PROGRAMMABLE CONTROLLER FP-Safe

Copyright © 2010. All rights reserved. Specifications are subject to change without notice. Printed in Europe. ACGM0146V1EN 7/2010

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Headquarters Panasonic Electric Works Europe AG Rudolf-Diesel-Ring 2, 83607 Holzkirchen, Tel. +49 (0) 8024 648-0, Fax +49 (0) 8024 648-111, www.panasonic-electric-works.com

Austria Panasonic Electric Works Austria GmbH Rep. of PEWDE, Josef Madersperger Str. 2, 2362 Biedermannsdorf, Tel. +43 (0) 2236-26846, Fax +43 (0) 2236-46133, www.panasonic-electric-works.at

PEW Electronic Materials Europe GmbH Ennshafenstraße 30, 4470 Enns, Tel. +43 (0) 7223 883, Fax +43 (0) 7223 88333, www.panasonic-electronic-materials.com

Benelux Panasonic Electric Works Sales Western Europe B.V.

De Rijn 4, (Postbus 211), 5684 PJ Best, (5680 AE Best), Netherlands, Tel. +31 (0) 499 372727, Fax +31 (0) 499 372185, www.panasonic-electric-works.nl

Czech Republic Panasonic Electric Works Czech s.r.o. Prumtyslová 1, 34815 Planá, Tel. (+420-)374799990, Fax (+420-)374799999, www.panasonic-electric-works.cz

France Panasonic Electric Works Sales Western Europe B.V.

Succursale française, 10, rue des petits ruisseaux, 91371 Verrières le Buisson, Tél. +33 (0) 1 6013 5757, Fax +33 (0) 1 6013 5758, www.panasonic-electric-works.fr

Germany Panasonic Electric Works Europe AG Rudolf-Diesel-Ring 2, 83607 Holzkirchen, Tel. +49 (0) 8024 648-0, Fax +49 (0) 8024 648-111 www.panasonic-electric-works.de

Hungary Panasonic Electric Works Europe AG Magyarországi Közvetlen Kereskedelmi Képviselet, 1117 Budapest, Neumann János u. 1., Tel. +36(0)1482 9258, Fax +36 (0) 1482 9259, www.panasonic-electric-works.hu

Ireland Panasonic Electric Works UK Ltd. Dublin, Tel. +353 (0) 14600969, Fax +353 (0) 14601131, www.panasonic-electric-works.co.uk

Italy Panasonic Electric Works Italia s.r.l. Via del Commercio 3-5 (Z.I. Ferlina), 37012 Bussolengo (VR), Tel. +39 (0) 456752711, Fax +39 (0) 456700444, www.panasonic-electric-works.it

Nordic Countries Panasonic Electric Works Nordic AB Sjöängsvägen 10, 19272 Sollentuna, Sweden, Tel. +46 859476680, Fax +46 859476690, www.panasonic-electric-works.se

PEW Fire & Security Technology Europe AB Jungmansgatan 12, 21119 Malmö, Tel. +46 40697-7000, Fax +46 40697-7099, www.panasonic-fire-security.com

Poland Panasonic Electric Works Polska sp. z o.o. Al. Krakowska 4/6, 02-284 Warszawa, Tel. +48 (0) 22 338-11-33, Fax +48 (0) 22 338-12-00, www.panasonic-electric-works.pl

Portugal Panasonic Electric Works España S.A. Portuguese Branch Office, Avda Adelino Amaro da Costa 728 R/C J, 2750-277 Cascais, Tel. +351 214812520, Fax +351 214812529

Spain Panasonic Electric Works España S.A. Barajas Park, San Severo 20, 28042 Madrid, Tel. +34 913293875, Fax +34 913292976, www.panasonic-electric-works.es

Switzerland Panasonic Electric Works Schweiz AG Grundstrasse 8, 6343 Rotkreuz, Tel. +41 (0) 417997050, Fax +41 (0) 417997055, www.panasonic-electric-works.ch

United Kingdom Panasonic Electric Works UK Ltd. Sunrise Parkway, Linford Wood, Milton Keynes, MK14 6 LF, Tel. +44(0) 1908 231555, +44(0) 1908 231599, www.panasonic-electric-works.co.uk

North & South America

USA PEW Corporation of America 629 Central Avenue, New Providence, N.J. 07974, Tel. +1-908-464-3550, Fax +1-908-464-8513, www.pewa.panasonic.com

Asia Pacific / China / Japan

China Panasonic Electric Works (China) Co., Ltd. Level 2, Tower W3, The Tower Oriental Plaza, No. 2, East Chang An Ave., Dong Cheng District, Beijing 100738, Tel. (010) 5925-5988, Fax (010) 5925-5973, www.pewc.panasonic.cn

Hong Kong Panasonic Electric Works (Hong Kong) Co., Ltd.

RM1205-9, 12/F, Tower 2, The Gateway, 25 Canton Road, Tsimshatsui, Kowloon, Hong Kong, Tel. (8520) 2956-3118, Fax (0852) 2956-0398

Japan Panasonic Electric Works Co., Ltd. 1048 Kadoma, Kadoma-shi, Osaka 571-8686, Japan, Tel. (06)-6908-1050, Fax (06)-6908-5781http://panasonic-electric-works.net

Singapore Panasonic Electric Works Asia Pacific Pte. Ltd. 101 Thomson Road, #25-03/05, United Square, Singapore 307591, Tel. (06255)-5473, Fax (06253)-5689

China

Panasonic Electric Works Global Sales Companies

FP-Safe User’s M

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M0146V1EN

7/2010

PROGRAMMABLE CONTROLLER

FP-SafeUser’s Manual

BEFORE BEGINNING

Liability and Copyright for the Hardware

This manual and everything described in it are copyrighted. You may not copy this manual, in whole or part, without written consent of Panasonic Electric Works Europe AG (PEWEU).

PEWEU pursues a policy of continuous improvement of the design and performance of its products. Therefore we reserve the right to change the manual/product without notice. In no event will PEWEU be liable for direct, special, incidental, or consequential damage resulting from any defect in the product or its documentation, even if advised of the possibility of such damages.

We invite your comments on this manual. Please e-mail us at:

[email protected].

Please direct support matters and technical questions to your local Panasonic representative.

LIMITED WARRANTY

If physical defects caused by distribution are found, PEWEU will replace/repair the product free of charge. Exceptions include:

When physical defects are due to different usage/treatment of the product other than described in the manual.

When physical defects are due to defective equipment other than the distributed product.

When physical defects are due to modifications/repairs by someone other than PEWEU.

When physical defects are due to natural disasters.

Important Symbols

One or more of the following symbols may be used in this documentation:

!

DANGER!

The warning triangle indicates especially important safety instructions. If they are not adhered to, the results could be fatal or critical injury.

CAUTION

Indicates that you should proceed with caution. Failure to do so may result in injury or significant damage to instruments or their contents, e.g. data.

� NOTE

Contains important additional information.

� EXAMPLE

Contains an illustrative example of the previous text section.

1.2.3.

Procedure

Indicates that a step-by-step procedure follows.

REFERENCE

Indicates where you can find additional information on the subject at hand.

FP-Safe User's Manual

Table of Contents

iii

Table of Contents

1.

2.

Important Preliminary Information........................................1

1.1 Declaration of Conformity .......................................................................... 2

1.2 Safety Instructions ..................................................................................... 4

1.3 Proper Use, Disposal................................................................................. 5

Hardware .................................................................................7

2.1 Available Units ........................................................................................... 8

2.1.1 Product Description.................................................................................... 9

2.2 Individual Units ........................................................................................ 10

2.2.1 Controller Unit .......................................................................................... 10

2.2.2 Motion Monitoring Unit ............................................................................. 10

2.2.3 Relay Expansion Unit............................................................................... 11

2.2.4 Transistor I/O Expansion Unit .................................................................. 11

2.3 Troubleshooting....................................................................................... 13

2.4 Inputs and Outputs .................................................................................. 14

2.4.1 Inputs........................................................................................................ 14

2.4.1.1 Inputs for Safety-Related Functions................................................ 14

2.4.1.2 Inputs for Two-Hand Control ........................................................... 14

2.4.1.3 Inputs for Operation Mode Switches (OMS) ................................... 15

2.4.1.4 Using Proximity Switches to Record Machine Motion .................... 15

2.4.1.5 Using Incremental Measurements to Record Motion...................... 15

2.4.1.6 Brake Monitoring with the Motion Monitoring Unit .......................... 16

2.4.1.7 Direction Monitoring with the Motion Monitoring Unit ..................... 17

2.4.1.8 Inputs for Rotation Speed Monitoring ............................................. 17

2.4.2 Outputs..................................................................................................... 17

Table of Contents FP-Safe User's Manual

iv

2.4.2.1 Output Structure ..............................................................................18

2.4.2.2 Safety Outputs on the Controller Unit .............................................19

2.4.2.3 Relay Outputs on the Relay Expansion Unit...................................19

2.5 Installation and Removal ..........................................................................20

2.6 Technical Data .........................................................................................22

2.6.1 General Specifications .............................................................................22

2.6.2 Controller Unit ..........................................................................................23

2.6.3 Motion Monitoring Unit .............................................................................23

2.6.4 Relay Expansion Unit ...............................................................................23

2.6.5 Transistor I/O Expansion Unit ..................................................................24

2.6.6 Dimensions...............................................................................................24

3.

4.

Introduction to the Configuration Software....................... 25

3.1 System Requirements ..............................................................................26

3.2 User Interface...........................................................................................27

3.2.1 Hardware Configuration ...........................................................................28

3.2.2 Circuit Diagram.........................................................................................29

3.2.3 Unit Toolbars ............................................................................................29

3.2.4 Explanation of Toolbar Icons....................................................................31

3.2.5 Connecting the Icons in the Circuit Diagram............................................35

3.3 Creating an Application ............................................................................40

3.4 Print Application .......................................................................................41

3.5 Menus.......................................................................................................42

3.5.1 "Parameters" Menu ..................................................................................42

3.5.2 "Project" Menu..........................................................................................42

3.5.3 "Download" Menu.....................................................................................43

Configuring Parameters ...................................................... 45

4.1 Available Unit Parameters........................................................................46

FP-Safe User's Manual Table of Contents

4.2 Controller Unit Timer................................................................................ 48

4.2.1 Off-Delayed Timers .................................................................................. 48

4.2.2 On-Delayed Timers .................................................................................. 49

4.2.3 Creating a Timer ...................................................................................... 50

4.3 Motion Monitoring .................................................................................... 51

4.3.1 Motion Monitoring with the Controller Unit ............................................... 51

4.3.1.1 Using Proximity Switches to Record Machine Motion .................... 51

4.3.1.2 Configuring Motion Monitoring ........................................................ 52

4.3.1.3 Virtual Output Function at Monitoring Points 1 and 2 ..................... 52

4.3.1.4 Creating a Motion Monitoring Point................................................. 53

4.3.2 Brake Monitoring with the Motion Monitoring Unit ................................... 54

4.3.2.1 Operation Modes for Motion Monitoring.......................................... 55

4.3.2.2 Creating a Motion Monitoring Point................................................. 56

4.4 Additional Monitoring Functions............................................................... 59

4.4.1 Position Monitoring................................................................................... 59

4.4.2 Direction Monitoring ................................................................................. 61

4.4.3 Brake Monitoring ...................................................................................... 61

4.5 Using Inputs............................................................................................. 62

4.5.1 Overview .................................................................................................. 62

4.5.2 Inputs for Safety-Related Functions......................................................... 63

4.5.2.1 Creating a Safety-Related Function................................................ 64

4.5.2.2 Antivalent Control Signals for Safety-Related Functions ................ 66

4.5.2.3 Acknowledgement........................................................................... 67

4.5.2.4 Emergency Stop Function............................................................... 68

4.5.2.5 Automatic Emergency Stop at Machine Error................................. 69

4.5.2.6 Protection Cover / Safety Door Function ........................................ 70

4.5.2.7 Permission Switch........................................................................... 71

4.5.3 Inputs for Two-Hand Control .................................................................... 72

4.5.4 Inputs for Operation Mode Switches (OMS) ............................................ 73

4.5.5 Inputs for Rotation Speed Monitoring ...................................................... 75

4.6 Using Outputs .......................................................................................... 77

4.6.1 Overview .................................................................................................. 77

4.6.2 Safety Outputs on the Controller Unit ...................................................... 77

v

Table of Contents FP-Safe User's Manual

vi

4.6.3 Relay Outputs on the Relay Expansion Unit ............................................77

4.6.4 Configurable Outputs ...............................................................................78

4.6.4.1 Controller Unit .................................................................................78

4.6.4.2 Motion Monitoring Unit ....................................................................78

4.6.4.3 Transistor I/O Expansion Unit .........................................................79

4.6.5 Configuring Outputs .................................................................................80

4.7 Sample Application...................................................................................82

5. Rack Diagnosis Program..................................................... 85

5.1 Introduction...............................................................................................86

5.2 User Interface...........................................................................................87

5.2.1 Diagnosis Menu........................................................................................87

5.2.2 Rack Illustration........................................................................................88

5.2.3 Enlarged View of the Selected Unit..........................................................89

5.2.4 Status Information Screen........................................................................89

5.2.4.1 Controller Unit .................................................................................90

5.2.4.2 Motion Monitoring Unit ....................................................................91

5.2.4.3 Relay Expansion Unit ......................................................................92

5.2.4.4 Transistor I/O Expansion Unit .........................................................92

5.2.5 Unit Illustrations: What to Watch For........................................................93

5.3 Starting a Diagnosis .................................................................................94

5.3.1 Error Diagnosis.........................................................................................95

5.3.2 History ......................................................................................................96

5.4 Error Codes ..............................................................................................97

Index .......................................................................................... 101

Record of Changes

Chapter 1

Important Preliminary Information

Important Preliminary Information FP-Safe User's Manual

1.1 Declaration of Conformity

Document No. D10-EUA-PLC05-00

Manufacturer's name and address

Panasonic Electric Works Europe AG ACD Automation Control Devices Division Rudolf-Diesel-Ring 2, D-83607 Holzkirchen

Object of the declaration

Product: Safety units

Trade name: Panasonic

Model No.: AFSC series (FP-Safe)

The object of the declaration described above is in conformity with the requirements of the following EU legislation and harmonized standards:

Council directive: 2006/42/EC; 2004/108/EC

Council recommendation: None

Harmonized standards: EN 55011:2007 + A2:2007; EN61000-6-2:2005; EN62061:2009; EN574:1996 + A1:2008;

Additional information:

Year of CE marking: 2010

EC Type examination: BG No.: ET 10149 dated July 2010, by DGUV, Gustav-Heinemann-Ufer 130, D-50868 Köln, ID No: 0340

Low voltage directive (2006/95/EC):

The essential safety requirements are met by conforming EN60947-5-1: 2004+A1:2009.

Serial number format: YYMMxxxx (xxxx beginning with No. 2001)

Signed for and on behalf of the manufacturer:

(authorized to compile the technical file)

Signature:

Printed name: Christoph Oehler

Title: Senior Manager

Place/Date of issue: Holzkirchen, 4 August 2010

2

FP-Safe User's Manual 1.1 Declaration of Conformity

FP-Safe: approved product list

Part number Description/Function

AFSC1605 FP-Safe controller unit

AFSCR1613 FP-Safe controller unit with relay expansion unit

AFSCP2410 FP-Safe controller unit with I/O expansion unit

AFSCRP2418 FP-Safe controller unit with relay expansion unit and I/O expansion unit

AFSCM2207 FP-Safe controller unit with motion monitoring unit

AFSCRM2215 FP-Safe controller unit with relay expansion unit and motion monitoring unit

AFSCPM3012 FP-Safe controller unit with I/O expansion unit and motion monitoring unit

AFSCWH3020 FP-Safe controller unit with relay expansion unit and I/O expansion unit and motion monitoring unit

� NOTE

All safety functions must be tested in the application.

The switch-off limits of the rotation speeds, and of any other speeds monitored, must be checked.

Safety-relevant cables must be laid in wiring ducts.

The requirements of the category cited can only be met when the controller's overall design has been validated.

3

Important Preliminary Information FP-Safe User's Manual

1.2 Safety Instructions

!

WARNING

This device may only be installed and commissioned by professional electricians or trained personnel who are familiar with these instructions and the associated regulations on occupational safety and accident prevention. Please adhere to all national and regional regulations, especially those regarding safety precautions.

Failure to comply with safety regulations can result in death, severe injury, or extensive damage to equipment.

All safety functions must be tested in your application.

The switch-off limits of the rotation speeds, and of any other speeds monitored, must be checked.

Safety-relevant cables must be laid in wiring ducts.

For emergency stop applications, you must either (a) use the restart lockout, or (b) use a higher-level controller to prevent automatic restart of the machine.

For transport, storage, and machine operation, you must adhere to the regulations specified in EN 60068-2-1, 2-2!

All guarantees become null and void should the device be tampered with in any way. Improper use of the device can result in severe injury or even death.

Install the device in a switching cabinet with a minimum of IP54 degree of protection! Failure to comply can cause dust and moisture buildup, which may impair device performance. Installing the device in a switching cabinet is mandatory.

Ensure there is adequate protective circuitry at the output terminals for capacitive and inductive loads!

When mounting the device, adhere to the installation distances prescribed by DIN EN 50274, VDE 0660-514. During operation, the control units are subjected to hazardous voltage. Protection covers must not be removed during device operation.

Replace the device immediately after a malfunction has occurred as a result of defective hardware! In the case of system errors, a system message will specify whether the device must be replaced.

Keep these instructions in a safe place for reference!

4

FP-Safe User's Manual 1.3 Proper Use, Disposal

1.3 Proper Use, Disposal

The FP-Safe series is a product featuring safety-relevant functions for machines and equipment. You can use this product to monitor and control various machine or equipment functions.

� NOTE

The safety-related control functions fulfill the requirements of SIL CL 3 regarding safety integrity according to DIN EN 62061. The mean probability of hazardous failure per hour (PFHD) equals 6.24x10-8. The product can be used as a logic unit for two-hand control of type III C according to DIN EN 574.

The products fulfill the requirements of the current standards and directives listed in the documentation.

Disposal

Dispose of the device properly upon decommissioning!

5

Chapter 2

Hardware

Hardware FP-Safe User's Manual

2.1 Available Units

All products are delivered preassembled, including a rack.

Order number Units mounted on the rack Unit name

AFSC1605 Controller Unit FP-Safe Controller Unit

Controller Unit FP-Safe Controller Unit AFSCR1613

Relay Expansion Unit FP-Safe Relay Unit

Controller Unit FP-Safe Controller Unit AFSCP2410

Transistor I/O Expansion Unit FP-Safe Transistor I/O Unit

Controller Unit FP-Safe Controller Unit


AFSCRP2418


Controller Unit FP-Safe Controller Unit AFSCM2207

Motion Monitoring Unit FP-Safe Motion Monitoring Unit



AFSCRM2215




AFSCPM3012





AFSCWH3020


� NOTE

The controller unit has a V.24 interface (COM port) for data download.

8

FP-Safe User's Manual 2.1 Available Units

2.1.1 Product Description

The FP-Safe series comes in a metal housing (hereinafter called "rack") and can be installed on a DIN rail. The number of units mounted determines the width of the rack.

All units are interconnected via a redundant bus system on the bus card. LEDs display the status of inputs, outputs, and operating voltage.

FP-Safe function units Rack with FP-Safe controller unit Relay

expansion unit Transistor I/O expansion unit

Motion monitoring unit

9


2.2 Individual Units

The following units are available:

Controller Unit FP-Safe Controller Unit (see page 10)

Motion Monitoring Unit FP-Safe Motion Monitoring Unit (see page 10)

Transistor I/O Expansion Unit FP-Safe Transistor IO Unit (see page 11)

Relay Expansion Unit FP-Safe Relay Unit (see page 11)

2.2.1 Controller Unit

The controller unit has 16 redundant digital inputs for functions relevant to safety and non-safety, as well as 4 positive-switching, redundant outputs O2 to O5. Three further outputs can be freely configured.

The O1 output can be configured as a system-ready output, control output, or as a frequency input for single-channel rotation speed monitoring.

Outputs O6 and O7 can be configured as control or clock outputs.

LEDs display (see page 89) the switching status of the inputs and outputs.

Control unit connection diagram

2.2.2 Motion Monitoring Unit

The motion monitoring unit checks machine drives for position, direction of motion, various maximum speeds, and standstill. Brake monitoring is also integrated.

The motion monitoring unit can monitor 2 drives. An incremental measuring system monitors movement. Both TTL and sine/cosine signals can be processed (configure with FP-Safe Configurator).

HTL signals are connected to the measuring system using the connecting cable DNRJ 45-SL-HTL. The power supply voltage is accessed via terminals A1 and A2 on the controller unit.

The unit has 2 inputs for 2 incremental measuring systems, 6 digital redundant inputs for various safety and non-safety functions as well as 4 freely configurable, positive-switching outputs. The inputs are activated by 24V signals. The power supply voltage (24V DC) for the outputs is accessed via the P1 terminal for O1 and O3 and the P2 terminal for O2 and O4.

10

FP-Safe User's Manual 2.2 Individual Units

To configure safety or clock outputs, pair up as follows: O1 with O3 and O2 with O4. LEDs display the switching status of the inputs and outputs.

Connection diagram, motion monitoring unit for encoder

2.2.3 Relay Expansion Unit

The relay expansion unit offers 4 additional relay outputs with 2 safety contacts and 1 diagnosis contact each. LEDs display the switching status of the relay outputs.

Connection diagram, relay expansion unit

2.2.4 Transistor I/O Expansion Unit

The transistor I/O expansion unit has 8 safety digital inputs (see page 14) and 10 positive-switching, freely configurable outputs. The unit and the outputs O21 and O22 get their power from the power supply voltage terminals A1 and A2 on the controller unit. LEDs display the switching status of the inputs and outputs.

For outputs O11, O13, O15, and O17, the power supply voltage (24V DC) is accessed via terminal P1; for outputs O12, O14, O16, and O18, it is accessed via terminal P2.

For safety outputs, pair up as follows:

O11 with O12

O13 with O14

O15 with O16

O17 with O18

11


The inputs are activated by 24V signals.

Transistor I/O expansion unit

12

FP-Safe User's Manual 2.3 Troubleshooting

2.3 Troubleshooting

The following events indicate an error in the unit:

Output O1 turns off. The LED for O1 does not light up.

The LED on the left of the block does not light up. The LED on the right of the block flashes short/long.

Try the following to fix the error (see page 94):

Check the wiring

Check the configuration: Are the units in the rack correct, or have you opened a project with a different unit combination in FP-Safe Configurator?

To clear errors, switch the power off and then back on.

13


2.4 Inputs and Outputs

2.4.1 Inputs

The table shows the units and their available inputs. The inputs can be used for various functions, both relevant to safety and otherwise.

Unit Available inputs

Controller unit I1, I2, I3, I4, I5, I6, I11, I12, I13, I14, I15, I16, I17, I18, I19, I20

Motion monitoring unit B11, B12, B13, B14, B21, B22, B23, B24

Transistor I/O expansion unit I21, I22, I23, I24, I25, I26, I27, I28

2.4.1.1 Inputs for Safety-Related Functions

The following inputs can be used for safety-related functions (SRF). (Ack = Acknowledge input):

SRF1 SRF2 SRF3

Unit In1 In2 Ack In1 In2 Ack In1 In2 Ack

Controller unit I1 I2 I3 I4 I5 I6 I11 I12 I13

Motion monitoring unit B11 B12 B13 B21 B22 B23

Transistor I/O expansion unit I21 I22 I23 I25 I26 I27

SRF4 SRF5

Unit In1 In2 Ack In1 In2 Ack

Controller unit I15 I16 I17 I18 I19 I20

You can use these input groupings to configure:

Emergency stop function (see page 68)

Protection cover / safety door function (see page 70)

Permission switch (see page 71)

In1 and In2 can be activated statically with 24V DC or dynamically with the clock signal from FP-Safe.

With dynamic activation, the clock signal must be generated via 2 clock outputs in FP-Safe to ensure short-circuit protection.

2.4.1.2 Inputs for Two-Hand Control

The control terminals Ack1, In1, In2, and Ack2 can only be activated statically. You can configure the following inputs for two-hand control:

Unit In1 Ack1 In2 Ack2

Controller unit I1 I2 I3 I4

Motion monitoring unit B11 B12 B13 B14

Transistor I/O expansion unit I21 I22 I23 I24

14

FP-Safe User's Manual 2.4 Inputs and Outputs

2.4.1.3 Inputs for Operation Mode Switches (OMS)

For this safety function, only inputs I1 to I6 on the controller unit can be used. Operation mode switches can be used with 3 and 6 switching positions. Activation occurs statically. Only one switching position can be selected. In case of error, for example if more than one input is activated, the operation mode switch turns off all operation mode switch outputs. In such cases, no operation mode is active.

Set up this function in FP-Safe Configurator.

3 switching positions 6 switching positions

Unit 1 2 3 1 2 3 4 5 6


2.4.1.4 Using Proximity Switches to Record Machine Motion

This function is only available for the controller unit. Use inputs I11 to I14 to record the drive speed. Activation occurs via 24V signals, e.g. from proximity switches.

2 proximity switches and 2 inputs are required per drive.

Two axes can be monitored. I11 and I12 are for axis 1, I13 and I14 for axis 2.

The maximum input frequency is 1200Hz.

Axis 1 Axis 2

Unit In1 In2 Ack In1


2.4.1.5 Using Incremental Measurements to Record Motion


4V – 5V or 0,8 – 1Vss sin/cos

The motion monitoring unit can be used to monitor 2 axes in the various operation modes. You set up the operation modes in FP-Safe Configurator.

Operation mode selection for motion monitoring

Use the operation mode switch (OMS) to select the operation mode. To activate your drives, you must trigger the appropriate permission switches.

MM1 MM2 Function

MT1 MT2 Muting of operation modes. This input is used to mute motion monitoring in certain situations. The virtual standstill output is not affected.

F13 F23 Automatic mode

F12 F22 Semi-automatic mode

F11 F21 Setup mode

15


� NOTE

The virtual input priorities at monitoring point 1 (MM1) and monitoring point 2 (MM2) are as follows: MT1 / MT2 > F13 / F23 > F12 / F22 > F11 / F21 > standstill

Activation of the virtual inputs

Activation can occur via hardware inputs or virtual outputs in FP-Safe Configurator. You can use the following permission switches to activate the hardware inputs:

F11 / F21: inching function contact

F12 / F22: permission contact

F13 / F23: safety door contact

MT1 / MT2: muting contact

2.4.1.6 Brake Monitoring with the Motion Monitoring Unit

For brake monitoring, the virtual outputs at MM1 and at MM2 are used. You can use these virtual outputs to activate hardware outputs or virtual inputs.

The speed at both monitoring points is recorded in increments of 100ms over a 500-ms interval. After 500ms, the first value is overwritten.

Virtual outputs BR1 and BR2 have a LOW signal during:

Standstill

Constant speed

Acceleration

The outputs switch to a HIGH signal when the braking action reduces the speed by at least 5% within 500ms. The shortest response time is 100ms.

16


2.4.1.7 Direction Monitoring with the Motion Monitoring Unit

At MM1 and MM2, virtual output emits a HIGH signal at standstill and with an advancing sine wave, and a LOW signal with an advancing cosine wave. To define the preferred direction, use the hardware inputs and a logic operation in FP-Safe Configurator. The third input, "Mute", can be used to mute the function if necessary.

2.4.1.8 Inputs for Rotation Speed Monitoring

Unit Inputs


Motion monitoring unit B11 B12 B13 B14 B21 B22 B23 B24

Rotation speed monitoring can be used for up to 48 different speeds in the automatic mode, with 2 different drives operating at varying speeds. Two frequency tables are available: Rotation Speed Table 1 and Rotation Speed Table 2, each with up to 48 values. The frequency is selected via bit-coded switching of inputs I1 to I6 on the controller unit or B11 to B24 on the motion monitoring unit. Enter the frequencies to be monitored in the table. The following rotation speed monitoring options are available:

Number of speeds monitored

Selection via these inputs on the controller unit

Selection via these inputs on the motion monitoring unit

8 I1 – I3 B11 – B13

16 I1 – I4 B11 – B14

48 I1 – I6 B11 – B22

Use the rotation speed table (see page 75) in FP-Safe Configurator to define these parameters.

2.4.2 Outputs

You can use the outputs for all control functions relevant to safety and otherwise, e.g. for emergency stop, safety door, permission, drive release, network release, unlock safety door, and other safety-related functions. They can also be used to activate valves, chip conveyors, cooling systems, and other non-safety functions.

In terms of output function, FP-Safe features safety outputs, freely configurable outputs, and control outputs. As to output types, both the positive-switching semiconductor and the relay types are available.

The following outputs are available on the units:

Unit Outputs

Controller unit O1 O2 O3 O4 O5 O6 O7

Motion monitoring unit O1 O2 O3 O4

Transistor I/O expansion unit O11 O12 O13 O14 O15 O16 O17 O18

Relay expansion unit 13-14 23-24 33-34 43-44 53-54 63-64 73-74 83-84

17


2.4.2.1 Output Structure

The following output structure applies to the various units:

Controller unit

Output number and properties

24V

O1: Configurable, 0.1A

24V DC

O2 to O5: Safety outputs, 1A

24V O6, 0.25A

24V O7, 0.25A

Output pair, freely configurable



P1 O1

P2 O2

Freely configurable

1A

P1 O3

P2 O4

Freely configurable

1A

Transistor I/O expansion unit


P1 O11

P2 O12

Freely configurable

1A

P1 O13

P2 O14

Freely configurable

1A

P1 O15

P2 O16

Freely configurable

1A


P1 O17

P2 O18

Freely configurable

1A

24V O21

24V O22

Freely configurable

0.25A

Relay expansion unit

13-14 to 83-84

DC 13: 4A

AC15: 3A

O1 to O4: Signaling contacts


13 14

23 24

Safety contacts

24V DC O1

33 34

43 44

Safety contacts

24V DC O2

53 54

63 64

Safety contacts

24V DC O3

73 74

83 84

Safety contacts

24V DC O4

18


2.4.2.2 Safety Outputs on the Controller Unit

The outputs are positive-switching. The outputs are supplied with 24V DC via terminal A1 on the controller unit.

Unit Outputs Symbol in FP-Safe Configurator

Controller unit O2 to O5

2.4.2.3 Relay Outputs on the Relay Expansion Unit

O13-14 to O83-84

O1 to O4: Signaling contacts

13 14

23 24

24V DC O1

33 34

43 44

24V DC O2

53 54

63 64

24V DC O3

73 74

83 84

24V DC O4

19


2.5 Installation and Removal

To install the unit, proceed as follows.

1.2.3.

Procedure

1. Hold the unit between your thumb and index finger

2. Insert the unit into the rack

3. Push the unit all the way into the rack with a vibrating movement

4. Mount the rack on a DIN rail or something similar

20

FP-Safe User's Manual 2.5 Installation and Removal

Removal

There are two ways to remove the unit:

1.2.3.

Procedure

1. Grab the unit on both sides under the yellow cover and pull it out of the rack

or Pry the unit out of the rack with a pointed object

21


2.6 Technical Data

2.6.1 General Specifications

Item Data

Operating voltage (Vo) 24V DC via A1 / A2 on the controller unit for all units

Voltage tolerance at Vo 85 - 110%

Ripple at Vo Max. 10%

Electrical requirements

Power consumption at Vo Depends on number of units

Ambient temperature -10 to +60°C / +14 to 140°F Ambient conditions

Storage temperature -40 to 85°C / -40 to +185°F

Vibration resistance on all 3 axes Sine 10 – 55Hz, 0.35mm, 10 cycles, 1 octave/min

Maximum wire diameter, wiring terminal 1 x 1.0mm2, spring force terminals, pluggable

Housing material Galvanized sheet steel, powder-coated

Degree of protection May only be used in switching cabinets with IP54

Input voltage 24V DC -15%, +10% Inputs

Power consumption Maximum 3.5mA

Residual voltage at 5mA load current (4.8k)

< 4.5V


< 2.5V

Residual voltage at the load in case of error at semiconductor outputs: Power line A2 to unit interrupted


< 1.0V

Residual current when 0V output (A2) is short-circuited

< 5µA

Residual voltage at 1A load current

< 200mV

Residual voltage at 0.5A < 100mV

Residual voltage at minimum load ( 0.1A)

< 50mV

Residual current, residual voltage, and minimum switching capacity for semiconductor outputs

Minimum switching capacity

1mA

Required interference suppression of the output load for all semiconductor outputs

By surge absorber

22

FP-Safe User's Manual 2.6 Technical Data

2.6.2 Controller Unit

Item Data

Power consumption via A1, A2 Max 2.9W

Internal fuse 6A, automatic

Switching and continuous current output O1, resistive load Max. 100mA

Maximum input frequency for I11 – I14 and O1 as input 1200Hz

Switching and continuous current, inductive and resistive load

Max. 1A, short-circuit- and overvoltage-proof

Sum of the switching and continuous currents

Max. 2A

Specifications for outputs O2 – O5

Minimum switching capacity 1mA


Max. 0,25A, short-circuit- and overvoltage-proof Specifications for outputs O6 and O7 Sum of the switching and continuous

currents Max. 0,4A

2.6.3 Motion Monitoring Unit

The motion monitoring unit uses incremental signals.

Item Data

Power consumption via A1 and A2 on the controller unit Max 2.5W

Input voltage at P1, P2 24V DC +10% – 15%

Ripple at P1, P2 10%

Input voltage at the encoder inputs, sine/cosine 0.8 – 1Vss

Input voltage at the encoder inputs, TTL 4-5V

Input voltage at the encoder inputs, sine/cosine, TTL 496937Hz

Switching and continuous current, inductive or resistive load

Max. 1A, short-circuit- and overvoltage-proof Technical data for outputs O1 and O4


Max. 2A

2.6.4 Relay Expansion Unit

Item Data

Power consumption via A1 and A2 on the controller unit Max. 4.8W

Minimum switching current of contacts 13/13-83/84, O1 – O4 10mA

Switching capacity according to DIN EN 60947-4-1 / EN 60947-5-1

AC15: 230V / 3A, DC13: 24V / 4A / 0.1Hz

Lifetime at switching capacity DC13: 1A, 24V 100,000 switching cycles

Lifetime at switching capacity DC13: 4A, 24V 40,000 switching cycles

Lifetime at switching capacity AC15: 1A, 230V 200,000 switching cycles

23


24

Item Data

Lifetime at switching capacity AC15: 3A, 230V 80,000 switching cycles

Mechanical lifetime >10 x 106

Contact fusing 5A slow

Maximum switching cycles 360 cycles/h at AC15: 3A and DC13: 4A

Short-circuit withstand 1000A SCPD 6A gG safety fuse

Rated insulation voltage 250V AC

Surge breakdown voltage 4kV, pollution degree 2

Response and reset times 10ms (typical)

Switching capacity O1 – O4 0.25A

2.6.5 Transistor I/O Expansion Unit

Item Data

Power consumption via A1 and A2 on the controller unit Max 2.2W

Input voltage at P1, P2 24V DC +10% -15%

Ripple at P1, P2 10%

Switching and continuous current, inductive or resistive load

Max. 1A, short-circuit- and overvoltage-proof Specifications for outputs O11 – O18


Max. 4A


Max. 0,25A, short-circuit- and overvoltage-proof Specifications for outputs O21 and O22


Max. 0,4A

2.6.6 Dimensions

The units are installed on a rack. The narrowest rack is 58mm wide. Rack width depends on the number of function units mounted. The controller unit occupies two slots.

Front Top

Controller unit with grounding screw (1)

Controller unit and function unit with DIN rail clamp (2)

Chapter 3

Introduction to the Configuration Software

Introduction to the Configuration Software FP-Safe User's Manual

3.1 System Requirements

Item Description

Operating system Windows XP

RAM requirements at least 512MB

Java version JRE6U12 (included)

Connection cable between PC and controller unit's COM port

V.24 (1:1) connection cable required. For this cable, only pins 2, 3, and 5 are relevant.

� NOTE

If an older version is preinstalled, you must uninstall this version before installing the new one. The new version will be installed to your C: drive.

26

FP-Safe User's Manual 3.2 User Interface

3.2 User Interface

FP-Safe Configurator menu

Menu item Shortcut Description Icon

N New

O Open

S Save

-- Print

File

-- Exit --

T Unit configuration (see page 46) -- Parameters

H Application data (see page 42) --

P Settings (see page 42) -- Project

F4 Statistics (see page 42) --

F9 Hardware configuration

F11 Circuit diagram

View

F12 Rack diagnosis

Download -- Download application: PC FP-Safe (see page 43)

Port (see page 43)

--

Help F1 Help file for FP-Safe Configurator

System information -- Contains:

Program version

Date

Diagnosis program version

Operating system information

Java version

Standard file path

Online diagnosis -- Displays the color-coded connection lines. The (user-defined) colors indicate whether the connection has a HIGH or a LOW signal (see page 42).

Add page -- Adds circuit diagram page

Delete page -- Deletes active circuit diagram page

27


Unit toolbar

Display all circuit diagram pages created

Use the tabs to display the circuit diagram pages. If a page has been named, the system displays the page name on the tab.

Options in the circuit diagram context menu

To open the context menu, right-click on the circuit diagram.

Context menu in the circuit diagram

Parameter Function

Add text Opens a dialog where you can define:

Font

Font size

Font color

In the "Text" field you can enter a text.

Page name Opens a dialog where you can enter a page name.

Grid Switches the grid function on or off.

3.2.1 Hardware Configuration

To configure your hardware, proceed as follows:

1.2.3.

Procedure

1. Select the "Hardware configuration" tab

2. Choose the desired unit

3. Drag and drop the unit to the desired slot (0 – 14)

28


The controller unit now occupies slot 0.

4. To delete a unit, select the unit and press [Del]

3.2.2 Circuit Diagram

To open the circuit diagram, choose [Circuit diagram] or press <F11>.

3.2.3 Unit Toolbars

To display the unit toolbars, choose the yellow buttons at the top of the screen, e.g., for the controller unit. On the yellow button, the digit at the right refers to the unit's position on the rack. You use this toolbar to display function elements such as logic elements, inputs and outputs, safety-related functions, and two-hand control, as well as the operation mode switch, timer, clock generator, restart lockout, motion monitoring function, etc.

� NOTE

The toolbar icons are explained here (see page 31).

29


(Display with )

Controller unit toolbar

(Display with )

Motion monitoring unit toolbar

(Display with )

Transistor I/O expansion unit toolbar

30


(Display with )

Relay expansion unit toolbar

3.2.4 Explanation of Toolbar Icons

Icon Parameter and/or explanation Circuit diagram icon

Jump label

Branch destination

To select the appropriate jump label, use the list box under "Label."

Virtual 24V

For activating virtual inputs in the circuit diagram.

31


32


AND/NAND gate

OR/NOR gate

XNOR gate

Not negated:

0 & 0 = 1

0 & 1 = 0

1 & 0 = 0

1 & 1 = 1

Negated:

0 & 0 = 0

0 & 1 = 1

1 & 0 = 1

1 & 1 = 0

Flipflop gate


33


Inverter

External device monitoring

Time chart:

Starter element

Time chart:

Operation mode switch

For the "OMS" option, choose "3" for 3 and "6" for 6 operation modes.

Restart lockout

The virtual restart lockout input is available for one-time use. This function acknowledges an emergency stop, which is triggered if a rotation overspeed has been detected. The acknowledgement can be transmitted via a hardware input.

Input

The inputs can be used for various functions, both relevant to safety and otherwise.


34


Output

Timer

Timers 1 to 12 are off-delayed; timers 13 to 15 are on-delayed. For every timer, 4 adjustable time settings are available. Activation occurs via inputs t/A1, t1, t2, and t3.

Safety-related function (SRF)

The following SRFs can be configured:

Emergency stop function (see page 68)

Protection cover / safety door function (see page 70)

Permission switch (see page 71)

Two-hand control


35


Motion monitoring

Rotation speed, standstill, direction, and position monitoring

3.2.5 Connecting the Icons in the Circuit Diagram

In the circuit diagram, the icons are always connected from a virtual output to a virtual input. The connection lines can be positioned in two ways:

Automatic placement (recommended for adjacent icons)

Manual placement (recommended for icons located one below the other, or for branches)

� NOTE

For easy placement of icons and connection lines, we recommend that you display the grid. To do so, right-click anywhere in the circuit diagram, and in the context menu, select "Grid."

Automatic placement of connection lines

This procedure is recommended for adjacent icons. You can also place the connection lines manually.

1.2.3.

Procedure

1. Select the virtual output on the "ES_Off" AND gate.


2. Select the virtual input "t" on the "Shaft1" timer

The system positions the connection.

Manual placement of connection lines

This procedure is recommended for icons located one below the other.

1.2.3.

Procedure


2. Select the first point where the line requires an endpoint

36


3. Select the second point where the line requires an endpoint

4. Continue selecting further points until you can reach the virtual input with a straight connection line

5. Select the virtual input "t" on the "Shaft1" timer

The connection is now complete.

Positioning connection branches

In certain cases, a virtual output must be connected to several virtual inputs; that is, the connection line must branch out. In this case, proceed as follows:

1.2.3.

Procedure


37


The branch consists of a connection line that partly overlaps with another connection line.

2. Select the endpoints of your connection line, one after another, until the virtual input can be reached with a straight connection line

The connection is now complete.

38


Deleting connection lines

To delete a connection line, proceed as follows:

1.2.3.

Procedure

1. Select the connection line

2. Right-click

3. Choose "Delete connection"

The system deletes the connection line.

39


3.3 Creating an Application

To configure units and functions, you must first create an application:

1.2.3.

Procedure

1. Select File New or , or press <N>

2. Select [Hardware configuration]

This option enables you to select the units you intend to use.

3. Choose [Circuit diagram]

At the top of the screen, the available units are identified by yellow buttons.

4. Choose the tab for the first page

5. Select the desired unit by pressing the appropriate button

The toolbar (see page 29) for that unit appears.

To enter additional application-specific data (see page 42), choose Parameters Application data and save.

40

FP-Safe User's Manual 3.4 Print Application

3.4 Print Application

To document your applications, you can save the application properties, the circuit diagram, and various additional information in a PDF file. To open this dialog, choose File Print:

The following options are available:

Option Function

List of units Prints a table listing all units mounted on the rack, their position numbers, and (if applicable) their names.

Circuit diagram Prints the circuit diagram. For circuit diagrams that are two or more pages long, you can specify whether to print all pages, only the current page, or only selected pages.

Network list Lists the sequence in which the circuit diagram elements are executed.

Statistics Prints statistics on the remaining number of circuit diagram elements available as well as the maximum number that can be used.

List of (jump) labels Prints all jump labels, including their number, name, and the circuit diagram page on which they were used.

Unit parameters Prints the inputs, outputs, safety-related functions, and timers by unit.

41


3.5 Menus

In addition to the functions that can be accessed via icons or buttons, the "Parameters," "Project," and "Download" menus provide several further options.

3.5.1 "Parameters" Menu

The "Parameters" menu offers the following options:

Unit configuration

Application data

Unit configuration

Use this option to display the parameter tabs for each unit (see page 46).

Application data

To display FP-Safe Configurator version data, as well as the application file creation date, choose Parameters Application data. In addition, you can define the following settings:

Machine

Version

Author

Date (current date; provided by the system)

3.5.2 "Project" Menu

The "Project" menu offers the following options:

Settings

Statistics

Settings

Choose Project Settings to define the following settings:

Tab Function

Directories Define your project directory here. All current project data is saved to this directory. To define your project directory, press [Select directory].

Communication Define the COM port for your rack diagnosis (see page 86) here.

Safety settings Define or change your password here. The fields required for each procedure are outlined in black.

Diagnosis settings Select the elements for display or testing during the diagnosis here.

Switching interface language Use this switch to toggle between the English and German user interfaces.

Note: After choosing the desired language, you must restart FP-Safe Configurator.

42

FP-Safe User's Manual 3.5 Menus

43

Tab Function

Display options Define the options for the following elements here:

Hide/display grid: Defines the default grid setting.

Hide/display connection line name: Defines the default connection line (see page 35) name setting. To change a name that currently appears on the diagram, open the context menu and select "".

Color code for connections with HIGH or LOW signal: Define the color codes for connections or system status during online diagnosis.

Statistics

The "Statistics" option displays the remaining number of circuit diagram elements available. The numbers beside the element names refer to the number of inputs; e.g., AND4 signifies an AND gate with 4 inputs.

3.5.3 "Download" Menu

The "Download" menu offers the following options:

Download application: Use this option to download the application to the connected FP-Safe.

Port: Use this option to select the COM port for download or diagnosis (see page 86).

Chapter 4

Configuring Parameters

Configuring Parameters FP-Safe User's Manual

4.1 Available Unit Parameters

In FP-Safe Configurator, both the controller unit and the function units have tabs for parameters, inputs, and outputs. The transistor I/O expansion unit has only one tab listing the inputs and outputs.

1.2.3.

Procedure

1. To open the "Parameters" tab, press <T> or choose Parameters Unit configuration

2. Display the unit parameters by selecting the desired unit from the list at the left

This figure shows the controller unit parameters.

3. To switch between parameters and terminals, select the appropriate tabs

The following parameters are available:

Parameter Function

Name Name field. Enter the unit name here.

Delayed emergency stop

Switch-off delay time (0 – 25s) for all FP-Safe outputs after an internal or external error. See also Automatic emergency stop at machine error (see page 70)

46

FP-Safe User's Manual 4.1 Available Unit Parameters

47

Parameter Function

Autostart If this field is activated, FP-Safe is ready for operation immediately after the application has been downloaded. If this field is deactivated, the operating voltage (i.e., power supply) must be turned off for 2s and then switched back on.

Test O1-O7 You can deactivate the semiconductor output test. If the test mode is deactivated, a brief output switch-off is not performed (see Note).

Clock generator (100ms)

You can adjust the pulse and interval time in increments of 100ms (1 = 100ms). A range of 1 – 255 is valid. An entry that reads "255" represents 25.5s. To activate this function, select the "On" field.

O1 You can configure O1 as system OK, control output, or frequency input for rotation speed monitoring.

� NOTE

If you have deactivated the internal semiconductor output test, your safety category is no longer 4; it is only 3.

The "Terminals" tab lists the unit's inputs and outputs. You can name the inputs and outputs in the adjacent fields. These names then appear at the appropriate terminals in the circuit diagram. Alternatively, you can enter the names while you are configuring the inputs and outputs. In that case, the names also appear on the tab.

Inputs and outputs on the controller unit


4.2 Controller Unit Timer

Timers 1 to 12 are off-delayed; timers 13 to 15 are on-delayed. For every timer, 4 adjustable time settings are available.

Input Function

t/A1 (last output) General on-/off-delay time. If none of the other inputs is set, only the time for t/A1 is valid.

t1 Additional on-/off-delay time for operation mode 1.



Activation occurs via inputs t/A1, t1, t2, and t3. Using t1 to t3, you can select a different time setting for every operation mode; this time expires after t/A1 has expired. If outputs t1, t2, and t3 remain open, only the time for t/A1 is valid.

With an off-delayed timer the time expires when the t/A1 input changes from HIGH to LOW. At the end of this interval, the output changes from HIGH to LOW.

With an on-delayed timer the time expires when the t/A1 input changes from LOW to HIGH. At the end of this interval, the output changes from LOW to HIGH.

� NOTE

If inputs t1, t2, and t3 are continually connected to the HIGH signal, only the time for input t3 is valid.

The adjustable interval is 0.02s to 300s. This interval is accurate up to ± 10ms.

4.2.1 Off-Delayed Timers

Timers 1 to 12 are off-delayed.


Timer

48

FP-Safe User's Manual 4.2 Controller Unit Timer

4.2.2 On-Delayed Timers

Timers 13 to 15 are on-delayed.


Timer

49


4.2.3 Creating a Timer

To create a timer, proceed as follows:

1.2.3.

Procedure

1. Choose the list box next to the icon in the toolbar

A list of available timers appears.

2. Select the desired timer

The timer configuration dialog appears.

3. Define the time values

4. Choose [OK]

When the cursor is located within the circuit diagram field, the circuit diagram icon appears in the diagram.

5. Position the circuit diagram icon as desired

The units can be positioned in random order. We recommend placing the diagram elements in a straight line and keeping them left-aligned. To ensure that you can place your units accurately, and to make it easier to create connection lines (see page 35) between icons, we recommend that you display the grid, which is available from the context menu. To cancel positioning, choose [Cancel] or <Esc>.

50

FP-Safe User's Manual 4.3 Motion Monitoring

4.3 Motion Monitoring

The controller unit can monitor standstills and rotation speeds. In addition, a motion monitoring unit is available.

4.3.1 Motion Monitoring with the Controller Unit

The controller unit can monitor standstills and rotation speeds by means of the hardware inputs, which it uses to record motion speeds: Inputs I11 and I12 are used for the first monitoring point (MM1), and inputs I13 and I14 are used for the second (MM2). Motion speeds can be detected by means of proximity switches, for example. The maximum sampling rate is 1200Hz.

� NOTE

In the circuit diagram icon, these frequencies are rounded off slightly.

4.3.1.1 Using Proximity Switches to Record Machine Motion

This function only applies to the controller unit. Use inputs I11 to I14 to record the drive speed. Activation occurs via 24V signals, e.g. from proximity switches.

2 proximity switches and 2 inputs are required per drive.

Two axes can be monitored. I11 and I12 are for axis 1; I13 and I14 are for axis 2.

The maximum input frequency is 1200Hz.

Axis 1 Axis 2

Unit In1 In2 Ack In1


Activating the inputs

At machine standstill When the machine is in motion

Input signal position

Sensors S1 and S2, or S3 and S4, must be mounted on the gearwheel in such a way that, during standstill, at least one sensor is active and emitting a 24V signal. You position one sensor in front of the gear; place the other in front of the gap on the gearwheel. Sensor functioning is tested both in motion and at standstill.

51


52

4.3.1.2 Configuring Motion Monitoring


SS1: Standstill

F11: Setup mode

F12: Semi-automatic mode

F13: Automatic mode

Selection: MM1

SS2: Standstill

F21: Setup mode

F22: Semi-automatic mode

F23: Automatic mode

Selection: MM2

4.3.1.3 Virtual Output Function at Monitoring Points 1 and 2

Icon Function

Virtual output for standstill:

HIGH signal at standstill

LOW signal at Vis > Vstandstill

This output is independent of the operation mode selected.

Virtual output for Vmax:

HIGH signal at Vis < Vmax

LOW signal at Vis > Vmax

The speed being monitored depends on the operation mode selected. If no operation mode has been selected via inputs F11/F21, F12/F22, F13/F23, or MT1/MT2, this function yields the following result:

HIGH signal at standstill

LOW signal at Vis > Vstandstill


53

4.3.1.4 ring Point Creating a Motion Monito

To create a motion monitoring point for the controller unit, proceed as follows:

1.2.3.

Procedure


A list of available monitoring points appears, e.g., MM1 for the first and MM2 for the

2.

second standstill and rotation speed monitoring point.

Select the desired monitoring point

The monitoring configuration dialog appears.

3. In the "Name" field, enter the name of the axis to be monitored

4. In the "Frequency" fields, enter the frequencies (in Hz) for the operation

[OK]

iagram icon agram.

6.

ed in random order. We recommend placing the diagram -aligned. To ensure that you can r to create connection lines (see

.

modes

In the motion monitoring unit, the maximum frequency is 496937Hz.

5. Choose

When the cursor is located within the circuit diagram field, the circuit dappears in the di

Position the circuit diagram icon as desired

The units can be positionelements in a straight line and keeping them leftplace your units accurately, and to make it easiepage 35) between icons, we recommend that you display the grid, which is available from the context menu. To cancel positioning, choose [Cancel] or <Esc>


4.3.2 Brake Monitoring with the Motion Monitoring Unit

The following options are available:

Parameter Function

Current values Displays the predefined frequencies.

Enter values Button for opening a dialog where you enter up to 4 frequencies.

Name Name field. Enter the unit name here.

Encoder 1 Define whether the encoder will be working with sine/cosine or TTL signals. The "Increment" field is for operation modes that will be implemented at a later date.

[Fx3-RSM1/2] For rotation speed monitoring, use the button [RSM] at the top to select the rotation speed table. In the "Slot" field, define the position of the unit whose inputs select frequencies in the rotation speed table. These inputs are displayed directly underneath. The display indicates the rack positions of only those units whose inputs can be used to select these frequencies.

In the rotation speed table (see page 75) you define the number of inputs required. Select the unit position. The "Terminal" field then displays the number of inputs and their names.

Position monitoring Position monitoring (see page 59) configuration button.

Port Enter data on the drive or machine to be monitored here.

Adapter Enter the cable adapter type used to connect the drive being monitored.

� NOTE


54


4.3.2.1 Operation Modes for Motion Monitoring

There are 4 operation modes available. You select these modes via the motion monitoring unit inputs.

Dialog "Enter values: Frequency"

Icon Function Explanation

Setup mode Use input F11 to select this operation mode.

F11 = HIGH

F12, F13, MT1 = LOW

Semi-automatic mode Use input F12 to select this operation mode.

F11, F12 = HIGH

F13, MT1 = LOW

Automatic mode Use virtual input F13 to select this operation mode.

F11, F12, F13 = HIGH

MT1 = LOW

Unmonitored automatic mode

Use virtual input MT1 to select this operation mode. In this case, you do not need to enter a frequency.

Standstill frequency For operation safety reasons, an absolute standstill cannot be monitored;

therefore you must enter a frequency for standstill monitoring. We recommend that you define this frequency at 5-10% of the setup mode speed. Standstill monitoring is active when no operation mode has been selected, i.e., F11, F12, F13, MT1 = LOW.

The system automatically enters this frequency in the field directly above the frequency definition field. Instead of monitoring a frequency, the system can also monitor (see page 59) axis position.

� NOTE

Confirm the desired frequency by choosing [Apply].

The system automatically displays these frequencies, slightly rounded off, in the table above.

If you are using rotation speed monitoring, the frequency in field F13 is not taken into consideration.

55


4.3.2.2 Creating a Motion Monitoring Point

To create a motion monitoring point for the motion monitoring unit, proceed as follows:

1.2.3.

Procedure

1. Display the table field by pressing <T> or choose Parameters Unit Configuration

56


2. From the list of units at the left, select the motion monitoring unit

3. Choose [Enter values]

4. In the "Frequency new" fields, enter the frequencies (in Hz) for the operation modes


5. Choose [Apply]



The units can be positioned in random order. We recommend placing the diagram elements in a straight line and keeping them left-aligned. To ensure that you can

57


place your units accurately, and to make it easier to create connection lines (see page 35) between icons, we recommend that you display the grid, which is available from the context menu. To cancel positioning, choose [Cancel] or <Esc>.

� NOTE

If the motion monitoring point has already been inserted in the circuit diagram, you can display the frequencies for editing by selecting the icon, pressing the right mouse button and selecting "Properties" from the pop-up menu.

58

FP-Safe User's Manual 4.4 Additional Monitoring Functions

4.4 Additional Monitoring Functions

The motion monitoring unit has the following functions:

Standstill monitoring

Position monitoring (see page 59)

Rotation speed monitoring (see page 75)

Direction monitoring (see page 61)

Brake monitoring (see page 61)

4.4.1 Position Monitoring

Axis position will be monitored if you have not selected (see page 55) an operation mode. In this case, the system interprets the current axis position as position "zero." For axis position monitoring to be performed, Rotation Speed Table 2 must have an entry in the second or third column. If the entry is "0," standstill monitoring is active.

You can also define a monitoring combination where MM1 monitors position and MM2 monitors standstill, or vice versa.

� NOTE

You enter position monitoring data in Rotation Speed Table 2. Therefore, this table is no longer available for rotation speed monitoring.

To define and activate position monitoring, proceed as follows:

1.2.3.

Procedure

You display the table by entering <T> via keyboard.

1. Display the table field by pressing <T> or choose Parameters Unit configuration

59


2. From the list of units at the left, select the motion monitoring unit

3. Choose [Position monitoring]

4. Choose "Position monitoring"

In the "Index" column, "PM" stands for "Position monitoring" and "FU" for function unit. The number stands for the unit's position on the rack. In the motion monitoring

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FP-Safe User's Manual 4.4 Additional Monitoring Functions

61

unit, you enter the number of increments in columns MM1 and MM2. The entries are highlighted in yellow. Since every clock edge monitored counts as one, you enter the number of increments times 4. For an entry of 500, the motion window is 125 increments in both directions.

When you exit the monitoring screen, the virtual outputs and switch toa LOW signal.

4.4.2 Direction Monitoring

At MM1 and MM2, the virtual output emits a HIGH signal at standstill and with an advancing sine wave, and a LOW signal with an advancing cosine wave. To define your preferred direction, use the hardware inputs and a logic operation. The third input, "Mute," can be used to mute the function if necessary.

Sample application

4.4.3 Brake Monitoring

For brake monitoring, the virtual outputs at MM1 and at MM2 are used. The speed at both monitoring points is recorded in increments of 100ms over a 500-ms interval. After 500ms, the first value is overwritten. At standstill, at constant speeds, and during acceleration, the BR1 and BR2 outputs have a LOW signal. The outputs switch to a HIGH signal when braking action reduces the speed by 5% within the 500-ms interval. The shortest response time is 100ms. You can use these virtual outputs to activate hardware outputs or virtual inputs.

Time chart


4.5 Using Inputs

4.5.1 Overview

The table shows the units and their available inputs. The inputs can be used for various functions, both relevant to safety and otherwise.

Unit Available inputs

Controller unit I1, I2, I3, I4, I5, I6, I11, I12, I13, I14, I15, I16, I17, I18, I19, I20

Transistor I/O expansion unit I21, I22, I23, I24, I25, I26, I27, I28

virtual output

View in FP-Safe Configurator

On the circuit diagram icon, the hardware terminal is at the left, and the virtual output is on the right. The virtual output has a HIGH signal at 24V DC at the input, and is LOW when the input is open.

To create a timer, proceed as follows:

1.2.3.

Procedure


A list of available inputs appears.

2. Select the desired input

The input configuration dialog appears. In the "Name" field you can enter a name with up to 6 characters.

3. Choose [OK]


for the controller unit

for the transistor I/O expansion unit

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FP-Safe User's Manual 4.5 Using Inputs



4.5.2 Inputs for Safety-Related Functions

The following inputs can be used for safety-related functions (SRF). (Ack = Acknowledgement input):

SRF1 SRF2 SRF3

Unit In1 In2 Ack In1 In2 Ack In1 In2 Ack


Transistor I/O expansion unit I21 I22 I23 I25 I26 I27

SRF4 SRF5

Unit In1 In2 Ack In1 In2 Ack


The following safety-related functions can be configured with the above-mentioned input groups:

Emergency stop function

Protection cover / safety door function

Permission switch

Inputs I1 and I2 can be activated statically with 24V DC, or dynamically with the clock signal from FP-Safe. With the dynamic trigger, the clock signal must be generated by FP-Safe via 2 outputs.

63


Time charts

The time behavior is controlled by the "Restart" and "Activation" settings defined in the safety-related function (see page 64) configuration dialog. The acknowledgement retention time is displayed as "t."

The "SRF" virtual outputs have a HIGH signal if the conditions are met at the SRF input. The output has a LOW signal when errors occur, or when a function is inactive.

"Restart" = "Manual", "Activation" = "Static"

"Restart" = "Manual", "Activation" = "Dynamic"

"Restart" = "Automatic"

4.5.2.1 Creating a Safety-Related Function

To create a safety-related function (SRF), proceed as follows:

1.2.3.

Procedure


A list of available SRFs appears.

2. Select the desired SRF

64


The SRF configuration dialog appears. This example shows the controller unit dialog. In function unit dialogs, the options "Antivalent," "Save acknowledgement for," "Acknowledgement," "Force emergency stop," and "Dual channel OFF" are deactivated.

3. Select the SRF function

Select for emergency stop, for the safety door function, and for the permission switch. is a safety light curtain function that will soon be implemented. In the "Name" field you can enter a name with up to 6 characters. For the terminals, you can enter the names in the fields below "Input."

4. Choose "Antivalent" if the system startup will be using 2 antivalent signals

Alternatively, the startup can use 2 identical signals (see page 70).

5. Set "Restart"

You can choose between "Manual" and "Automatic." Note that the configuration for this option will affect the acknowledgement (see page 67).

6. Set "Activation"

Define whether the inputs will be activated statically or dynamically via clock signal.

7. Set "Acknowledgement"

With the controller unit, acknowledgement occurs regardless of the "Restart" setting, either via acknowledgement input Ack, or via restart lockout. With SRFs without an acknowledgement contact, "Restart" must be set to "Automatic." For additional information, see the section on antivalent control signals for SRFs on the controller unit (see page 66).

65


8. Configuring acknowledgement retention time

The acknowledgement retention time can be 0s, 1s, 3s, or 5s. In the function units, the acknowledgement retention time is defined at 1s if "Restart" is set to "Manual."

9. If desired, activate "Force emergency stop"

The "Force emergency stop" function is relevant if SRF1 is used (see page 69) via I1 - I3, or SRF2 is used via I4 - I6, as an emergency stop SRF on the controller unit.

10. If necessary, activate "Dual channel OFF"

This function regulates whether the SRF must be (see page 69) turned on and then off again, or acknowledged, after the machine has resumed operation.

11. Choose [OK]




4.5.2.2 Antivalent Control Signals for Safety-Related Functions

If "Antivalent" has been activated, "Activation" must be set to "Static." The input for the LOW signal changes from red to green. This is always the second input in the safety-related function.

For SRF activation, the first input I1 (red) must switch from LOW to HIGH, and the second input I2 (green) must switch from HIGH to LOW. In FP-Safe Configurator, the acknowledgement signal "Ack" at the third input is saved via the predefined delay setting (0s, 1s, 3s, or 5s). It then becomes invalid.

66


67

Symbol in FP-Safe Configurator

Conditions met Conditions not met

SRF

4.5.2.3 Acknowledgement

The acknowledgement input must be supplied with 24V DC.

Control signals I1 and I2 can be controlled statically ("Activation" = "Static") or dynamically ("Activation" = "Dynamic"). To ensure short-circuit protection, select the dynamic trigger and use clock outputs.

� NOTE

For SRFs without an acknowledgement contact, "Restart" must be set to "Automatic."

For the safety door function with an acknowledgement contact, "Restart" must be set to "Automatic." The acknowledgement signal source must be connected to FP-Safe's acknowledgement input.

Acknowledgement on the controller unit

Regardless of your "Restart" setting, acknowledgement for SRF1, SRF2, and SRF5 can occur via the acknowledgement input ("Acknowledgement" = "Input Ack") or the restart lockout input. If "Acknowledgement" is set to "Off," the source can also be switched off. The acknowledgement input then becomes available to other functions.

If "Restart" is set to "Manual," the acknowledgement signal must be switched independently of the source.


If "Restart" is set to "Automatic," the acknowledgement can be kept ON independently of the source.

The acknowledgement retention time can be 0s, 1s, 3s, or 5s.

To configure SRFs 3 and 4 on the controller unit, you must use identical parameter settings. Wherever the settings differ, FP-Safe Configurator applies the settings of the SRF that was last changed.

Acknowledgement on the function units

Acknowledgement occurs only via the acknowledgement input.

If "Restart" is set to "Manual," the acknowledgement signal must be switched independently of the source. The acknowledgement retention time is defined at 1s.

If "Restart" is set to "Automatic," the acknowledgement can be kept ON independently of the source.

4.5.2.4 Emergency Stop Function

"Restart" = "Manual" "Restart" = "Automatic"

Controller unit Transistor I/O expansion unit

Description SRF1 via I1, I2, I3

Acknowledgement retention time: 0s, 1s, 3s, or 5s

Start: 2 equivalent or 2 antivalent signals

Clock signal activation: via 2 clock signal outputs from FP-Safe

SRF1 via I21, I22, I23

Start: 2 equivalent signals

Acknowledgement retention time: 1s (fixed)

Configuration dialog

68


69


In function unit dialogs, the options "Antivalent," "Save acknowledgement for," "Acknowledgement," "Force emergency stop," and "Dual channel OFF" are deactivated.

Circuit diagram icon

Time chart "Activation" = "Dynamic"

t = Acknowledgement retention time

"Activation" = "Static"


4.5.2.5 Automatic Emergency Stop at Machine Error

"Force emergency stop" function

The "Force emergency stop" function can be applied if you are using SRF1 via I1 - I3, or SRF2 via I4 - I6, as an emergency stop SRF on the controller unit. With an external or internal error, FP-Safe forces an emergency stop, as if the emergency stop button had been pushed. The "Delayed emergency stop" interval expires (see page 46). During this interval, FP-Safe operates normally. At the end of this interval, all outputs on FP-Safe are switched off and the machine is shut down. The "Delayed emergency stop" interval must be defined such that the machine can be shut down safely.

"Dual channel OFF" function

Dual channel OFF

"Restart" setting Effect on safety-related function

"Automatic" After machine restart, the SRF does not require an ON/OFF test.

Activated

"Manual" The SRF must be acknowledged.

Deactivated --- After machine restart, the SRF requires an ON/OFF test.


4.5.2.6 Protection Cover / Safety Door Function





Start: 2 identical or 2 antivalent signals

Clock signal activation: via 2 clock outputs from FP-Safe



Start: 2 identical signals







70


4.5.2.7 Permission Switch
















71


4.5.3 Inputs for Two-Hand Control

Control terminals Ack1, E1, E2, and Ack2 can only be activated statically ("Activation" = "Static"). You can configure the following inputs for two-hand control.

Unit In1 Ack1 In2 Ack2


Transistor I/O expansion unit I21 I22 I23 I24

Two-hand control Symbol in FP-Safe Configurator

If the inputs for Ack1 and Ack2 receive a 24V signal within the 500-ms interval, the two-hand control function is activated. The virtual output at the right switches from a LOW to a HIGH signal. At a time difference >500ms, no function can be executed.

Time chart

� NOTE

The inputs for E1 and E2 must receive a signal that is antivalent to Ack1 and Ack2. Otherwise, the function cannot be executed.

To create a two-hand control, proceed as follows:

1.2.3.

Procedure


72


The two-hand control selection list appears.

2. Choose TH1

The two-hand control configuration dialog appears. This example shows the controller unit dialog.

In the "Name" field you can enter a name with up to 6 characters. For the terminals, you can enter the names in the fields below IN1 to IN4.

3. Choose [OK]




4.5.4 Inputs for Operation Mode Switches (OMS)

For this safety function, only inputs I1 to I6 on the controller unit can be used. Operation mode switches can be used with 3 and 6 switching positions. Activation occurs statically. Only one switching position can be selected. In case of error, for example if more than one input is activated, the operation mode switch turns off all operation mode switch outputs. Is such cases, no operation mode is active.

Set up this function in FP-Safe Configurator.

3 switching positions 6 switching positions

Unit 1 2 3 1 2 3 4 5 6


73


Function type Symbol in FP-Safe Configurator

Operation mode switch 1 of 3

Operation mode switch 1 of 6

The hardware inputs on the controller unit are on the left. The virtual outputs are on the right.

Depending on the operation mode selected, the virtual output switches to a HIGH signal via a hardware input. All other outputs have a LOW signal. If more than one operation mode has been selected, all virtual outputs switch to a LOW signal.

To create an operation mode switch, proceed as follows:

1.2.3.

Procedure

1. Select the icon from the toolbar

The operation mode switch configuration dialog appears.

In the "Name" field you can enter a name with up to 6 characters.

2. Choose for 3 operation modes or for 6 operation modes

Depending on the selection, you can enter 3 names for inputs I1 to I3, or 6 names for inputs I1 to I6.

74


3. Choose [OK]




4.5.5 Inputs for Rotation Speed Monitoring

Rotation speed monitoring can be used to monitor up to 48 different speeds during automatic control of 2 different drives with varying speeds. Two frequency tables are available: Rotation Speed Table 1 and Rotation Speed Table 2, each with up to 48 values. Select a frequency by bitcode-switching I1 to I6 on the controller unit. In the table fields, enter the frequencies of the rotation speeds to be monitored.

75


Display the table by entering <T> via keyboard and choosing the [RSM] button.

Set the frequencies for rotation speed monitoring in this table.

Selection under "Inputs for RSM"

Required inputs and table fields Number of speeds monitored

3 inputs I1 to I3, fields 1 to 8 8



For every rotation speed to be monitored, you must predefine the reference frequency in the table. You can enter frequencies up to 496937Hz.

Additional parameters

Parameter Function

[Calculate 0 - 15] For a rotation speed monitoring point with 16 rotation speeds (0-15), define the lower and upper limit here. Choose this button for automatic calculation of the intermediate values.

[Tolerance] Define tolerances for the speeds that are to be monitored. Recommended tolerance: 10%. A tolerance prevents unintentional drive shutdowns, since it allows the maximum rotation speed to be exceeded by a predefined value.

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FP-Safe User's Manual 4.6 Using Outputs

4.6 Using Outputs

4.6.1 Overview

You can use the outputs for all control functions relevant to safety and otherwise, e.g. for emergency stop, safety door, permission, drive release, network release, safety door unlock, and other safety-related functions. They can also be used to activate valves, chip conveyors, cooling systems, and other non-safety-related functions.

In terms of output function, FP-Safe features safety outputs, freely configurable outputs, and control outputs. As to output types, both the positive-switching semiconductor type and the contact type are available.

Unit Outputs

Controller unit O1 O2 O3 O4 O5 O6 O7

Transistor I/O expansion unit O11 O12 O13 O14 O15 O16 O17 O18

Relay expansion unit 13-14 23-24 33-34 43-44 53-54 63-64 73-74 83-84

4.6.2 Safety Outputs on the Controller Unit

The outputs are positive-switching. They are supplied with 24V DC via terminal A1 on the controller unit.


O2 to O5:

4.6.3 Relay Outputs on the Relay Expansion Unit


Re13-14, Re23-24: Paired safety relay outputs with 2 safety contacts

O1: Diagnosis contact

, then selection via list box

Re33-34, 43-44: Paired safety relay outputs with 2 safety contacts


77


78






4.6.4 Configurable Outputs

All units have configurable outputs.

4.6.4.1 Controller Unit

Outputs O6 and O7 can be configured in FP-Safe Configurator, either as 2 control outputs or as 2 clock outputs for activating the SRFs to ensure short-circuit protection. The power supply voltage is provided internally.


O6

O7

"Use" = "1 channel not-safe" (individual control outputs)

Control output

"Use" = "Clock signal" (2 clock outputs for activating the SRFs to ensure short-circuit protection)

Clock output

4.6.4.2 Motion Monitoring Unit

You can configure outputs O1 to O4 in FP-Safe Configurator as:

4 individual control outputs


2 parallel-switching safety outputs

2 antivalent-switching safety outputs

Pairing: O1 with O2, and O3 with O4

Various combinations can also be configured.

The following applies to the power supply voltage:

For O1 and O3, the power supply voltage is provided via P1.

For O2 and O4, the power supply voltage is provided via P2.

4.6.4.3 Transistor I/O Expansion Unit



4 parallel-switching safety outputs

4 antivalent-switching safety outputs

2 clock outputs

Pairing: O11 with O12, O13 with O14, O15 with O16, O17 with O18, O21 with O22

Various combinations can also be configured.

The following applies to the power supply voltage:

For O11, O13, O15, O17 the power supply voltage is supplied via P1.

For O12, O14, O16, O18 the power supply voltage is supplied via P2.



1 parallel-switching safety output, 1 antivalent-switching safety output

2 clock outputs for activating the SRF inputs to ensure short-circuit protection

Pairing: O21 with O22

The power supply voltage is provided internally.

79


80


O11 – O18

"Output" = "1 channel not-safe" (8 individual control outputs)

Control output

"Use" = "1 channel parallel" (4 parallel-switching paired safety outputs; pairing: O11 with O12, O13 with O14, O15 with O16, O17 with O18)

Safety output (parallel-switching)

"Use" = "1 channel antivalent" (4 antivalent-switching paired safety outputs; pairing: O11 with O12, O13 with O14, O15 with O16, O17 with O18)

Safety output (antivalent-switching)

"Use" = "Clock signal" (2 paired clock outputs; pairing: O21 with O22)

Clock output

� NOTE

The outputs are continually tested for errors, regardless of the function type.

In the controller unit, the test can be switched on and off.

If a system error occurs, all outputs are switched off (see page 46) after a delay (0s to 25s) which can be predefined in FP-Safe Configurator.

4.6.5 Configuring Outputs

To configure your outputs, proceed as follows:

1.2.3.

Procedure

1. In the toolbar, choose the list box next to the unit icon, or


81

2. Select output

enter a name cters.

The output configuration dialog appears. In the "Name" field you canwith up to 6 chara

For the screw terminals, enter the names in the fields under "Terminals" (up to 6 characters).

3.

4. Choo

, the circuit diagram icon agram.

5.

ed in random order. We recommend placing the diagram -aligned. To ensure that you can r to create connection lines (see

.

From "Output type" or "Use," select the output type

se [OK]

When the cursor is located within the circuit diagram fieldappears in the di

Position the circuit diagram icon as desired

The units can be positionelements in a straight line and keeping them leftplace your units accurately, and to make it easiepage 35) between icons, we recommend that you display the grid, which is available from the context menu. To cancel positioning, choose [Cancel] or <Esc>


4.7 Sample Application

The "Emergency stop" signal merges the signals emitted by the motion monitoring points "Shaft1" and "XAxis." These two signals are joined by the "ES Out" AND gate, which in turn activates the "EmStop" emergency stop output.

Automatic mode

To select the "automatic" mode, activate the "ModSel" operation mode switch at Position OM1, and then the protection cover.

Signal transmission: External device monitoring to motion monitoring inputs

Both signals are transmitted to motion monitoring inputs F13 and F23 via the the "Mode1" AND gate. To select the "setup" mode, activate the operation mode switch at Position OM2, and then the permission switch.

Both signals are transmitted to motion monitoring inputs F11 and F21 via the "Mode2" AND gate. To select the "semi-automatic" mode, activate the operation mode switch at Position OM3, and then the permission switch.

Both signals are transmitted to motion monitoring inputs F12 and F22 via the "Mode3" AND gate.

Signal transmission: "EmStop" output to timers and release outputs

The "EmStop" output signal from the "ES Out" AND gate controls the "Shaft" 5s off-delayed timer. This timer controls the "Shaft" shaft release output. After an emergency stop, or an axis or shaft overspeed, this output remains active for 5s in order to brake the shaft. The shaft is then cut off from the power supply.

The "EmStop" output signal from the "ES Out" AND gate controls the "Axes" 0.5s off-delayed timer. This timer controls the "Rel Ax" axis release output. After an emergency stop, or an axis or shaft overspeed, this output remains active for 0.5s in order to brake the axis. The axis is then cut off from the power supply.

The "EmStop" output signal from the "ES Out" AND gate controls the "Netwrk" 0.5s off-delayed timer. This timer controls the "Netwrk" network release output. After an emergency stop, or an axis or shaft overspeed, this output remains active for 0.5s in order to brake the drives. The network is then disconnected.

Virtual direction monitoring output

If necessary, the virtual output can be used for direction monitoring. This output can be wired within the emergency stop circuit, or it can activate a separate output.

Restart lockout acknowledgement

After a rotation overspeed, the restart lockout acknowledgement input "RSTLAc" must be connected to 24V DC for ca. 0.5s.

Connections via jump label

The following signals are connected via jump labels, to enable use on other pages in the application:

82

FP-Safe User's Manual 4.7 Sample Application

Emergency stop button (JL_ES)

ES Out (JL_ESO)

Protection cover button (JL_PC)

Unlock protection cover (JL_Unl)

Permission switch (JL_PS)

Emergency stop circuit with motion monitoring points and release functions

83

Chapter 5

Rack Diagnosis Program

Rack Diagnosis Program FP-Safe User's Manual

5.1 Introduction

"Rack diagnosis" is a diagnosis program for the units mounted on the rack. The diagnosis program reports system diagnosis and status information.

� NOTE

For the diagnosis, the FP-Safe must be connected directly to the PC via the COM port on the controller unit. When you are defining your program settings, ensure that you have selected the correct COM port for communication.

86


5.2 User Interface

The user interface is divided into 4 areas:

Screen area Description

1 Diagnosis menu for configuring, starting, and ending the diagnosis, as well as for opening various information screens (see page 87).

Several buttons in this area have a dual function. By clicking these buttons, you switch the function, and the display changes accordingly.

2 Rack illustration showing the available units. The slots are numbered 0 – 14. During a diagnosis run, a simulated (see page 88) rack appears in this area. Unused slots are displayed as empty.

3 Enlarged view (see page 89) of selected unit.

4 Status information screen with diagnosis data concerning the selected unit (see page 89).

5.2.1 Diagnosis Menu

In screen area 1, the diagnosis menu features the following buttons:

Button Function Description

Standard diagnosis Use this button to start or interrupt the diagnosis. The standard diagnosis reads all current diagnosis results and status data from FP-Safe.

Trigger event diagnosis

You can program FP-Safe to save all status data generated at the precise moment of a trigger event. Use this button to display the stored status information.

Read rack data To perform a diagnosis on a new rack, or if you have changed any application data saved previously in FP-Safe, use this button to refresh the diagnosis information.

Error diagnosis Use this button to switch to the error diagnosis screen (see page 95). This screen displays errors that have caused a system shutdown.

History For every FP-Safe configuration, FP-Safe saves history checkpoints containing data such as the programming date and time, checksum value, etc.; a maximum of 16 checkpoints is available. Use this button to display the checkpoint data.

87


88

Button Function Description

Selecting a unit for diagnosis

All units mounted on the rack are diagnosed consecutively at regular intervals. The user is thus continually provided with a complete overview of diagnosis data for the entire rack. Depending on the number of units mounted on the rack, each unit update will take some time, because the units are diagnosed one at a time.

You use this button to select the units for your diagnosis runs. You can also select a single unit from the rack, in which case diagnosis will be faster. For the units not selected, no diagnosis will be performed.

Slot number field Normally, all units on the rack are diagnosed consecutively at regular

intervals. The slot for the unit currently undergoing diagnosis appears in this field. If a diagnosis has been interrupted, or if no unit has been selected for diagnosis, an "XX" appears instead of a slot number.

5.2.2 Rack Illustration

Screen area 2 shows the rack to be diagnosed according to data read from FP-Safe. A total of 15 units can be displayed. If the controller unit is running properly, it appears in slots 0-1. Because of its size, the controller unit requires 2 slots. If a defective unit has been mounted, it is highlighted with a light red background color. The slot number beneath that unit is highlighted in bright red.

Rack illustration with 2 defective units

To display the error data, click the slot numbers that have been highlighted. Any errors that have occurred are then displayed with an error number and a brief description.

Slot numbers outlined in blue signify the units you have selected with the button. If the unit selection option has been activated, you can select or deselect additional units for diagnosis.


5.2.3 Enlarged View of the Selected Unit

When you select a unit from the rack, an enlarged view of the selected unit appears in screen area 3. In addition, several diagnosis items concerning the selected unit appear in screen area 4. To ensure that signal colors can be recognized in the enlarged view, the defective units that were originally highlighted in red (in screen area 2) are not highlighted.

Both the rack illustration and the enlarged view show status and diagnosis data concerning the units.

The rectangular LEDs at the left of the units change from gray to green if their SRFs have been activated. The round LEDs at the right show the signal status on the units' inputs and outputs: green LEDs for signal level HIGH or gray LEDs for signal level LOW.

� NOTE

Because of the high speed of data download via the COM port, signals that are rapidly changing cannot be displayed accurately.

5.2.4 Status Information Screen

The status information screen displays diagnosis data concerning the selected unit, and is thus unit-dependent (see page 93).

89


5.2.4.1 Controller Unit

Parameter Function

SRF1 – SRF5 Safety-related function 1 – safety-related function 5

TH Two-hand control

F11, F12, F13, MT1 Settings for channel 1


OMS Operation mode switch

RSM1 activated Rotation speed monitoring activated/deactivated for channel 1

RSM2 activated Rotation speed monitoring activated/deactivated for channel 2

SS1, SS2 Standstill monitoring activated/deactivated for channel 1/2

RS1, RS2 Status of the virtual output for rotation speed monitoring (activated = HIGH, deactivated = LOW)

RSLT Restart lockout

CG Clock generator

Actual frequency channel A/B Actual frequency determined by channels A and B

Standstill target value Predefined target value for standstill monitoring

Rotation speed target value Predefined target value for rotation speed monitoring

To open the dialog with the rotation speed values, choose [RSM].

� NOTE

This option is recommended if the application file ".SLW2" is not available.

90


5.2.4.2 Motion Monitoring Unit

Parameter Function

SRF1, SRF2 Safety-related function 1 – safety-related function 2

TH Two-hand control

RSLT Restart lockout

Slot Slot number for data displayed here

Flashcard SD memory card whose data content is displayed here

Sin/Cos, TTL Operation mode for motion monitoring unit

Target value Target value for selected motion monitoring unit

Actual value As-is value recorded at motion monitoring unit

RS1/RS2 Rotation speed monitoring status (activated / deactivated)

SS1/SS2 Standstill monitoring

BR1/BR2 Brake monitoring


L, R Left-hand, right-hand rotation

If you have selected "MT1" in the application, the motion monitoring unit's target value will be defined as "infinite." In the target value field, "no limit" appears.

If "Position monitoring" is activated for the rotation speed card, the incremental values appear instead of the actual (i.e., as-is) and target values. In this case, the numbers displayed are labeled "Inc".

91


5.2.4.3 Relay Expansion Unit

Parameter Function


A1 – A4 Output terminal status

A1-EDM – A4-EDM External device monitoring for A1 – A4

5.2.4.4 Transistor I/O Expansion Unit

Parameter Function


SRF1, SRF2 Safety-related function 1 – safety-related function 2

TH Two-hand control

92


5.2.5 Unit Illustrations: What to Watch For

In the diagnosis program, the unit illustrations will differ in accordance with their varying builds.


In the following figure, the motion monitoring unit has two terminals for monitoring rotation speeds: Additional text and graphics elements display the signal status on these connectors.

1 Encoder box for RSM1 with related information

2 Encoder box for RSM2 with related information

3 LED for RS1. LED changes from gray to green if RSM1 has been activated

4 LED for RS2. LED changes from gray to green if RSM2 has been activated

5 LED block displays rotation speed monitoring status.

Rotation speed < Target value LED block lights up in green

Rotation speed > Target value LED block lights up in red

6 Direction monitoring. The arrow points in the direction of rotation.

7 Text field for standstill monitoring.

At machine standstill, a red "STOP" appears in the text field

If the machine is rotating, a green "<GO>" appears

93


5.3 Starting a Diagnosis

You can use the diagnosis function to detect errors quickly and to evaluate your system status; it also enables you to take the required steps to eliminate such errors.

To start a diagnosis, proceed as follows:

1.2.3.

Procedure

1. Select the "Rack diagnosis" tab

The rack illustration (see page 88) appears. When the rack illustration download is complete, the diagnosis program automatically attempts to establish a connection with FP-Safe.

2. Wait for notification

If a connection has been established, "Please wait" appears; this message disappears after all data required for the rack illustration has been downloaded from FP-Safe. If the connection with FP-Safe has failed, an error message appears. In this case, you must ensure that the appropriate COM port (see page 86) has been selected, and that the devices have been properly wired.

After a connection has been established, the program automatically selects all units on the rack, and diagnoses them in consecutive order. First, a continual status evaluation is run on all input and output terminals in consecutive order. Errors, if any, are immediately recognized and displayed. The diagnosis keeps running until you have selected another option in the main menu. You can start a new diagnosis

at any time by pressing the button.

� NOTE

If you have made any changes to the FP-Safe application that is scheduled for diagnosis, you must update the basic diagnosis information by pressing the

button.

There are two kinds of errors:

System-OFF errors, which can cause a system shutdown (error codes 01 – 18 and 24 – 64)

Status-related errors indicating that FP-Safe's system status is abnormal but noncritical (i.e., will not cause a shutdown; in this case, the error code numbers are 65 and higher)

94

FP-Safe User's Manual 5.3 Starting a Diagnosis

For every error detected, the unit's slot number is highlighted in red on the rack illustration. To display unit-specific errors, select the slot that is highlighted in red.

5.3.1 Error Diagnosis

To display a separate list of system-OFF errors, use the button.

� NOTE

To display the full-length error text, select the colored field next to the error description.

1 "Display current errors" icon

If this button is activated, any error information currently being generated by FP-Safe is continually read and displayed.

2 "Display errors last saved" icon

If this button is activated, the error data last detected and saved by FP-Safe is continually read and displayed.

All errors detected are saved in an EEPROM, and can be displayed after a power outage. If FP-Safe has reported an error, but has resumed operation after a

95


power outage, you use this function to determine what caused the error in order to prevent its recurrence.

3 "Delete archived errors" icon:

The errors last saved can be deleted with this button.

4 Password field If FP-Safe is being operated with a password, you must enter the correct password to be able to delete the errors.

5 Icons for error display (total: 64)

If an error has occurred, the error button is highlighted in red. To obtain additional information on an error, press the highlighted button. With the exception of errors 19 – 24 (dynamic trigger SRF1 – dynamic trigger SRF5), all other errors on this screen represent status errors that can cause a system shutdown.

If an error has occurred, certain buttons now display a number (in this illustration: 4). This number is the slot number of the unit that has triggered the error.

6 Diagnosis progression icon

During an ongoing system-OFF error diagnosis, this circle continually changes color. This enables you to determine whether the diagnosis is working properly.

7 Identification properties When creating an application with FP-Safe Configurator, a programmer can add (see page 42) properties for identification of the machine, the programmer's name, checksums, and the library versions of the firmware used. These

identification properties are read from FP-Safe every time you choose .

5.3.2 History

For every FP-Safe configuration, FP-Safe saves history checkpoints containing data such as the programming date and time, checksum value, etc.; a maximum of 16 checkpoints is

available. You can use the button to read and display this information.

To delete the history, use the button.

96

FP-Safe User's Manual 5.4 Error Codes

5.4 Error Codes

Error code Description Corrective measure

01 The firmware versions of the master and the slave channel differ!

02 The firmware versions of the master channel and the function unit differ!

Please send us the hardware for testing. Please contact us.

03 The firmware versions of the master channel and FP-Safe Configurator differ!

Ensure that your units are using a firmware version that is supported by your version of FP-Safe Configurator.

04 Error at one of the function units. In the rack illustration, the unit concerned is highlighted in red. This unit requires further testing.

05 Stuck-at error at one of inputs I1 to I6. At one of the inputs, a value cannot be changed.


06 Variant error between FP-Safe Configurator and the controller unit.

The controller unit defined in FP-Safe Configurator must match the one actually used on the rack.

07 Memory card error The memory card you are using is defective. Please exchange the card.

08 --- ---

09 Error at output O5.




Check the output for external signals.

13 Clock error at transistor outputs O6 and O7. Check the outputs for external signals.

14 Hardware error at the transistors.

15 Hardware error at the relays.


16 --- ---

17 Interprocessor communication error Communication between the master and the slave channel has been interrupted. If the error reoccurs after rebooting, replace the card.

18 Hardware error at one of the outputs O2 to O5. Check the outputs for external signals.

19 SRF1 dynamic clock signal error.




23 SRF5 dynamic clock signal of error.

If the inputs of a safety-related function are activated dynamically, the clock signal must be generated by 2 outputs in FP-Safe Configurator (see page 63).

24 --- ---

25 Error on clock signal line T1T2 (outputs O6 and O7).

If the inputs of a safety-related function are activated dynamically, the clock signal must be generated by 2 outputs in FP-Safe Configurator (see page 63).

26 Error at the slave channel after power-up. Please send us the hardware for testing. Please contact us.

27 --- ---

97


98


28 One of the function units is not signaling the controller unit.

Please check whether all function units are installed in the appropriate slots.

In the rack illustration, the unit concerned is highlighted in red. This unit requires further testing.

29 One function unit is signaling the controller unit but not FP-Safe Configurator.

Either (a) the number of function units installed on the rack exceeds the number of units defined in the application, or (b) the units have not been installed in the appropriate slots as defined in the application.

30 Checksum master is not equal to checksum slave. The checksum comparison of both channels yields an error.

31 One or more master channel input pins is displaying signals that differ from those of the slave channel.

32 One or more master channel output pins is displaying signals that differ from those of the slave channel.


33 Error at output O5. Check the output for external signals.

34 The firmware and software do not match. Please send us the hardware for testing. Please contact us.

35 --- ---

36 --- ---

37 --- ---

38 --- ---

39 --- ---

40 --- ---

41 Unknown terminals in the user program and in FP-Safe Configurator.


42 --- ---

43 Timeout power measurement Please send us the hardware for testing. Please contact us.

44 Invalid firmware on one of the units. The firmware versions on all units must be recognized as valid by FP-Safe Configurator. Check all units.

45 Invalid firmware version on the controller unit. The FP-Safe Configurator data is not functioning properly on this unit.

Ensure that the units you are programming with FP-Safe Configurator have valid firmware versions. Please contact us if you have any questions.

46 The controller unit on the rack is inconsistent with the corresponding unit in the user program.

Ensure that the controller units you have installed on your rack match the corresponding units in the user program.

47 Stuck-at fault at one or more of inputs I1 to I6. At one of the inputs, a value cannot be changed.


48 Error at one of the function units. In the rack illustration, the unit concerned is highlighted in red. This unit requires further testing.

49 --- ---

FP-Safe User's Manual 5.4 Error Codes

99


50 Timeout error during serial V.24 communication.

51 Hardware error at the relays.

52 Clock signal / transistor error.

If the error reoccurs after the FP-Safe has been restarted, please send us the unit for testing.

53 The master and slave channel inputs differ! Inputs I1 – I6 are affected.

54 Inconsistency during attempted activation of transistor outputs.


55 Timeout during communication. If the error reoccurs after the FP-Safe has been restarted, please send us the unit for testing.

56 Error during program upload from the library.

57 Error on clock signal line 1.

58 Error on clock signal line 2.

59 Internal communication between the master and the slave channel has not been synchronized.

If the error reoccurs after the FP-Safe has been restarted, please send us the unit for testing.

60 One of the function units is not signaling the controller unit.

Check whether all function units are installed in the appropriate slots. In the rack illustration, the unit concerned is highlighted in red. Possible cause: An interruption in the voltage to the unit in question.

61 Unexpected function unit found in the user program.

Check the user program.

62 The checksums for the master and slave are not equal.

63 The checksums for the slave and for FP-Safe Configurator are not equal.

Reload the user program.

64 Firmware checksum error during power-up. If the error reoccurs after the FP-Safe has been restarted, please send us the unit for testing.

86 No input device at RSM1. Ensure that the rotation speed sensor is connected to RSM1 and is emitting a signal.

87 No input device at RSM2. Ensure that the rotation speed sensor is connected to RSM2 and is emitting a signal.

99 Plausibility test shows rack configuration error. The current rack configuration does not match the unit sequence in the application.

Ensure that you have the correct application on your rack, and check that the configuration matches the unit sequence in the application.

100 Error at Relay1 output. Relay switches to unexpected status.





120 Rotation speed monitoring point 1: Sensor not connected.

121 Rotation speed monitoring point 1: Error(s) at channel A.

122 Rotation speed monitoring point 1: Error(s) at channel B.

The rotation speed cannot be determined via encoder 1. Possible cause: A measurement cable is not connected. Ensure that you are using the correct cable adapter, or check if the encoder is defective.


100


123 Rotation speed monitoring point 1: Synchronization error.

130 Rotation speed monitoring point 2: Sensor not connected.

131 Rotation speed monitoring point 2: Error(s) at channel A.

132 Rotation speed monitoring point 2: Error(s) at channel B.

133 Rotation speed monitoring point 2: Synchronization error.

The rotation speed cannot be determined via encoder 2. Possible cause: A measurement cable is not connected. Ensure that you are using the correct cable adapter, or check if the encoder is defective.





Check the output for external signals.

201 – 220 Error at input I<input number>. Check signal at I<input number>.

101

Index

1

1 channel antivalent................................79

1 channel not safe ..................................78

1 channel parallel....................................79

A

Acknowledgement ..................................67

Acknowledgement input..........................67

Acknowledgement on the controller unit.67

Acknowledgement on the function units .67

Acknowledgement retention time ( ...64, 67

Activation ................................................64

Ambient conditions .................................22

Antivalent control signals........................66

Application data ................................40, 42

Automatic control ..............................15, 52

B

Brake monitoring...............................16, 61

Bus diagnosis .........................................87

Bus system ...............................................9

C

Calculating 0 - 15....................................75

Checksum value .....................................96

Circuit diagram........................................29

Circuit diagram icon................................31

Connecting circuit diagram icons ......35

Circuit diagram page...............................27

Clock generator ......................................46

Clock signal ............................................78

Colors ...............................................27, 42

COM port ....................................42, 43, 86

Configurable outputs.........................78, 79

on the controller unit ..........................78 on the motion monitoring unit ............78 on the transistor I/O expansion unit...79

Configuring outputs.................................80

Connection lines

Connection lines, highlighting in color......................................................42

Connection lines, labeling .................42 Creating branched connection lines ..35 Deleting connection lines...................35

Controller unit ...................................10, 23

Technical data ...................................23

Creating a project directory ....................42

Creating a safety-related function...........64

Creating a timer ......................................50

Creating an application...........................40

Current values ........................................54

D

Degree of protection ...............................22

Delayed emergency stop........................46

Diagnosis contact ...................................77

Diagnosis menu......................................87

Direction monitoring....................17, 61, 93

Downloading application to FP-Safe ......43

Dual channel OFF...................................64

E

Emergency stop................................68, 69

automatic, at machine error...............69

Emergency stop function ........................68

Encoder box............................................93

Error codes .............................................97

Error diagnosis..................................87, 95

Error types ..............................................94

Index FP-Safe User's Manual

F

Force emergency stop ......................64, 69

FP-Safe Controller Unit.........10, 23, 78, 90

FP-Safe Motion Monitoring Unit.10, 23, 78, 91

FP-Safe Relay Expansion Unit ...11, 23, 92

FP-Safe Transistor IO Expansion Unit...11, 24, 79, 92

G

Grid, for aligning circuit diagram icons...27, 42

H

History...............................................87, 96

I

I/O expansion unit ...................................23

Technical data ...................................23

Inputs ............................. 14, 15, 63, 72, 73

for operation mode switches........15, 73 for safety-related function ............14, 63 for two-hand control .....................14, 72

Installation...............................................20

J

Java version............................................26

L

LEDs .................................................89, 93

Motion monitoring units......................93

M

Measure drive speed ..............................15

Motion monitoring .......................51, 54, 55

Creating motion monitoring .........53, 56 Operation modes ...............................55 with the controller unit........................51 with the motion monitoring unit..........54

Motion monitoring unit ..........10, 23, 78, 91

Technical data ...................................23

Muting ...............................................15, 17

Muting contact.........................................15

O

Off-delayed .............................................48

Off-delayed timer ....................................48

OMS - see operation mode switch..........15

On-delayed .............................................48

On-delayed timer ....................................48

Operation mode ......................................15

Operation mode switch ...........................73

Creating an operation mode switch...73

Output schematics ..................................18

Outputs .............................................17, 19

on the unit ..........................................19

P

Password ................................................42

Permission ..............................................71

Permission contact .................................15

Permission switch ...................................71

Placing automatic connection lines in the circuit diagram.....................................35

Placing manual connection lines in the circuit diagram.....................................35

Position monitoring .................................59

Power supply voltage........................10, 11

Motion monitoring unit .......................23 Transistor I/O expansion unit.............11

Preferred direction ..................................17

Project settings .......................................42

Protection cover ......................................70

Protection cover contact .........................15

102

FP-Safe User's Manual

Index

R

Rack..........................................................9

Rack diagnosis .................................86, 94

Rack illustration ................................87, 88

Read rack data .......................................87

Removal..................................................20

Restart ....................................................67

Rotation speed monitoring................17, 75

Runtime environment..............................86

S

Safety contact outputs ......................19, 77

on the relay expansion unit................77

Safety door (protection cover) function...70

Safety inputs ...........................................14

Safety outputs...................................19, 77

on the controller unit ..........................77

Sample application .................................82

Selecting a unit for diagnosis..................87

Semi-automatic mode.......................15, 52

Setup operation ................................15, 52

Slot number field.....................................87

Specifications..........................................22

Standard diagnosis .................................87

Standstill monitoring ...............................93

Starting a diagnosis ................................94

Status information.......................90, 91, 92

Controller unit ....................................90 Motion Monitoring Unit.......................91 Relay Expansion Unit ........................92 Transistor I/O Expansion Unit............92

Status information screen.......................89

Status-related errors ...............................94

Stuck-at error ..........................................97

Switching GUI language .........................42

System OFF error .............................94, 95

System requirements..............................26

T

Technical data ........................................22

Terminals ................................................80

Time charts .............................................63

Time chart, emergency stop..............68 Time chart, external device monitoring

......................................................31 Time chart, permission switch ...........71 Time chart, safety door / protection

cover.............................................70 Time chart, starter element................31 Time chart, two-hand control .............72

Timer.......................................................48

Tip contact ..............................................15

Tolerance................................................75

Trigger diagnosis ....................................87

Two-hand control ....................................72

U

Unit configuration..............................42, 46

Unit display .............................................93

Unit error.................................................13

Unit parameters ......................................46

Units..........................................................8

V

Vibration resistance ................................22

W

Wiring in the circuit diagram ...................35

103

Record of Changes

Manual Number Date Changes

ACGM0146V1EN July 2010 First edition

Copyright © 2010. All rights reserved. Specifications are subject to change without notice. Printed in Europe. ACGM0146V1EN 7/2010

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PROGRAMMABLE CONTROLLER

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PROGRAMMABLE CONTROLLER FP-Safe