Sysmac Safety Mini Guide - Support

Sysmac Safety Mini Guide - Support
Sysmac Safety Mini Guide
NX Safety Control
Actuators
Sensors
Controllers
Automation Center Europe
Sysmac is a trademark or registered trademark of OMRON Corporation in Japan and other countries for OMRON factory
automation products.
Although we strive for perfection, Omron Europe BV and/or its subsidiaries and affiliated companies do not warrant or
make any representations regarding the correctness or completeness of the information described in this document, we
reserve the right to make any changes at any time without prior notice.
Cat.No. CD_EN_02B+Sysmac-Safety+Guide
CONTENT
1-1
Omron Safety Portfolio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-1-1
1-1-2
1-1-3
1-2
Safety Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3
Safety Architectures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-4
NX Safety Distributed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4-1
1-5
1-6
EtherNet/IP standard network topologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-6-1
1-6-2
1-6-3
1-6-4
1-6-5
1-6-6
1-6-7
1-6-8
1-6-9
1-6-10
1-6-11
1-7
EtherCAT safety network topologies (FSoE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
NX Safety Stand-Alone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-5-1
Safety CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Safety inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Safety outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Version information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Product combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Certifications and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Input sensor types & connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Output safety connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Terminal block references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Safety inputs & outputs calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
How to select the correct S-FBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Software Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-7-1
1-7-2
1-7-3
1-7-4
1-7-5
1-7-6
1-7-7
1-7-8
Sysmac Studio programming tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Main menus standard + safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Safety function block parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Insert input & output parameters in the S-FBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Safety simulation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Online parameters (DEBUG MODE RUN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1-8
Support Engineering Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-9
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1-9-1
1-9-2
Sysmac Safety Mini Guide
Safety sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety controllers family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Programming tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Program structure suggestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1-1
1-9-3
Accepted data types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1-10 NX Safety Distributed: How to... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1-10-1
1-10-2
1-10-3
1-11
Start a safety distributed system step by step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Sysmac Studio EtherCAT configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Backup copy fail safe + standard program from an existing installation . . . . . . . . . . . . . . . 1-30
NX Safety Stand-Alone: How to... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1-11-1
1-11-2
Start a safety stand-alone system step by step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Sysmac Studio EtherNet/IP configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1-12 NX Safety Logic: How to... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1-12-1
1-12-2
1-12-3
1-12-4
1-12-5
Start a system step by step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Transfer the safety program to the safety controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Transfer information from safety to standard program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Transfer information from standard to safety program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Delete the NX-SL memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
1-13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
1-13-1
Find errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
1-14 Standards Brief Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
1-15 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
1-2
Sysmac Safety Mini Guide
1-1
Omron Safety Portfolio
1-1-1
Safety sensors
Category
Appearance
Description/link to the website
A165E
Emergency stop push button 16 mm Ø, optional with LED
http://industrial.omron.eu/en/products/catalogue/safety/emergency_stop_switches/e-stop_pushbutton_switches/a165e/default.html
Emergency
stops
A22E
Emergency stop push button 22 mm Ø, optional with LED
http://industrial.omron.eu/en/products/catalogue/safety/emergency_stop_switches/e-stop_pushbutton_switches/a22e/default.html
ER
Rope pull emergency stop switches, up to 126 mts
http://industrial.omron.eu/en/products/catalogue/safety/emergency_stop_switches/e-stop_rope_pull_switch/default.html
F3S-TGR-N__C/R
Non-contact switches, coded, non-coded, plastic/metal
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/non_contact_switches/f3s_tgr_n_c/default.html
Non-contact
switches
F3S-TGR-N_M/F3S-TGR-N_U
RFID sensor, non-contact switches, master code (M) or unique code (U)
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/non_contact_switches/f3s-tgr-n_m-_u/default.html
D4NS
Safety door switch, plastic
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/safety_door_switch/d4ns/default.html
D4BS
Safety door switch, metal
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/safety_door_switch/d4bs/default.html
Electro
mechanic
position
switches
D4NH
Safety door hinge switch, plastic
http://industrial.omron.eu/en/products/catalogue/safety/safety_limit_switches/safety_limit_switches_plastic/d4nh/default.html
D4N
Safety limit switch, plastic
http://industrial.omron.eu/en/products/catalogue/safety/safety_limit_switches/safety_limit_switches_plastic/d4n/default.html
D4B
Safety limit switch, metal
http://industrial.omron.eu/en/products/catalogue/safety/safety_limit_switches/safety_limit_switch_metal/d4b-_n/default.html
D4NL/D4JL
Guard lock safety door switch, plastic
Safety door
switches with
guard locking
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/guard_lock_safety_door-switch/d4nl/default.html
D4SL-N
Guard lock safety door switch, plastic (metal head available)
http://industrial.omron.eu/en/products/catalogue/safety/safety_door_switches/guard_lock_safety_door-switch/d4sl_n/default.html
Sysmac Safety Mini Guide
1-3
Category
Appearance
Description/link to the website
F3S-TGR-CL
Safety light curtain, finger, hand body detection, type 2 and type 4
http://industrial.omron.eu/en/products/catalogue/safety/safetysensors/safety_light_curtain/f3s-tgr-cl/default.html
Safety light
curtain
E3FS
Single beam safety light sensor, type 2
http://industrial.omron.eu/en/products/catalogue/safety/safetysensors/single_beam_safety_sensors/e3fs/default.html
E3ZS
Single beam safety light sensor, type 2
F3S-TGR-CL_-K_
Safety multi beam sensor, type 2 and type 4
Safety light
curtain for
muting
http://industrial.omron.eu/en/products/catalogue/safety/safetysensors/multi_beam_safety_sensor/f3s-tgr-cl_-k/default.html
E3Z/E3JK
Standard single beam light sensor for muting application
http://industrial.omron.eu/en/products/catalogue/sensing/photoelectric_sensors/compact_square/e3z/default.html
Safety laser
scanner
OS32C
Safety laser scanner, type 3, up to 4 m safety zone, up to 15 m warning zone, up to 70 sets of
combination
http://industrial.omron.eu/en/products/catalogue/safety/safetysensors/safety_laser_scanner/os32c/os32c.html
1-1-2
Safety controllers family
Category/appearance/link to the website
http://industrial.omron.eu/en/products/catalogue/safety/programmable_safety_system/programmable_safety_system.html
1-4
Sysmac Safety Mini Guide
1-1-3
Safety actuators
Category
Appearance
Safety
contactors
Description/link to the website
J7KN
Contactors with mirror contacts according to EN 60947-4-1
http://industrial.omron.eu/en/products/catalogue/switching_components/low_voltage_switch_gear/motor_contactors/j7kn/default.html
G7SA
Relays with forcibly guided contacts according to EN 50205 class A
Safety relays
http://industrial.omron.eu/en/products/catalogue/safety/safety_actuating/relays_with_forcibly_guided_contacts/g7sa/default.html
G7Z
Relays with mirror contacts according to EN 60947-4-1, up to 40 A
http://industrial.omron.eu/en/products/catalogue/switching_components/electromechanical_relays/industrial_high_power_relays/g7z/default.html
Servo
systems with
safety
functions
Accurax G5
STO safety function PLd, through the contact CN8 safety external wired
http://industrial.omron.eu/en/products/catalogue/motion_and_drives/servo_systems/servo_drives/accurax-g5/default.html
Sigma-5
Option board, STO safety function PLd/e, SS1, SS2, SLS, SBB safety functions PLd through the
connectors CN21 and CN22 safey external wired
http://industrial.omron.eu/en/products/catalogue/motion_and_drives/servo_systems/servo_drives/sigma-5/default.html
Inverter
systems with
safety
functions
MX2
STO safety function PLd, through the contact CN8 safety external wired, 3/GS1 and 4/GS2,
11/EDM
http://industrial.omron.eu/en/products/catalogue/motion_and_drives/frequency_inverters/compact_solution/mx2/default.html
V1000
STO safety function PLd, through the contact CN8 safety external wired, H1/H2 HC, without EDM
http://industrial.omron.eu/en/products/catalogue/motion_and_drives/frequency_inverters/compact_solution/v1000/default.html
Sysmac Safety Mini Guide
1-5
1-2
Safety Situations
Situation
Normal
situation
Electrical
Control Safety
system system
Control Power
PLC
S-PLC
Yes
Safety situation
triggered by
guard or protective device
Emergency situation triggered by
emergency stop
push button
-
-
No
Yes
Yes
Yes
No
Yes
Depends,
normally
the power
is active
Yes
Yes, sometime with
few delay
Mechanical
Electronic
Power
Yes
No
Yes
Depends
Yes
Yes, sometime with
few delay
Pneumatic
Hydraulic
ElectroElectro- Hydraulic
Compressor
valve
valve
pump
Yes
No
Yes
Depends,
normally
doesn’t disconnect the
power
Yes
Yes, normally
exhaust the
pipelines
Yes
No
Yes
Depends,
normally
doesn’t disconnect the
power
Yes
Yes, normally driven
the fluid to
the tank
The necessary safety functions and/or protective measures (for example interlocks) shall be provided for safe operation. Measures shall be taken to prevent movement of the machine in an unintended or unexpected manner after any
stopping of the machine (for example due to locked-off condition, power supply fault, battery replacement, lost signal
condition with cable less control).
Where a machine has more than one control station, measures shall be provided to ensure that initiation of commands from different control stations do not lead to a hazardous situation.
• START: The start of an operation shall be possible only when all of the relevant safety functions and/or protective
measures are in place and are operational.
• STOP: The Stop category 0 and/or stop category 1 and/or stop category 2 stop functions shall be provided as indicated by the risk assessment and the functional requirements of the machine. Stop functions shall override related
start functions. Where required, facilities to connect protective devices and interlocks shall be provided. If such a
protective device or interlock causes a stop of the machine, it may be necessary for that condition to be signalled
to the logic of the control system. The reset of the stop function shall not initiate any hazardous situation.
• RESET: This reset shall be possible only by a manual action at that location where the command has been initiated.
The reset of the command shall not restart the machinery but only permit restarting.
• (E-stop) Emergency stop function: The purpose of the emergency stop function is to avert actual or impeding emergency situations arising from the behavior of persons or from an unexpected hazardous event.
The emergency stop function is to be initiated by a single human action.
The emergency stop function shall be available and operational at all times and override all other functions and
operations in all operating modes of the machine without impairing other protective functions (e.g. release of
trapped persons, fire suppression).
When the emergency stop function is activated it shall be maintained until it is manually reset. It shall not be possible for any start command to be effective on those operations stopped by the initiation of the emergency stop
function until the emergency stop function is reset by intentional human action. The reset of the emergency stop
function operated by disengagement of an emergency stop device shall not initiate the machine start up.
The emergency stop function shall not be applied as a substitute for safeguarding measures and other safety functions but shall be designed and incorporated for use as a complementary protective measure.
The emergency stop function shall be so designed, that after actuation of the emergency stop device, hazardous
movements and operations of the machine are stopped in an appropriate manner, without creating additional hazards and without any further intervention.
The emergency stop function shall be so designed that a decision to activate the emergency stop device does not
require the machine operator to consider the resultant effects.
For more information, please refer to EN 60204.
1-6
Sysmac Safety Mini Guide
1-3
Safety Architectures
Not integrated
Integrated but in different networks
Integrated but in different CPUs
Integrated
HMI: Information/Interaction for user’s
PLC: Standard, robotics, motion functions
S-PLC: Safety functions
Costs
Design
Hardware
Installation
Programming
Commissioning
Flexibility
Maintenance
Modifications
Sysmac Safety Mini Guide
Not integrated
€
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ST-Network
FS-Network
€€€
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FS-Network
Different S-CPU
€€
€€€
€€€
€€€
€€€
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Integrated
network
€€
€€€
€
€
€€
€
€€
€
1-7
1-4
NX Safety Distributed
Safety over EtherCAT enables safety-related communication and control communication on the same network.
The safety protocol is based on the application layer of EtherCAT, without influencing the lower layers. It is certified
according to IEC 61508 and meets the requirements of Safety Integrated Level (SIL) 3. The data length is variable,
making the protocol equally suitable for safe I/O data and for safe drive technology. Like other EtherCAT data, the
safety data can be routed without requiring safety routers or gateways.
• The safety controller meets Category 4, PLe according to the EN ISO 13849-1 and SIL3 according to the IEC 61508
• Integration in one software, Sysmac Studio
• Safety Function Blocks conforming with IEC 61131-3 standard programming PLCopen Function Blocks for safety
NJ Machine Controller
Sysmac Studio
NX Safety Controller
ISO 13849-1, PLe
IEC 61508, SIL3
NX Safety I/O
• IEC61131-3 based programming
• Safety FBs PLCopen standard
• User friendly following global standards
1-8
Sysmac Safety Mini Guide
1-4-1
EtherCAT safety network topologies (FSoE)
Daisy chain topology (FSoE)
Branching topology (FSoE)
Sysmac Safety Mini Guide
1-9
1-5
NX Safety Stand-Alone
NX-Safety Stand-alone is a powerful, modular and easily commissioned safety controller which, due to its scalability,
can be efficiently adapted to the requirements of a wide variety of safety applications. Thanks to this modular and
expandable hardware, the compact safety controller grows with its task slice-by-slice – right up to the highest safety
level. You can grow up to 256 I/O points in one single Safety CPU. The design of safe system solutions is thus considerably simplified.
• The system meets PLe according to the EN ISO 13849-1 and SIL3 according to the IEC 61508 and Cat.4
• Safety Function Blocks conforming with IEC 61131-3 standard programming
• Programming with Sysmac Studio software tool
• EtherNet/IP connectivity
Stand-alone
CJ or 3rd party EIP master
1-10
NX-EIC202 coupler
S. Studio
S. Studio
S. Studio
S. Studio
Standard NX-Slices
Local(*)
Remote
Remote
Local(*)
Safety NX-Slices
Local
Only local
Only local
Sysmac Safety Mini Guide
1-5-1
EtherNet/IP standard network topologies
Line
Star
Tree
Sysmac Safety Mini Guide
1-11
1-6
1-6-1
Hardware
Safety CPUs
Name
PL/SIL
PFD
(20 years)
PFH
Program
capacity
Nr nodes
Nr in/out
NX-SL3300*1
“e”
3
7.0E-6
4.4E-10
512 KB
32
256
“e”
3
7.0E-6
4.4E-10
2 MB
128
1024
Appearance
NX-SL3500
*1. For the working with EtherNet/IP, version 1.10 or higher is needed.
1-6-2
Safety inputs
Name
PL/SIL
PFD
(20 years)
PFH
Nr. inputs
Nr. test
pulses
Input
voltage
NX-SIH400*1
“e”
3
6.6E-06
3.8E-10
4
2
11 V
NX-SID800
“e”
3
6.6E-06
3.8E-10
8
2
15 V
Appearance
*1. For the working with EtherNet/IP, version 1.10 or higher is needed.
1-6-3
Safety outputs
Appearance
1-12
Name
PL/SIL
PFD
(20 years)
PFH
Nr. outputs
Max. load
Type
NX-SOH200
“e”
3
7.9E-06
8.8E-10
2
2A
PNP
NX-SOD400
“e”
3
7.9E-06
8.8E-10
4
0.5 A
PNP
Sysmac Safety Mini Guide
1-6-4
Version information
V_Sept_2014
NX unit
Model
NX-SL3300
NX-SL3500
NX-SIH400
NX-SID800
NX-SOH200
NX-SOD400
1-6-5
EtherCAT
Version
ver 1.0
ver 1.1
ver 1.0
ver 1.1
ver 1.0
ver 1.1
ver 1.0
ver 1.0
ver 1.0
Communication
coupler unit
ver 1.1
ver 1.2
ver
ver
ver
ver
ver
1.1
1.1
1.1
1.1
1.1
EtherNet/IP
Communication
CPU unit (NJ) Sysmac Studio
Sysmac Studio
coupler unit
ver 1.07
ver 1.06
ver 1.10
ver 1.0
ver 1.10+
ver 1.08
ver 1.07
ver 1.10
ver 1.06
ver 1.07
ver 1.06
ver 1.10
ver 1.0
ver 1.10+
ver 1.06
ver 1.07
ver 1.0
ver 1.10+
ver 1.06
ver 1.07
ver 1.0
ver 1.10+
ver 1.06
ver 1.07
ver 1.0
ver 1.10+
Product combinations
Sysmac Safety Mini Guide
1-13
1-6-6
Certifications and Approvals
Approved
1-6-7
Input sensor types & connections
INPUT
Detection technology
Connection technology
Mechanic
Electro-mechanic free potencial
Sensor codify. magnetic
Electro-mechanic with potencial
Inductive sensor
Digital with test pulses (1ch)
Transponder sensor
Digital with test pulses (1ch) delay/mirror feedback
Safety camera
Optoelectronic sensor direct reflection
OSSD (2 channels)
Optoelectronic sensor diffuse reflection
1-14
Sysmac Safety Mini Guide
Setting
PL
Single dual
Test pulse
W/o test pulse
c
Single channel
With test pulse
W/o test pulse
d
Dual channel
equivalent
Same test source for
pair of inputs
Different test sources
for pair of inputs
e
W/o test pulse
d
Dual channel
antivalent
e
Same test source for
pair of inputs
Different test sources
for pair of inputs
Error detection
Contact with
Short circuits in
positive side of Ground fault*1 Disconnection
input wiring
power line
NOT detectable NOT detectable NOT detectable
Detectable
Detectable
when inputs NOT detectable
turns ON
Detectable
NOT detectable*2 NOT detectable when inputs NOT detectable*2
turns ON
Detectable
Detectable
Detectable
when inputs
when inputs
NOT detectable
turns ON
turns ON
Detectable
Detectable
Detectable
Detectable
when inputs
when inputs
turns ON
turns ON
Detectable when
Detectable
Detectable
Detectable
inputs turns ON when inputs
when inputs
or OFF
turns ON or OFF turns ON or OFF
Detectable
Detectable
Detectable
when inputs
when inputs
Detectable
turns ON or OFF turns ON or OFF
Detectable
Detectable
Detectable
Detectable
when inputs
when inputs
turns ON or OFF turns ON or OFF
*1. To detect ground faults, the 0V line of the external power supply must be grounded.
*2. Detection possible with the OSSD diagnostic function of the light curtain or laser scanner.
Sysmac Safety Mini Guide
1-15
1-6-8
Output safety connections
Error detection
Contact with positive
side of power line
Test
Short circuits in output wiring
Ground fault*1
pulse Description
Short circuit
diagno- of diagnosis
Short circuit
Short circuit
when
one output
sis
Output ON Output OFF Output ON Output OFF when both out- when both outis ON and other
puts are ON
puts are OFF
is OFF
NOT
NOT
W/o test Test pulses
Detectable Detectable
NOT detectable NOT detectable
Detectable
detectable
pulse
are not detectable
working
With test
NOT
when the Detectable Detectable Detectable
Detectable
NOT detectable
Detectable
pulse
detectable
output is ON
*1. To detect ground faults, the 0V line of the external power supply must be grounded.
1-6-9
Terminal block references
NX unit model
number
NX-SL3300
NX-SL3500
NX-SIH400
NX-SID800
NX-SOH200
NX-SOD400
1-16
Model number
NX-TBA081
NX-TBA082
NX-TBA161
NX-TBA162
NX-TBA081
NX-TBA082
NX-TBA081
NX-TBA082
Terminal block
Number of terminals
Ground terminal mark
8
None
16
None
8
None
8
None
Current capacity
4A
10 A
4A
10 A
4A
10 A
4A
10 A
Sysmac Safety Mini Guide
1-6-10
Safety inputs & outputs calculations
Table to convert Safety functions regarding the PL and Nr inputs and outputs.
The signal lamps indicators, like reset, e-stop lamps...etc, can be a ratio from 45 to 83% of the total safety inputs &
outputs.
Emergency stop
Type
Emergency stop
Push-button or rope
NC- Free pot.
Guide forces
Lamp indicator
LED or lamp
Total
S-In
Safety
S-Out
Standard
In
Out
2
1
2
0
0
Indication
When push-button ok:
contacts closed
Lamp ON: OK
Lamp OFF: NOT OK
Flashing: ESTOP pressed
1
Reset
Type
Reset push-button
NO- Free pot.
Lamp indicator
LED or lamp
Total
S-In
Safety
S-Out
Standard
In
Out
1
1
1
0
0
Indication
Manual and volunteer
action
Lamp OFF: OK
Flashing: Press push-button
1
Operating mode
Type
S-In
Safety
S-Out
Standard
In
Out
Indication
Selector
Positions of selector
NO- Free pot.
8
Mechanical lock, sensor
detects if selector are NO- Free pot.
locked
1
Set mode
Signal 1 of N: when
selector is in this position
Some selectors has a
mechanical key who
block/allows change
position
Signal 1: software allows
changes
Signal 0: software
doesn’t allows changes
1
PNP
Total
9
0
1
0
Safety sensor
Type
Safety
S-In
S-Out
Standard
In
Out
When sensor closed:
contacts closed
Each sensor is decreasing
the voltage, please check
the serial connections
Magnets, RFID...
Sysmac Safety Mini Guide
Switch 1, channel 1
NC- Free pot.
1
Switch 1, channel 2
NC- Free pot.
1
Total
2
Indication
0
0
0
1-17
S-sensors with pulses
Type
D40A/D40Z
Test pulses
Switch 1, channel 1
Switch 1, channel 2
NC- Free pot.
NC- Free pot.
Total
Safety
S-In
S-Out
Standard
In
Out
Indication
When sensor closed:
contacts closed
1
1
2
0
0
0
Guard monitoring
Type
S-In
Safety
S-Out
Standard
In
Out
When guard closed: all
contacts closed
Guard monitor
Switch 1
Switch 2
Indication
NC- Free pot.
NC- Free pot.
Total
1
1
2
Both switches for the
same guard
0
0
0
Guard locking
Type
S-In
Safety
S-Out
Standard
In
Out
Needed when the inertia
in the machine is longer
than the human access
Contact status of the
door
Contact monitor the status lock
Guard interlocking
Channel 1
NC- Free pot.
1
Channel 2
NC- Free pot.
1
Lock - coil
Access request with
lamp
Reset with lamp
Locking is open when no
danger
1
1
NO- Free pot.
Signal dangerous
movement
1
1
Total
4
Lamp flashing: access
already request, wait for
permission
Lamp ON: You can enter
Lamp OFF: No access
required
Exist some inertia in the
machine, or some danger
is remaining
1
NO- Free pot.
Indication
1
1
1
Lamp OFF: OK
Flashing: Press push-button
2
Two hands
Type
S-In
Safety
S-Out
Standard
In
Out
Indication
2 hands monitor
Right hand
Left hand
1-18
NO/NC- Free
pot.
NO/NC- Free
pot.
Total
2
Right hand monitoring
2
Left hand monitoring
4
0
0
0
Sysmac Safety Mini Guide
Footswitch
Type
Safety
S-In
S-Out
Standard
In
Out
Indication
Monitoring the correct
working of the pedal
switch
Pedal/foot switch
Pedal switch
NO/NC- Free
pot.
2
When pedal are press
Pedal switch
Optional
1
When pedal are fully
press
Total
3
0
0
0
EDM
Type
Safety
S-In
S-Out
Standard
In
Out
Monitor any external
actuator
Signal 1: contactors i.e.
working
Signal 0: contactors
switched OFF
Signal 0: contactor working
Signal 1: contactor is OFF
External device monitoring
2
Relays or contactors
Coils
Feedback
NC- Free pot.
2
Total
2
2
Indication
0
0
Light curtain
Type
AOPD - Active opto-electronic protective device
OSSD-output
Test pulses generated
signal switchby the sensor
ing device
Reset with lamp
Sysmac Safety Mini Guide
S-In
Safety
S-Out
Standard
In
Out
Indication
Any resolution and
length
Signal 1: area free
Signal 0: object detected
2
NO- Free pot.
1
Total
3
1
0
0
Lamp OFF: OK
Flashing: presh push-button
1
1-19
Muting
Type
Safety
S-In
S-Out
OSSD-output
AOPD - Active opto-elecsignal switchtronic protective device
ing device
2
Sensor 1
PNP/Free pot.
1
Sensor 2
PNP/Free pot.
1
Sensor 3
PNP/Free pot.
1
Sensor 4
PNP/Free pot.
1
Conveyor moving
PNP/Free pot.
1
Reset with lamp
NO- Free pot.
1
Muting lamp
Muting override with
lamp
Standard
In
Out
Signal 1: area free
Signal 0: object detected
1
1
NO- Free pot.
1
Total
9
Indication
1
1
0
Signal should be 1 when
detect object
Signal should be 1 when
detect object
Signal should be 1 when
detect object
Signal should be 1 when
detect object
Signal 1: conveyor is
moving
Signal 0: conveyor is
stopped
Lamp OFF: OK
Flashing: Press push-button
Optional: When muting
active lamp ON
Lamp ON: override
required
Lamp OFF: OK
Flashing: Press push-button
2
Scanner
Type
S-In
Safety
S-Out
Standard
In
Out
Indication
AOPDDR - Active opto-electronic protective device responsive to diffuse
reflection
Free safety area
OSSD-output
signal switching device
2
Reset with lamp
NO- Free pot.
1
Warning field 1
Warning field 2
PNP
Signal 1: when warning
field free
Signal 0: when warning
field infringed
1
PNP
1
Total
1-20
1
5
Signal 1: when safety
area free
Signal 0: when safety
area infringed
Lamp OFF: OK
Flashing: Press push-button
0
0
1
Sysmac Safety Mini Guide
1-6-11
How to select the correct S-FBs
List of a Safety function vs Safety function blocks.
Safety function
Movable guard
Movable door
Guard locking
Ref
Door_1/2
Door_1/2
D4NL/D4JL
SF_GuardMonitoring
Emergency stop
ES/ES
SF_EmergencyStop
Enable switch
Light curtain
Light barrier (3 beams)
Scanner
Only for Omron
SF_EnableSwitch
A4EG-C000041
A4EG-BE2R041
SF_Equivalent + SF_EmergencyStop
A4EG-BM2B041
All tipes
All tipes
SF_ESPE
All tipes
Operating mode
All tipes
Grip switch
Safety FBs
SF_GuardLocking
SF_ModeSelector
SF_MutingPar
SF_MutingPar_2Sensor
Muting
SF_MutingSeq
Single beam with external test
All tipes
SF_TesteableSafetySensor
SF_TwoHandControlTypeII
2 hand
SF_TwoHandControlTypeIII
Footswitch
Safety Mats
SF_GuardMonitoring
Resistive
2 signals antivalent
2 signals equivalent
External device monitoring
EDM valves and special
actuators
SF_ESPE
SF_Antivalent
SF_Equivalent
Contactors +
relay, servos
Valves or special actuators
SF_EDM
S_FB request
Note For more detailed information about S-FBs, please refer to the Z931 reference manual.
Sysmac Safety Mini Guide
1-21
1-7
Software Tool
1-7-1
Sysmac Studio programming tool
1-7-2
Programming
NJ Series
NX safety CPU unit
1-22
Sysmac Safety Mini Guide
1-7-3
Main menus standard + safety
All configuration of the EtherCAT and NX-slices
are in the Sysmac standard
1-7-4
Safety inputs and outputs, must be defined in the
Sysmac Safety
Safety function block parameters
Note Yellow highlight shows the safety inputs and outputs type.
Sysmac Safety Mini Guide
1-23
1-7-5
Insert input & output parameters in the S-FBs
M_E
Note Please, wait until the target has changed to green color.
Some times, according to your PC speed visualization, may take few seconds.
1-7-6
1-24
Safety simulation panel
Sysmac Safety Mini Guide
1-7-7
Online parameters (DEBUG MODE RUN)
Remember: The safety inputs and outputs are common for Sysmac standard and Safety, so ensure that the Debug are
started to activate the outputs.
1-7-8
Validation
Validation must be only in DEBUG MODE RUN status.
Sysmac Safety Mini Guide
1-25
1-8
Support Engineering Tools
http://industrial.omron.eu/en/products/cad-library
http://www.eplandata.de/portal/portal.php?action=search-list&mf=OMR&qfs=1&clang=en_US&mcat=_eplan&lang=en_US&s=1&edpp=1.0&tab=c&ev=1.9.11&pfsc=-1&ptg=1&pg=9&psg=1
http://industrial.omron.eu/en/services-and-support/technical-support/sistema-library
http://industrial.omron.eu/en/products/software-registration-downloads
1-26
Sysmac Safety Mini Guide
1-9
1-9-1
Programming
Programming tips
Do not uses the instruction in Sysmac Studio RESET ECAT, otherwise all S-FBs will show error.
Do not disconnect nodes, via power supply, via ECAT, or connector, otherwise the watch dog FSoE will be activated.
Do not uses the auto names, each name take time in the safety process.
Suggestions:
• Uses the standard lamps sequence in the safety program, to maintain the same info to user
• Uses the S-External variables in all programs
• Uses SI_ for safety inputs
• Uses SO_ for safety outputs
• Uses M_ for marker information inside the safety program
• Uses M_xxx xxx_OK as a summary of all safety function
• Uses FS_ in the standard program for the signals ho came from safety program
• Uses ST_ in the safety program for the signals ho came from standard program
1-9-2
Program structure suggestion
PREPARATION: All the signals needed for all program,
like, blinking, edges monitoring,...etc
E_STOP: All the signals belonging to emergency stops
MODE SELECTION: All the signals belonging to selecting
operating mode of the machine
GUARDS: All the signals belonging to guards divided in
areas
ENABLING: All the signals belonging to enabling’s
MUTING: All the signals belonging to a mutings
GUARDLOCKING: All the signals belonging to guard
locking, you can use in the guard’s
LIGHT_CURTAINS: All the signals belonging to light
curtains, yu can use in the guard’s
SCANNERS: All the signals belonging to scanners, you
can use in the guard’s
OPANEL: All the signals belonging to lamps and
signalizing to operator, and the signals to exchange to
standard NJ program
MACHINE RUN: All the signals belonging to allow the
machine run
OUTPUTS: All the signals belonging to safety outputs.
Sysmac Safety Mini Guide
1-27
1-9-3
Accepted data types
Type
Boolean
Bit strings
Integers
Data type
BOOL
SAFEBOOL
BYTE
SAFEBYTE
WORD
SAFEWORD
Safety/standard data type
Range of values
Standard data type
FALSE or TRUE
Safety data type
Standard data type
byte#16#00 to
byte#16#FF
Safety data type
Standard data type
byte#16#0000 to
byte#16#FFFF
Safety data type
INT
SAFEINT
DINT
Standard data type
Safety data type
Standard data type
SAFEDINT
Safety data type
TIME
Durations
SAFETIME
1-28
Standard data type
Safety data type
Notation
bool#0 or bool#1
FALSE or TRUE
byte#2#0101010
byte#2#0101_1010
byte#16#5A
You can use the separator
character “_”.
100
int#-32768 to int#32767
int#100
int#2#00000000_1100100
dint#-2147483648 to
int#16#64
dint#2147483647
-100
t#0ms to
t#2147483647 ms and
t#3000ms
t#0d0h0m0s0ms to
t#24d20h31m23s647ms
Sysmac Safety Mini Guide
1-10
1-10-1
NX Safety Distributed: How to...
Start a safety distributed system step by step
You should have the proper EtherCAT configuration on your program, and check NJ Firmware is 1.6 or higher:
• You can prepare that off-line or
• You can upload the configuration if you have the configuration available
Check if the hardware is the proper one
Rebuild the program
We need to ensure that all parts of the program are properly transferred, Variables, Hardware configuration…
Transfer the program
• Go on-line
• Synchronize
• Turn the standard NJ on RUN mode
Note For Safety configuration, refer to Section 1-12 NX Safety Logic: How to...
Sysmac Safety Mini Guide
1-29
1-10-2
Sysmac Studio EtherCAT configuration
1-10-3
Backup copy fail safe + standard program from an existing installation
The Safety program is stored in the NX-SL3_00 unit, and had not access to the SD memory, therefore only a backup
is possible with computer via Sysmac Studio, and only if the safety program is already VALIDATED.
1-30
Sysmac Safety Mini Guide
During the Upload process you will see similar information as in the following steps.
If you don’t see this message something is wrong. In this case, please try again from the beginning.
Sysmac Safety Mini Guide
1-31
1-11
1-11-1
NX Safety Stand-Alone: How to...
Start a safety stand-alone system step by step
You should have the proper EtherNet/IP system configuration in your program. Please, check in detail all hardware
and their versions.
1-32
Sysmac Safety Mini Guide
Sysmac Safety Mini Guide
1-33
Transfer the program
• Go on-line
• Synchronize
• Turn the standard coupler on RUN mode
Note For Safety configuration, refer to Section 1-12 NX Safety Logic: How to...
1-11-2
1-34
Sysmac Studio EtherNet/IP configuration
Sysmac Safety Mini Guide
Sysmac Safety Mini Guide
1-35
1-12
1-12-1
NX Safety Logic: How to...
Start a system step by step
Please, be aware that all previous steps for standard system are described in the previous chapters according to your
system.
Safety configuration
Switch to the Safety program. All modifications should be off-line.
a) Establish the hardware and S-I/O’s configuration.
b) Put names in the I/O map table, this names will be used in the logic.
c) Start your S-Logic program code.
Establish the hardware configuration
1-36
Sysmac Safety Mini Guide
In that area you should configure the inputs and outputs on a hardware level, which means:
Inputs: Mechanical contact for single channel
or dual channel, with or without test pulses.
Semiconductor, dual channel (OSSD) or single
channel
Outputs: Dual channel with or without test pulse,
single channel with or without test pulse
You can write the name of the input and output information, it will be displayed as a variable comment in the I/O
map.
Note We recommend not change source parameters until you have the real hardware.
Allocate the I/O map
You should allocate the configured hardware I/O, write the variable name in order to use the hardware in the program.
Sysmac Safety Mini Guide
1-37
Program the safety logic
In the Programming area, you should insert all safety FB you may need.
Some tips are explained in the Section 1-7 Software Tool.
To select the correct S-FBs for your application, please refer to Section 1-6-11 How to select the correct S-FBs.
1-12-2
Transfer the safety program to the safety controller
Once you’re sure the program code is correct, and already simulated we can transfer:
a) Before you transfer the program you should build them.
b) Go on-line:
c) To transfer the program in the safety, we have special DEBUG mode (no insert a password).
1-38
Sysmac Safety Mini Guide
d) You already transfer the program, but you need to START-it.
e) Check if your program fulfill your expectations and needs.
f) As soon as you’re sure that the program is correct, and from Debug start/run mode, please validate (means
auto-run) or (Ctrl+4).
This message confirms that your program is correctly validated.
Sysmac Safety Mini Guide
1-39
1-12-3
Transfer information from safety to standard program
Please, follow this sequence:
Even that the safety and standard are integrated, internally work as independent system.
You should have the variables defined in the safety global variables in the safety program.
After that should be defined as an input or output to safety program in the EXPOSED VARIABLES.
Transfer to the S-PLC and start them.
Output in safety program means input in ST area.
Distributed system
Change to the standard area CPU unit and insert the new name in the I/O map.
1-40
Sysmac Safety Mini Guide
Stand-alone system
You need to assign the slice and bits for the standard I/O’s.
1-12-4
Transfer information from standard to safety program
Please, follow this sequence:
Even that the safety and standard are integrated, internally work as independent system.
We should start from the safety CPU, global variables (defined as bool).
...and exposed variable.
Input in safety program means output in ST area.
Sysmac Safety Mini Guide
1-41
Distributed system
Change to standard area.
Use the defined variables in the standard program.
Stand-alone system
1-42
Sysmac Safety Mini Guide
1-12-5
Delete the NX-SL memory
Select the coupler and connect the USB cable directly, (ensure that your PC recognizes the USB port connection).
If you are not available to go to the online menu, please check your USB configuration.
Select the NX-SL safety CPU, and with the right mouse + click open the menu, after that select “Clear all memory”.
You should wait until message memory deleted successful.
Sysmac Safety Mini Guide
1-43
After that select the coupler unit, press the right mouse and click open the menu.
As soon as you have the confirmation of deleted programs, please proceed with power off for 5 seconds and transfer
the programs again, starting from non safety and after that the safety program.
1-44
Sysmac Safety Mini Guide
1-13
Troubleshooting
Indicator
Color
Status
Lit
Green
TS indicator
-
Green
FS indicator
Sysmac Safety Mini Guide
The unit is operating normally
The unit is ready to refresh I/O
Flashing at Initialization is in progress (from when the power supply is turned
2-s intervals ON until ready mode is entered)
Lit
Red
Meaning
A hardware error, WDT error, or other serious error has occurred
Flashing at An NX bus communications error or other recoverable minor error
1-s intervals that is attributed to the NX bus has occurred
Not lit
Power is not being supplied
Lit
The FSoE slave connection is established and there are no errors
in any of the functions in the safety I/O unit
Flashing at
The FSoE slave connection is being established
1-s intervals
Red
Flashing at An FSoE communications error, safety I/O terminal error, or other
1-s intervals minor error has occurred
-
Not lit
Power is not being supplied or a fatal fault has occurred
1-45
1-13-1
Find errors
The safety and the standard errors are on the same database. (in the standard)
Safety Troubleshooter you can detect:
• Hardware inside I/O devices, slices or external
• Safety Function Block Problem (signals missing, sequence not correct,....)
• Safety I/O Hardware Problem (short cuts, dual signals synch, hardware...etc)
• You can find the detailed error in the details area.
1-46
Sysmac Safety Mini Guide
1-14
Standards Brief Information
• EN 13849-1: Performance Level
• EN 62061: Safety Integrity Level
Sysmac Safety Mini Guide
1-47
1-15
Glossary
Abbreviation
ACR
AOPD
AOPDDR
CCF
CRC
DC
E/E/PES
EDM
ESPE
FMEA
FS
FSoE
MTTF
MTTFd
PDS
PDS(SR)
PES
PFD
PFH
PFHd
PL
SIL
SRP/CS
STO
1-48
Description
Automatic Configuration Recovery
Active Opto-electronic Protective Device
Active Opto-electronic Protective Device responsive to Diffuse Reflection
Common Cause Failure
Cyclic Redundancy Check
Diagnostic Coverage
Electrical, Electronic & Programmable Electronic Safety related systems
Electrical Device Monitoring
Electro-Sensitive Protective Equipment
Failure Mode Effects Analysis
Functional Safety
FailSafe over EtherCAT
Mean Time To Failure
MTTFd Mean Time To Failure
Power Drive System
Power Drive System (Safety Related)
Programmable Electronic Systems
Probability of Failure on Demand
Probability of Failure per Hour
Probability of dangerous Failure per Hour
Performance Level
Safety Integrity Level
Safety-Related Part(s) of Control System
Safe Torque Off
Sysmac Safety Mini Guide
CD_EN_02B+Sysmac-Safety+Guide
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