiring to the IOAN MC3 connector C1 is shown below IQAN MC3 Customer 120 ohm specified resistor connector Connecting for CAN to PC communication Bypass application If the ADDR L pin is shorted to ADDR H detected when the unit starts powers up the application will not be loaded This is a special start up mode that is used for master units and puts the MC3 in a safe state without starting any application When this mode is desired a jumper is put in place of an ID Tag 44
56. of DIN inputs in pairs 31 MC3 SMR 010 A Use of FIN inputs in pairs sese eee eee eee 32 MC3 SMR 011 A Use of DFIN inputs in pairs 33 MC3 SMR 012 A Minimum current when using COUT as power driver 37 MC3 SMR 013 A COUT error detection limits 37 MC3 SMR 014 A COUT undetected wiring faults 37 MC3 SMR 015 A Minimum current when using DOUT as power driver 40 MC3 SMR 016 A DOUT used as alarm ders sees 40 MC3 SMR 017 A DOUT undetected wiring faults 40 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Parker Hannifin Electronic Controls Division SE 435 35 M lnlycke Sweden Tel 46 31 750 44 00 Fax 46 31 750 44 21 www parker com For the latest information visit our website www iqan com RESOURCES Publ no HY33 8001 IB UK Edition 2013 05 17 Parker Hannifin Electronic Controls Division 1651 N Main Street Morton IL 61550 USA Tel 1 309 263 7788 Fax 1 309 266 6674 Information in this instructionbook is subject to change without notice GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED
57. ol SAE J1939 or Generic user defined CAN protocol e g CANopen Communication The communication interfaces are used for uploading downloading applications or diagnostics when connected to a computer It is recommended to reserve one of the CAN buses for communication and diagnostics A CAN communication card is required to be installed in your PC to use this feature Please contact Parker for a list of CAN cards that are currently supported GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety 4 Safety Safety concept All IQAN modules are designed for controlling hydraulic implements on mobile machines and when basic safety principles are observed they can be used for normal functions The IQAN MC3 is designed in accordance with IEC 61508 for use in applications with higher demands on functional safety When there is a need to prove the safety integrity of each implemented safety function the unit can be used for functions with a maximum safety integrity of SIL2 Safe state The safety analysis of the IQAN MC3 is done under the assumption that the system is in a safe state when the controller is off WARNING System design must not allow any unintentional movement when the unit is off MC3 SMR 003 A Safe state The application shall be d
58. ontrol system Read the relevant sections of this document before conducting any work on the control system MC3 SMR 001 A Use within specification The product shall only be used within its specified range WARNING This product is not field repairable MC3 SMR 002 A No field repair A damaged product shall not be used and may only be repaired by the manufacturer NOTICE As much as possible of the welding work on the chassis should be done before the installation of the system If welding has to be done afterwards the electrical connections on the system must be disconnected from other equipment The negative cable must always be disconnected from the battery before disconnecting the positive cable The ground wire of the welder shall be positioned as close as possible to the place of the welding The cables on the welding unit shall never be placed near the electrical wires of the control system Read This Design of control system WARNING A Risk of injury may be introduced by design of control system This product is designed to control hydraulic outputs The control application must be designed using basic safety principles so that unintentional movement is avoided The machine must be equipped with an emergency stop that stops all movement Please refer to section Emergency stop on page 24 Before you start Read this document as a minimum sections 1 7 Read the IQANdesign software user manual section on
59. ources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Inputs 7 VO functionality 7 WO functionality This section contains information about how to connect and use the I O with specific additional information about rules that apply when the I O is used in a safety function Inputs There are 3 types of inputs in the IQAN MC3 Voltage inputs Digital inputs Frequency inputs Voltage inputs Connecting sensors to the voltage inputs The range of the voltage inputs is 0 5 Vdc For input characteristics see Appendix A In order to detect errors such as open circuit in the wiring the active signal range from the sensor must be limited e g 0 5 4 5 Vdc VIA B T Error detection range L TTT V f Active signal range t 0 Error detection range Active signal range The positive terminal of the sensor is connected to the VREF position and the corresponding negative terminal to the VREF position The sensor signal is connected to appropriate VIN position EXAMPLE Connect the positive and negative terminals of the position sensor to VREF and VREE respectively Then connect the sensor signal to a VIN IQAN MC3 VREF e VIN e VREF Position Sensor Connecting VREF and sensor signal VIN 27 GLOBAL GS Global Resources 1 800
60. r IQANrun not started 6 ON Check via IQAN software all modules that Machine engine CAN connection is OK not started 7 ON Check via IQAN software all modules that Machine engine inputs are OK if not check the harness or not started re calibrate adjust the input signals 8 ON Check via IQAN software all modules that OmA Machine engine current out COUT is OmA when joystick is 0 not started not activated 9 OFF Check via IQAN software all modules that Machine engine current out COUT is OK use the joystick to not started command the outputs 10 ON Ensure that the following requirements are Machine engine fulfilled before any work is carried out on the not started hydraulics control electronics The machine cannot start moving Functions are positioned safely The machine is turned off The hydraulic system is relieved from any pressure 11 ON Check that electrical output signal correspond Start machine equal with hydraulic direction engine 12 OFF Tune current settings and slope times Engine ON 43 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Diagnostic interfaces 9 Diagnostics and troubleshooting 9 Diagnostics and troubleshooting Diagnostic interfaces IQAN software includes many tools for tuni
61. rces com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B On under current detection disabled Failure mode Detected Comment DOUT open No current through load DRET open No current through load DOUT short circuit to BAT Reverse feed No influence on function in this state DOUT short circuit to BAT Thermal shutdown or fuse blows DOUT short circuit to DRET Thermal shutdown or fuse blows DOUT over current s DRET short circuit to BAT N Detected or fuse blows Detection is limited to this output Reverse feed is not detected DRET short circuit to BAT No influence on function in this state DOUT short circuit to 2 DOUT No influence on function in this state DOUT short circuit to 2 COUT No influence on function in this state DOUT short circuit to 2 9 CRET active No influence on DOUT error detected on 2 COUT DOUT short circuit to 29 DRET active Thermal shutdown or fuse blows DOUT short circuit to 27 CRET DRET No influence on function in this state passive DRET short circuit to 2 9 DRET active No influence on function in this state DRET short circuit to 2 4 CRET active No influence on DOUT error detected on 2 d COUT DRET short circuit to 2 CRET DRET No influence on function in this state passive Insufficient voltage on BAT Under current 59
62. remost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Proportional outputs 7 VO functionality There are faults that are detected on startup and that will prevent the module from starting the application These are all faults where an output is connected to BAT on startup To detect these faults it is important that all connectors are plugged in before the module is started See section Start up on page 41 For details on failure modes see Appendix B on page 50 Reset of faults The reset behaviour of the COUT is configured in the application file see IQANdesign user manual Use of COUT in safety functions COUT safe state The COUT is assumed to be in a safe state when the output is off in this state only the leakage current is delivered see Appendix A on page 45 Minimum current MC3 SMR 012 A Minimum current when using COUT as power driver When the load connected to the COUT is capable of initiating a hazardous movement it shall be designed so that it is only activated if the current is gt 50 mA This is to ensure that there is no movement when the output is off Error detection limits The COUT has a separate built in monitoring that detects deviations from the commanded output current To avoid spurious trips it is designed to tolerate some deviation refer to under over current threshold see Appendix A on page 45 An undetected error that falls within these li
63. short circuit to signal lt low trigger level Frequency 0 DFIN short circuit to BAT Frequency 0 52 RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Failure modes for external wiring faults on power drivers COUT NOTICE o Failure modes for internal faults are included in the total PFHd for the module Key to symbols and conditions detection leads to the power driver being disabled Restart conditions are applicaton specific Start up When module is started all COUT and CRET are off a test pattern is applied to detect faults Off When power driver is off COUT is on and CRET is off On When power driver is on COUT is on and CRET is controlling the commanded current Disabled After an error is detected both COUT and CRET are off No diagnostic is performed until there is an attempt to reactivate the output Restart condtions are application specific Reverse feed of the module Ability to shut down module via BAT inhibited Ability to shut down in the event of an internal error reduced Detected at next start up Current output Start up Failure mode Detected Comment COUT short circuit to BAT at start up N Module prevented from starting CRET short circuit to BAT at start up N
64. subsystems shall conform to the relevant requirements of EN 61508 Miscellaneous The manufacturer s information in English on installation and safety has been inspected and found to fulfil the relevant requirements of the Directive Validity This certificate was first issued on 11 April 2013 and remains valid as long as the conditions laid down in the specification s in reference are not modified significantly or at the latest until 11 April 2018 This is the first issue M nsson an Jacobson fifipati n Manager Certification Officer SP Technical Research Institute of Sweden Postal address Phone Fax Reg number Email internat Swedish Notified Bodies are appointed by SWEDAC the Swedish Board for Accreditation and SP 46 10516 5000 556464 5874 info sp se Conformity Assessment under the terms of Swedish legislation Box 857 446 33 13 55 02 www sp se This certificate may not be reproduced other than in full except with the prior written approval SE 501 15 Boras by SP SWEDEN 17 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 5 Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Certificates 4 Safety Declaration of Conformity According to EC Machinery directive 2006 42 EC We Parker Hannifin Manufacturing Sweden AB Electronic Controls Division Located at M lnlycke Fabriker 14 S 435
65. tem consists of the sensors or operator controls that initiate the safety function To get sufficient diagnostics on the inputs on the MC3 the requirements of that input type must be satisfied see section I O functionality on page 27 For most input types there is a requirement to always use the signal in pair with a secondary redundant signal The IQAN MC3 is suitable for connection to input subsystems of category 2 3 or 4 in accordance with EN ISO13849 1 up to PLd If inputs are connected as a Category B subystem that will restrict the overall PL to a lower level A category 1 subsystem is excluded because the unit is requiring simple electrical inputs connected to DIN to be used in pair with a diagnostic signal GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety Sensors MC3 IRSE AY m BA wey M EE DIN Signal L EM Conditioning Internal ue CORE diagnostics 1 l DIN Signal Pg Conditioning i E L L E N I EE EIT odor EE 2 Diagnostics performed in the application The IQAN MC3 module and input subsystem diagnostics It can also be used for input subsystems of up to SIL2 in accordance with EN IEC 62061 for subsystems type C zero fault
66. the cabling cannot pull twist or induce sideload on the con nector Locate the module so that severe physical impact is avoided e g impact from falling objects or the module being used as a step Locate the module so that air can circulat to eliminate excess heat Ensure that no external heat e g from the engine or heater is transferred to the module Locate the module to protect it from high pressure washing or similar For maximum cooling mount the module on a vertical surface Locate the module so that the LEDs are visible Recommended placing NOTICE Q The IQAN MC3 module must not be placed in any marine related or similar continuously damp salt spray environment without external protection 19 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Connectors C1 C4 6 Installation 6 Installation Connectors C1 C4 Connector C1 pin assignments Connector kit Parker no 5035016 Housing Deutsch no DT16 18SAK004 Pin types 1062 16 0644 Cables 0 75 mm 18 AWG Plugs empty pos Deutsch no 114017 Deutsch crimping DTT 20 00 tool reference Prototype cable Parker no 5030216 a Kit contains parts for all 4 connectors
67. tion carefully e n addition to these measures the machine shall also meet the machine directives for the country in question WARNING Work on the hydraulics control electronics may only be carried out by trained personnel who are well acquainted with the control system the machine and its safety regulations 42 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Check list for electronics 8 Start up Check list for electronics The following table has a list of steps which is a suggested guideline for the commissioning of an electronic control system on a machine Condition Task to be performed Limit v 1 OFF Measure the resistance of all ground connec lt 0 5 OFF no power tions between battery ground and BAT for all ohm supplied to control modules sensors measure in system har system harness ness no modules connected 2 ON Measure all power supply s to each module 12V Machine engine sensor measure in system harness no mod or not started ules connected 24V 3 OFF Connect all units to system harness Machine engine not started 4 ON Emergency stop check that all modules get OV Machine engine disconnected from the power BAT not started 5 OFF Connect PC with IQAN software IQANdesign Machine engine o
68. tion please refer to the IQANdesign user manual 25 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED IQAN MC3 addressing terminating 6 Installation The maximum number of addresses is eight denoted as addresses 0 1 2 3 4 5 6 7 respectively In order to assign any MC3 module a unique address the D tag will have to be connected to the positions ADDR H and ADDR L IQAN MC3 ADDR H m ADDR L Connecting of Id Tag Terminating To eliminate interference in the communications through the CAN bus the CAN bus must be terminated By default the MC3 is terminated internally on all of its CAN buses When an IQANdesign application is loaded it can set individual buses to be non terminated Togive an IQAN MC3 a unique address you may use an addressing ID tag or an ID tag having a combined address and terminating function The T values of ID tags are ignored i e an ID tag OT is equivalent to ID tag 0 If the module is located at the end of the CAN bus then leave the bus default terminated in the MC3 NOTICE Q The CAN bus should not be terminated at the MC3 using an external regular terminating resistor due to the fact that terminating is made from within the MC3 module by default 26 GLOBAL GS Global Res
69. ty Digital inputs The digital inputs can be connected to vehicle power i e BAT or VREF For digital input characteristics see Appendix A on page 45 Connecting switches to the digital inputs The switch would be powered by BAT when it is desired to conserve VREF for powering sensors and joysticks EXAMPLE Connect the positive and negative terminals of the switch to BAT and a DIN respectively Vv IGAN MC3 DIN Connecting a switch to DIN Using digital inputs in safety functions The following addional information applies when the inputs are used in safety functions where an incorrect input signal can lead to an immediate increase of the risk MC3 SMR 009 A Use of DIN inputs in pairs When digital inputs are used in safety functions the application shall be designed so that the input signals are compared to an additional signal to ensure that it is correct If the additional signal is read by another digital input it is recommended that the signals are not equal For example use linked normally open and normally closed switches 31 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Frequency inputs 7 VO functionality Frequency inputs Connecting sensors to the frequency inputs Frequency inputs can
70. ty related Logs LED diagnostics NOTICE Q The IQAN MC3 does not come with any pre existing safety function implemented An application file must always be created in IQANdesign before the module can be used GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Safety concept 4 Safety The IQAN MC3 provides some diagnostic features related to the interface with sensors and actuators valves However sensors actuators and wiring must be analyzed separately for their suitability to be used in safety functions The internal diagnostics of the IQAN MC3 as well as built in diagnostics on I O are dependent on the system cycle time a longer system cycle will in some cases delay the diagnostics MC3 SMR 004 A System cycle time The application shall be designed so that the system cycle time is 5096 of the maximum allowable error detection time Architecture for a complete safety function When analyzing a safety function the IQAN MC3 can be modeled as a safety related sub system With this approach there would also be at least one safety related input subsystem e g sensors and a safety related output subsystem e g valves Input IQAN MCS3 Output subsystem subsystem subsystem The IQAN MC3 module as subsystem Input subsystem The input subsys
71. uced other than in full Box 857 46 10 516 50 00 556464 8874 info sp se except with the prior written approval by SP SE 501 15 Bor s 46 33 13 55 02 Www 5p 58 SWEDEN 16 GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 5 Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Certificates 4 Safety No SC053 gt 13 EC Type Examination Certificate Electrohydraulic Control System IQAN MC3 Holder Issued to Manufacturer Parker Hannifin Manufacturing Sweden AB Box 222 M lnlycke Fabriker 14 SE 435 35 M lnlycke Sweden Product description and product identification Electrohydraulic Control System IQAN MC3 Hardware item number B5010065 Software version 3 00 Technical documentation The manufacturer s technical documentation latest dated 27 September 2012 Certification SP Technical Research Institute of Sweden hereby certifies that the manufacturer s technical file and the product have been inspected in accordance with the procedure described in Directive 2006 42 EG the Machinery Directive annex LX and found to fulfil the requirements in respect of products listed in annex 4 paragraph 21 Logic units to ensure safety functions The certification is verified by a type test in accordance with EN 61508 SIL 2 According to EN 62061 the design of complex programmable electronic
72. uency Forty 71 77 83 90 100 111 125 167 200 250 333 Hz Leakage current in OFF state 100 UA Maximum load 2A Maximum allowable load inductance 1 0 A load 500 mH 1 5 A load 200 mH 2 0A load 50 mH Protection SCB SCG Diagnostics Operational ON SCG SCB Operational OFF open load SCG Open load threshold gt 50 kohm when PWMOUT is OFF Power driver DOUT Number of DOUT 5 Maximum load DOUT A to DOUT C 3 0A DOUT D to DOUT E 1 5A Power driver voltage drop DOUT A to DOUT C typ 0 70 V 3A load DOUT D to DOUT E typ 0 90 V Q 1 5 A load Leakage current in OFF state DOUT A to DOUT C 2 mA DOUT D to DOUT E 100 HA Maximum allowable load inductance DOUT A to DOUT C 1 0 A load 500 mH 2 0 A load 200 mH 3 0 A load 50 mH Maximum allowable load inductance DOUT D to DOUT E 1 0 A load 500 mH 1 5 A load 200 mH Protection overload SCB SCG GLOBAL RESOURCES Foremost in Machine Performance for Life GS Global Resources 1 800 261 8735 gsglobalresources com 5050 S Towne Drive New Berlin WI 53151 GS GLOBAL REOURCES INC ALL RIGHTS RESERVED 48 IQAN MC3 Technical Overview Appendix A Power driver DOUT Diagnostics Operational ON under current SCB Operational OFF open load SCG SCB Open load threshold gt 50 kohm or 100 pA when DOUT is OFF Undercurrent threshold lt 300 mA when DOUT is ON
73. y if valid signal range is limited Digital input Failure mode Detected Comment DIN open Input low DIN short circuit to BAT Input high DIN short circuit to signal high trigger Input high level DIN short circuit to signal within low to Undefined input high or low high trigger level range DIN short circuit to signal low trigger Input low level DIN short circuit to BAT Input low SL GLOBAL GS Global Resources 1 800 261 8735 gsglobalresources com RESOURCES 5050 S Towne Drive New Berlin WI 53151 Foremost in Machine Performance for Life GS GLOBAL REOURCES INC ALL RIGHTS RESERVED Failure modes Appendix B Frequency input Failure mode Detected Comment FIN open Frequency 0 FIN short circuit to BAT Frequency 0 FIN short circuit to signal gt high trigger Frequency 0 level FIN short circuit to signal within low to Undefined high trigger level range FIN short circuit to signal lt low trigger Frequency 0 level FIN short circuit to BAT Frequency 0 Directional frequency input Failure mode Detected Comment DFIN open Frequency 0 DFIN short circuit to BAT Frequency 0 DFIN short circuit to signal gt high trigger level Frequency 0 DFIN short circuit to signal within low to high trigger level range Undefined DFIN

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