Sick Safe Linear Positioning Operating instructions

OPERATING INSTRUCTIONS
Safe Linear Positioning
Safety system
Described product
Safe Linear Positioning
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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CONTENTS
Contents
1
2
3
About this document........................................................................
7
1.1
1.2
1.3
1.4
1.5
Purpose of this document........................................................................
Scope.........................................................................................................
Target groups and structure of these operating instructions................
Symbols and document conventions......................................................
Further information...................................................................................
7
7
7
8
8
Safety information............................................................................
9
2.1
2.2
2.3
2.4
9
9
9
9
Product description........................................................................... 11
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.2
4.3
4.4
4.5
4.6
4.7
Manufacturer of the machine..................................................................
4.1.1
Calculating the performance level..........................................
Operating entity of the machine..............................................................
Design........................................................................................................
Integrating the equipment into the electrical control.............................
4.4.1
Circuit diagram.........................................................................
Testing plan...............................................................................................
Extension and modification......................................................................
Notes on fault detection...........................................................................
4.7.1
Illegible bar codes....................................................................
4.7.2
Bar code gaps..........................................................................
17
17
18
18
18
18
18
19
20
20
20
Mounting the sensor unit.........................................................................
Mounting the bar code tape....................................................................
Mounting Flexi Soft...................................................................................
21
22
23
Electrical installation........................................................................ 24
6.1
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11
11
12
12
13
14
15
15
16
Mounting............................................................................................. 21
5.1
5.2
5.3
6
Product identification...............................................................................
Application description.............................................................................
Components of the safety system...........................................................
Additional components required.............................................................
3.4.1
Requirements for additional components required..............
Structure and function.............................................................................
Limits of the safety system......................................................................
Product characteristics............................................................................
3.7.1
Safety functions.......................................................................
3.7.2
Safe state.................................................................................
Project planning................................................................................ 17
4.1
5
General safety note..................................................................................
Intended use.............................................................................................
Reasonably foreseeable misuse..............................................................
Requirements for the qualification of personnel....................................
General requirements..............................................................................
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3
CONTENTS
6.2
6.3
6.4
7
24
24
26
28
28
29
30
30
31
31
31
Configuration..................................................................................... 32
7.1
7.2
7.3
7.4
7.5
7.6
7.7
4
Connection and wiring..............................................................................
6.2.1
Wiring principle........................................................................
Safety controller pin assignment.............................................................
Interfaces and signals..............................................................................
6.4.1
Standard input interface: test signals....................................
6.4.2
SSI interface.............................................................................
6.4.3
Signal for PDS (SR) - drive (safety-related).............................
6.4.4
Signal for optional safe brake control....................................
6.4.5
Safe SLS request signal..........................................................
6.4.6
Signal for emergency stop pushbutton..................................
6.4.7
Signal for restart interlock.......................................................
Structure and application of the chapter on configuration....................
Requirements for software and firmware...............................................
Configuration procedure..........................................................................
7.3.1
Pre-configured project files.....................................................
7.3.2
Configuring the interface for BG100 motion sensor.............
7.3.3
Configuring speed limits..........................................................
7.3.4
Configuring position ranges....................................................
7.3.5
Assigning maximum speeds to the position ranges..............
7.3.6
Configuring safe cam (SCA)....................................................
7.3.7
Configuring stop ramps...........................................................
Expanding and modifying the safety system..........................................
7.4.1
Configuring additional safety functions.................................
7.4.2
External and internal signal for activating the safely limited
speed........................................................................................
7.4.3
Configuring the override function...........................................
7.4.4
Controlling the safety outputs directly via PLC......................
7.4.5
Use of internal status information..........................................
Contents of the CPU logic.........................................................................
7.5.1
Disclaimer page.......................................................................
7.5.2
Interface page..........................................................................
7.5.3
Safe Outputs page...................................................................
7.5.4
Safe Position and Diagnostics page.......................................
7.5.5
Stop/start/reset page.............................................................
Contents of the motion control logic.......................................................
7.6.1
Position_Cross_Check page....................................................
7.6.2
Position_Monitor page.............................................................
7.6.3
Safe Stop page.........................................................................
Notes on the Flexi Soft logic editor..........................................................
7.7.1
Creating or deleting links.........................................................
7.7.2
Jump addresses.......................................................................
7.7.3
Verification of the logic............................................................
7.7.4
Transfer configuration.............................................................
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32
32
33
35
37
40
41
42
45
49
49
51
52
53
53
54
54
55
55
57
61
64
64
66
69
71
71
72
72
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8
Commissioning.................................................................................. 73
8.1
8.2
Safety.........................................................................................................
Thorough check........................................................................................
9
Operating the components.............................................................. 74
10
Maintenance of the components.................................................... 75
11
Troubleshooting................................................................................. 76
11.1 Electromagnetic compatibility..................................................................
11.2 Exchange and repairs...............................................................................
12
13
77
Technical data.................................................................................... 78
13.1
13.2
13.3
13.4
14
76
76
Decommissioning............................................................................. 77
12.1 Disassembly and disposal.......................................................................
Data sheet.................................................................................................
XTIO module inputs..................................................................................
Dimensional drawings..............................................................................
Response times........................................................................................
13.4.1 Stopping time in the event of a drive fault.............................
13.4.2 Flexi Soft cycle time.................................................................
13.4.3 Maximum data reception interval...........................................
78
79
80
80
81
81
82
Ordering information........................................................................ 83
14.1 Safe Linear Positioning ordering information.........................................
83
15
Spare parts......................................................................................... 84
16
Accessories........................................................................................ 85
16.1 Connectivity...............................................................................................
17
85
Annex.................................................................................................. 86
17.1 Checklist for initial commissioning and commissioning........................
17.1.1 Thorough check of the requirements specified in the oper‐
ating instructions for the safety system.................................
17.1.2 Thorough check of the hardware requirements....................
17.1.3 Thorough check of the Flexi Soft configuration.....................
17.1.4 Thorough check of the Flexi Soft documentation..................
17.1.5 Thorough check on the process channel (standstill)............
17.1.6 Thorough check on the process channel (forward move‐
ment)........................................................................................
17.1.7 Thorough check on the process channel (backward move‐
ment)........................................................................................
17.1.8 Thorough check of the safety functions.................................
17.1.9 Thorough check of faults on the transmission path..............
17.1.10 Thorough check for foreseeable misuse and manipulation.
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86
87
88
89
90
90
91
92
92
93
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CONTENTS
17.1.11 Thorough check of the response time of the safety system
within the target application...................................................
17.1.12 Thorough check of the check intervals..................................
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ABOUT THIS DOCUMENT 1
1
About this document
1.1
Purpose of this document
These operating instructions contain the information required during the life cycle of the
safety system. This document describes:
•
•
•
•
•
•
•
•
1.2
The individual components
The project planning
The mounting and electrical installation, insofar as special measures are neces‐
sary for the safety system
The configuration
The necessary thorough checks
The commissioning
The maintenance
The troubleshooting
Scope
These operating instructions contain information regarding the Safe Linear Positioning
safety system.
NOTICE
The operating instructions of the components also apply. In the event of contradictions
between the operating instructions, the information specified in the operating instruc‐
tions for the safety system applies.
The relevant information must be made available to the employees for all work per‐
formed on the safety system.
The following documents contain information regarding the Safe Linear Positioning
safety system:
Table 1: Documents available for Safe Linear Positioning
Document type
Title
Part number
Operating instructions
OLM100 Hi linear measure‐
ment sensor
8014310
Operating instructions
Flexi Soft in the Flexi Soft
Designer software
8012998
Operating instructions
Flexi Soft modular safety con‐
troller hardware
8012999
This document is included with the following SICK part numbers (this document in all
available language versions):
8020939
1.3
Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
opers (planners, developers, designers), installers, electricians, operators, and mainte‐
nance personnel.
These operating instructions are organized by the life phases of the safety system:
project planning, mounting, electrical installation, commissioning, operation and main‐
tenance.
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1 ABOUT THIS DOCUMENT
1.4
Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
1.5
b
The arrow denotes instructions to action.
1.
2.
✓
The sequence of instructions for action is numbered.
Follow the order in which the numbered instructions are given.
The check mark denotes the result of an instruction.
Further information
www.sick.com
The following information is available via the Internet:
■
■
■
■
■
■
■
■
8
This document in other languages
Operating instructions and installation instructions of SICK components suitable
for the safety system
The Flexi Soft Designer configuration software
Pre-configured project file for Flexi Soft Designer for this safety system
Export file of the pre-configured project file for use in various Flexi Soft CPU mod‐
ules
Complete subsystems for SISTEMA for this safety system
Circuit diagram for the safety system (ePLAN)
Guide for Safe Machinery (“Six steps to a safe machine”)
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SAFETY INFORMATION 2
2
Safety information
2.1
General safety note
The information and tools will not fulfill the safety requirements for your application
without further adjustments being made. The project planning provided by way of exam‐
ple is intended to serve as the basis to allow you to perform your own project planning
and programming in line with your specific requirements. What this means is that the
information and tools merely provide an example to demonstrate how a safety function
can be taken care of.
When it comes to your own project planning and programming, you will need to rely on
qualified staff given that it is your responsibility to ensure that the following require‐
ments are complied with at the very least:
b
b
b
2.2
Carrying out a risk assessment
Taking into account applicable standards
Verifying and validating the safety function
Intended use
The Safe Linear Positioning safety system is designed for applications in which the posi‐
tion of linear drive systems (e.g., on rail systems) must be reliably detected.
Safe Linear Positioning is used to protect people. In terms of the Machinery Directive,
Safe Linear Positioning is a safety component that guarantees a safety function.
2.3
Reasonably foreseeable misuse
It may not be possible for the system to detect a potential mounting error that involves
the distance between a sensor and bar code tape falling outside of the permissible
range. For mounting instructions, see "Mounting the sensor unit", page 21.
WARNING
There is a risk of death or serious injury if the protective device is not working effec‐
tively.
b
Comply with the permitted speed.
The maximum permitted speed for this safety system is 4,000 mm/s. The speed must
not exceed this limit.
If a lower maximum speed applies to the application in question, it must be configured
as the maximum speed limit.
2.4
Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and ser‐
viced by qualified safety personnel only.
Project planning
For project planning, a person is considered competent when he/she has expertise and
experience in the selection and use of protective devices on machines and is familiar
with the relevant technical rules and national work safety regulations.
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2 SAFETY INFORMATION
Mechanical mounting, electrical installation, and commissioning
For the task, a person is considered qualified when he/she has the expertise and expe‐
rience in the relevant field and is sufficiently familiar with the application of the protec‐
tive device on the machine to be able to assess whether it is in an operationally safe
state.
Configuration
For configuration, a person is considered competent when he/she has the expertise
and experience in the relevant field and is sufficiently familiar with the application of
the protective device on the machine that he/she can assess its work safety aspects.
Operation and maintenance
For operation and maintenance, a person is considered competent when he/she has
the expertise and experience in the relevant field and is sufficiently familiar with the
application of the protective device on the machine and has been instructed by the
machine operator in its operation.
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PRODUCT DESCRIPTION 3
3
Product description
3.1
Product identification
The part number of the safety system is located on the packaging.
Further topics
•
3.2
"Ordering information", page 83
Application description
The Safe Linear Positioning safety system is designed for applications in which the safe
position monitoring of linear drive systems is required. Target applications are, for
example:
•
•
•
•
•
Skillet conveyors
Cranes
Storage and retrieval systems (SRS)
Gantry robots
Applications in which movable devices need to be positioned in relation to a refer‐
ence
The safety system fulfills the requirement of detecting the safe absolute position in the
case of linear drive systems. This makes it possible, for example, to safely delimit posi‐
tion ranges within which the maximum permitted speed is safely reduced so as to pro‐
tect people and materials.
The system can be used to determine the current movement status, including, e.g., the
position, speed, and acceleration at any point in time. If movement statuses cannot be
reliably detected or if there is a fault, the safety-related task of the safety system is to
switch the relevant parameterized outputs of the safety controller to the safe state.
If it is necessary to initiate and/or safely monitor a ramp or speed reduction at certain
positions, the safety system provides the corresponding safe position data alongside
the underlying safety functions for the machine. Additional safety functions can be
added to the safety system.
OLM100 Hi absolute displacement sensors (optical linear measurement sensors) from
SICK are used to monitor linear movements. These are opto-electronic sensors that can
measure product travel paths without moving parts. The sensors orientate themselves
using a bar code tape attached along the product travel path, using a visible, red LED
beam. By reading the bar code, the linear measurement sensors determine the
absolute position and deliver this via an interface. The Flexi Soft safety controller from
SICK, which also forms part of the safety system, uses appropriate diagnostics mea‐
sures to check whether the absolute positions of the OLM100 Hi sensors are plausible.
3.3
Components of the safety system
Safe Linear Positioning components
• 2 x OLM100 linear measurement sensor
• Flexi Soft safety controller main module
• Flexi Soft safety controller expansion module - I/O module (8 inputs, 4 outputs)
• Flexi Soft safety controller expansion module - motion control module (Flexi Soft
Drive Monitor)
• Flexi Soft safety controller system plug
• X-junction
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3 PRODUCT DESCRIPTION
Implementing all the safety functions for the application requires a complete system
consisting of sensors, a controller, actuators, and control switches. This safety system
comprises sensors and a controller only and is therefore only a subsystem. The require‐
ments for the additional components are defined in the system documentation. The
user is responsible for the safe design of the complete system and all safety functions.
The machine manufacturer must refer to the standard general guidelines for creating
safety functions within their application (see "Limits of the safety system", page 14).
3.4
Additional components required
The following components are also essential for using the safety system in an applica‐
tion:
•
Bar code tape
NOTE
All necessary components, such as the drive and safety brake, influence the parame‐
ters of the entire application that relate to safety technology. The components must
therefore have an MTTFd value that is suitable for the entire application and satisfies
the necessary performance level. The necessary performance level results from the risk
assessment.
For evaluating the performance level achieved, subsystems for SISTEMA are available
under:
www.sick.com
3.4.1
Requirements for additional components required
All safety-related components must be checked to ensure that they are suitable for use
with this safety system. This also applies to components that are not specified by this
safety system.
The safety values for the SLS request signal, the drive, the safe torque off (STO) function,
and the optional brake must be selected such that they at least comply with the PL e
general safety level. The structure must correspond to category 4.
The following table shows examples of PFHD values that allow for PL e to be reached.
Table 2: PFHD values when a brake is used (safe brake control)
Component
PFHD value
Subsystem T130: SLS request signal
PFHD ≤ 6 x 10-9
Subsystem R110 PDS (SR) - safe torque off (STO) function
PFHD ≤ 2.2 x 10-8
Subsystem R120 brake (optional)
PFHD ≤ 4 x 10-8
Table 3: PFHD values when a brake is not used (no safe brake control)
Component
PFHD value
Subsystem T130: SLS request signal
PFHD ≤ 6 x 10-9
Subsystem R110 PDS (SR) - safe torque off (STO) function
PFHD ≤ 6.7 x 10-8
If a safety brake (R120) is not used, the SLS request signal (T130) and the safe torque
off (STO) function of the drive (R110) may have even worse PFHD values when it comes
to still reaching PL e.
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PRODUCT DESCRIPTION 3
NOTE
The user of this safety system must ensure that all components used comply with the
requirements of category 4, PL e in accordance with EN ISO 13849-1 (or SILCL3 in
accordance with EN 62061).
3.5
Structure and function
On the sensor side, the safety system consists of two OLM100 Hi linear measurement
sensors with a shared bar code tape. On the controller side, the system consists of the
safe Flexi Soft controller, which is made up of the CPU main module, safe XTIO I/O mod‐
ule, and the FX3-MOC1 Drive Monitor module.
The complete system is divided up into the sensor and controller main modules, which
include submodules and general functional modules.
Sensor
Bar code tape measure
OLM 1
Voltage
supply
SSI
Voltage supply
Test request
SensorIDs
SSI
Voltage supply
OLM 2
Splitter
MOC 1
CPU
CPU
MOC 1
Assessment
Safe
Control
Logistics
Safe
Control
Logistics
Assessment
Input XTIO
Output XTIO
Assessment
Assessment
SSI
Communication
Control
Safe outputs
Control
Test signal (from the process)
Figure 1: System concept
The rail system of the linear drive has a bar code tape, e.g., on the mounting rail. Bar
codes are printed onto the bar code tape at fixed distances with linearly increasing dis‐
tance information. The two OLM100 Hi linear measurement sensors read the bar codes
at each position independently. The motion control module of the safety controller uses
the rate of change of the positions read to determine the vehicle’s speed and direction
of travel.
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3 PRODUCT DESCRIPTION
The test signals from the process controller are used to check the plausibility of the
direction of movement and standstill (see "Interfaces and signals", page 28).
OLM 1 is the leading sensor within this sensor system. Its position data is used within
the Flexi Soft safety controller, e.g., to monitor a safely delimited position and to poten‐
tially also monitor the speed. It is connected to the ENC1 input of the FX3-MOC1 mod‐
ule, and its position data is used by the FX3-MOC1 and by the process controller via a
splitter in the X-junction. This means that the user of the safety system has the option
of configuring the ENC1 input of the FX3-MOC1 as an SSI master or SSI listener in line
with the application in question.
OLM 2 is connected only to the ENC2 input of the FX3-MOC1 module, meaning that the
ENC2 interface is configured as an SSI master. The position data from OLM 2 is used
for testing and diagnostic action.
The linear measurement sensors are numbered when the X-junction is connected. The
connector plug for the OLM 2 has a colored mark and must be connected to the linear
measurement sensor for which the bar code tape displays a higher position value.
The two linear measurement sensors (OLM 1 and 2) output a code via the sensor ID
signals that can be used by the Flexi Soft safety controller to identify them.
3.6
Limits of the safety system
The system represents the part of the safety chain (partial safety function) that com‐
bines the sensor and logic. This does not, however, rule out the possibility of expanding
the chain with additional logic elements (e.g., a higher-level control). The output switch‐
ing elements of the Flexi Soft can also be used to control actuators.
The block diagram illustrates the limits of the safety system. For the user, they end at
the terminals of the Flexi Soft controller.
1
2
3
4
5
6
Figure 2: Block diagram for the safety chain
14
1
Sensor
2
Flexi Soft safety controller
3
Actuator
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PRODUCT DESCRIPTION 3
4
Emergency stop
5
Reset/restart
6
External SLS request
NOTICE
The area outside of this system falls within the user’s area of responsibility.
The actuator is not part of the safety system. These components must be introduced by
the user of the safety system in order to implement the full safety function. They must
be taken into account in the overall assessment.
3.7
Product characteristics
3.7.1
Safety functions
The Safe Linear Positioning safety system offers the following functions:
•
Safe stop 1
° This stop function corresponds to stop category 1 as per EN 60204.
•
Safe stop 2
° This stop function corresponds to stop category 2 as per EN 60204.
•
Safe position monitoring
° The Safe Linear Positioning safety system enables reliable position monitor‐
ing through the SCA (safe cam) and SLS (safely limited speed) functions.
•
Safely limited speed
° The position ranges within which only limited speeds are permitted must be
saved as parameters in the Flexi Soft safety controller program. The Safe Lin‐
ear Positioning safety system determines these position ranges automatically
and monitors the speed.
If the maximum permitted speed is exceeded, the Flexi Soft safety controller
initiates a safe stop 2.
° The safely limited speed can also be activated by an internal signal in the
controller or an external signal. This makes it possible for external processes
to activate monitoring of the safely limited speed.
WARNING
There is a risk of death or serious injury as the protective device cannot be
relied upon to monitor speeds that are too low.
Select the correct components in line with the risk assessment.
The lowest speed that can be monitored will depend on the sensor unit in
use. It is either 75 mm/s (part number 1087575) or 9 mm/s (part number
1090629).
•
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Emergency stop (shutting down in an emergency)
° The safety controller of the Safe Linear Positioning safety system provides a
safe dual-channel input to allow for the machine to be shut down in an emer‐
gency.
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3 PRODUCT DESCRIPTION
•
Safe brake control (optional)
° With this safety system, there is the option of using the “safe brake control”
(SBC as per EN 61800-5-2) safety function to control a brake when standstill
has been detected following a completed stop request (SS1). The Safe Linear
Positioning safety system has a dual-channel safety output for this purpose.
The user will be presented with the requirement for a brake in the results of
the risk assessment performed for the specific system.
NOTE
The user is responsible for the safety-focused hardware design of the brake.
The requirements of category 4, PL e (EN ISO 13849-1) must be fulfilled. A
fault in the brake must not lead to the loss of the safety function.
Preparations are also made for the implementation of an override function. However,
there is no logic available in this safety system for the activation of this function. If an
override function is required, the user is responsible for safely implementing it.
3.7.2
Safe state
In the safe state, the accordingly configured safe switching outputs are in the off state.
The machine is and remains switched off. The safe state is initiated in the following
cases:
•
•
•
•
•
•
•
•
•
If one of the safety functions provided by the FX3-MOC1 motion control module is
triggered
If one of the safety functions programed in the Flexi Soft CPU is triggered
If there are connection problems with the signal cables between at least one
OLM100 Hi and the FX3-MOC1
If the required voltage supply to at least one of the FX3-CPU, FX3-XTIO, FX3-MOC1
components and the OLM100 Hi fails
If implausible or impermissible events are detected for at least one of the two
OLM100 Hi sensors
If the statuses of the test signals supplied by the process are implausible or imper‐
missible
If there are faults with the OLM100 Hi sensor
If there are internal faults with the FX3 modules
If an impermissible OLM100 Hi sensor is used
When the safety system initiates the safe state, the machine manufacturer and user
must ensure that the hazard is rectified.
Delivery state
When delivered, Q1 and Q2 of module 1 are the parameterized safe switching outputs.
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PROJECT PLANNING 4
4
Project planning
4.1
Manufacturer of the machine
DANGER
Hazard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
b
Use of the safety system requires a risk assessment. Check whether additional
protective measures are required.
Comply with the applicable national regulations derived from the application (e.g.,
work safety regulations, safety rules, or other relevant safety guidelines).
The safety system was developed under consideration of typical application cases. A
partial safety function can be implemented with the safety system in these application
cases. The manufacturer must check whether the safety system is suitable for its spe‐
cific application case (risk assessment).
If the thorough check shows that the safety system is not suitable for the specific appli‐
cation case, the safety system can be used as a basis for an individualized develop‐
ment. This case will not be considered further in this document.
In any event, additional work is necessary for the safety system to be used, e.g., subse‐
quent configuration of the safety controller.
The manufacturer has the following duties:
b
b
b
b
b
4.1.1
Performing a risk assessment in accordance with ISO 12100
Verifying safety functions that are not part of this safety system
Validating all safety functions
Integrating the individual components in accordance with the appropriate stan‐
dards
Please note that C standards have priority compared to statements about this
safety system
Calculating the performance level
The file provided for SISTEMA can be used to calculate the performance level achieved.
It is necessary to enter the values of the components actually used and to define the
measures taken to protect against failures with the same cause.
The manufacturer of the machine must decide which measures are to be taken against
failures with the same cause in the case of subsystems they have developed. These
measures must be selected in the SISTEMA project file for each user-defined subsys‐
tem. An overall result of 65 must be achieved at the very least.
WARNING
Certain indicators for the individual components were used as the basis for calculating
the values for the subsystems. Accordingly, the subsystems are only valid if the selected
components of the safety system meet all requirements, see "Additional components
required", page 12.
During the development of the safety system, certain measures against common-cause
faults were implemented or defined. Some of these measures must be taken into
account during implementation, see "General requirements", page 24.
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4 PROJECT PLANNING
4.2
Operating entity of the machine
DANGER
Hazard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
b
4.3
Changes to the electrical integration of the safety system in the machine control
and changes to the mechanical mounting of the safety system necessitate a new
risk assessment. The results of this risk assessment may require the entity operat‐
ing the machine to meet the obligations of a manufacturer.
Changes to the safety system’s configuration may impair the protective function.
The effectiveness of the safety system must be checked after any change to the
configuration. The person carrying out the change is also responsible for maintain‐
ing the protective function of the safety system.
Design
This chapter contains information about implementing the design of the safety system.
Any design-related contents of the relevant operating instructions also apply. The follow‐
ing information is provided in the operating instructions for the linear measurement
sensor:
•
•
4.4
Bar code tape variants
Mounting of the bar code tape
Integrating the equipment into the electrical control
NOTE
Several safety functions are generally necessary in order to ensure a safe design for the
entire application. This requires additional components that are not part of the safety
system, such as switches, fuses, and contactors. The circuit diagrams contain informa‐
tion on wiring the safety system with additional components within an application.
4.4.1
Circuit diagram
A more detailed circuit diagram for Safe Linear Positioning is available online:
www.sick.com/Safe_Linear_Positioning
For the detailed pin assignment of the safety controller, see "Safety controller pin
assignment", page 26.
4.5
Testing plan
The safety system must be thoroughly checked by appropriately qualified safety person‐
nel during commissioning, after changes at regular intervals.
The regular thorough checks serve to assess the effectiveness of the safety system and
to identify defects as a result of changes or other influences (e.g., damage or manipula‐
tion).
The manufacturer and user must define the type and frequency of the thorough checks
on the basis of the application conditions and the risk assessment. Determination of
the thorough checks must be documented in a traceable manner.
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PROJECT PLANNING 4
•
•
•
A thorough check must be carried out during commissioning and following modifi‐
cations.
The regular thorough checks of the safety system must fulfill certain minimum
requirements. The minimum requirements for the thorough check of the safety
system comply at least with the sum of the minimum requirements for the thor‐
ough check of the components of the safety system (see operating instructions of
the components).
In many cases, depending on the application conditions, the risk assessment can
determine that further thorough checks are required.
Further chapters
•
•
4.6
Thorough check, see "Commissioning", page 73
Checklist for initial commissioning and commissioning, see "Annex", page 86
Extension and modification
Expansion for additional safety functions
Additional safety functions can be implemented to trigger a safe stop 1 or safe stop 2.
The hardware of the safety system must not be changed when doing so.
For information on configuring additional safety functions, see see "Configuring addi‐
tional safety functions", page 49
Modification
Only the following modifications are permitted:
•
Activation of the safely limited speed function by an external or internal signal (see
"External and internal signal for activating the safely limited speed", page 51)
NOTE
Internal and external trigger signals for activating the SLS function or for integrat‐
ing additional safety functions may only be introduced at the points in the soft‐
ware provided for the respective purpose. Trigger signals and additional safety
functions must comply with the required safety level. It is the responsibility of the
user to provide proof that this is the case.
•
•
Activation of the override function (see "Configuring the override function",
page 52)
Relocation of input and output signals to inputs and outputs with the same func‐
tion on the same or a different module
WARNING
There is a risk of death or serious injury as diagnostics and shock resistance for
the protective device are not reliable.
b
b
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Position inputs and outputs on different modules in such a way that they
have the same properties in terms of safety technology as the inputs and out‐
puts of the original module.
Adjust the current flow diagram accordingly (see "Safety controller pin assign‐
ment", page 26).
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4 PROJECT PLANNING
•
Omission of optional signals for controlling the “Reset required” light, the “Restart
required” light, and the brake of a drive
NOTE
Optional signals do not need to be included if the risk analysis indicates that they
are not required. The application must still comply with the required safety level,
however. It is the responsibility of the user to provide proof that this is the case.
The current flow diagram must be adjusted accordingly (see "Safety controller pin
assignment", page 26 and see "Signal for optional safe brake control",
page 30)
4.7
Notes on fault detection
As a general rule, any fault occurring at the bar code brings about the safe state of the
safety system.
Owing to the system’s internal sensing behavior, a snapshot of the bar code is
assessed as part of the cycle of the system’s internal processing time. This means that,
depending on the drive speed, not every single point on the bar code is assessed.
If a fault occurs at a point on the bar code and no snapshot has been generated for
that point, the system will not detect this fault. This is not critical to safety if correct bar
codes can be read again in good time. If read faults are present across a longer dis‐
tance, the system will switch to the safe state. Compliance with the response times (see
"Response times", page 80) is ensured.
4.7.1
Illegible bar codes
If bar codes are incorrect or if some bar codes have been affixed incorrectly by 180°, it
will not be possible to detect them at a speed of more than 3,700 mm/s in the case of
a length of up to five continuous bar codes (5 x 30 mm = 150 mm). If the length is
more than 150 mm, the system will switch to the safe state.
4.7.2
Bar code gaps
If the following values are exceeded, the system will switch to the safe state.
20
Speed of more than
Gap not detected
1,000 m/s
Up to the length of three bar codes (max. bar
code gap = 90 mm)
2,500 m/s
Up to the length of four bar codes (max. bar
code gap = 120 mm)
3,200 m/s
Up to the length of five bar codes (max. bar
code gap = 150 mm)
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MOUNTING 5
5
Mounting
NOTE
Information is included in the operating instructions for the components.
5.1
Mounting the sensor unit
The sensor unit is always fully mounted when delivered. It consists of two OLM 100 Hi
linear measurement sensors and a special mounting bracket. The sensors must not be
removed from the mounting bracket.
By using the mounting bracket and the safety screws for mounting, all of the mechani‐
cal requirements relevant to the system for the two sensors are taken care of in the
design and implemented. This reduces the risk posed by foreseeable misuse on the
part of the user and by manipulation.
The OLM100 Hi sensors are parameterized in advance and special firmware blocks
access so that parameters cannot be entered using the SOPAS ET software. Only the
approved sensors may be used.
The sensor system must be mounted such that the horizontal axis of the mounting
plate runs parallel to the bar code tape. The gap required between the sensor (front
screen) and the bar code tape must be between 80 mm and 120 mm. A distance of
between 100 mm and 110 mm is recommended.
WARNING
There is a risk of death or serious injury in the event of improper mounting as diagnos‐
tic action cannot be performed reliably.
b
Comply with the mounting distance stipulated.
The beams from the sensor lighting must be positioned centrally on the bar code tape.
Figure 3: Distance between sensor and bar code tape
If the bar code height is 30 mm, the distance between the lower edge of the mounting
plate and the lower edge of the bar code tape must be 22 mm.
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5 MOUNTING
β ≤ ± 3°
1
2
1
Height of bar code tape
2
Distance between lower edge of sensor unit and lower edge of bar code tape
Table 4: Vertical distance dependent upon the bar code tape
Height of bar code tape
Distance
Tolerance
25 mm
13 mm
±3.5 mm
30 mm
9 mm
±3.5 mm
40 mm
4 mm
±8.5 mm
60 mm
-6 mm
±18.5 mm
100 mm
-26 mm
±38.5 mm
100 ± 20 mm
(3.94 ± 0.78)
The mounting requirements set out in the operating instructions for the OLM100 Hi
must also be followed.
5.2
Mounting the bar code tape
WARNING
There is a risk of death or serious injury as diagnostics for the protective device are not
reliable.
Value range monitoring is implemented in the safety system so that diagnostics can be
performed. 0 is therefore not permitted as a minimum value and start value.
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MOUNTING 5
The self-adhesive bar code tapes must be stuck so they are facing the same way
around along the entire product travel path (either consistently 0° or 180° with respect
to the sensor). Small expansion joints and minor points of unevenness can be stuck
over.
At disruptive points which would cause the bar code tape to be significantly distorted
were it to be stuck over, it is possible to cut out an individual bar code at the corre‐
sponding cut marks and not use it.
To ensure optimum linearity, the distance between the two cut marks at the resulting
gap must be 30 mm. At least two contiguous bar codes must follow after a gap.
Continuous output of position values by the sensor unit is only ensured if the width of
the gap is not more than 30 mm and the bar codes were separated cleanly at the cut
mark. It is recommended that self-adhesive, cut-to-length blank white labels should be
stuck over the gap in order to allow it to be traversed without problems.
A sequence of bar code tapes with discontinuous measuring ranges is not allowed, oth‐
erwise a continuous position cannot be indicated (position jumps). The safety system
will switch to the safe state in the event of discontinuity.
SmartPOS repair tape can be stuck over faulty bar code tape across a maximum length
of 100 mm.
The mounting requirements set out in the operating instructions for the OLM100 Hi
must also be followed.
5.3
Mounting Flexi Soft
The Flexi Soft safety controller must be mounted in an environment corresponding to
enclosure rating IP54 (as per EN 60529), e.g., inside a control cabinet with enclosure
rating IP54.
Further mounting information can be found in the Flexi Soft hardware operating instruc‐
tions.
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6 ELECTRICAL INSTALLATION
6
Electrical installation
NOTE
Information is included in the operating instructions for the components.
6.1
General requirements
Only qualified personnel are allowed to perform the electrical installation work (see
"Requirements for the qualification of personnel", page 9).
The following measures to prevent common-cause failures must be considered during
electrical installation:
•
•
•
6.2
Separation of the signal pathways for the safety system signals, e.g., by separated
cable laying
Protection against overvoltage, overcurrent, etc. as per the manufacturer instruc‐
tions for the individual components
Measures for controlling the consequences of voltage failure, voltage fluctuations,
overcurrent, and undercurrent in the voltage supply of the higher-level control
Connection and wiring
All of the electrical installation work must be performed in accordance with EN
60204-1 (IEC 60204-1).
Pre-assembled wiring (X-junction) has been developed for the safety system. If longer
cables are required for an application, the sensor cables should be extended using preassembled extension cables. The maximum lengths must not, however, be exceeded
(see "Technical data", page 78).
6.2.1
Wiring principle
The components must be wired as follows in line with the documentation for the com‐
ponents.
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ELECTRICAL INSTALLATION 6
DV
+24V =
SSI signals from OLM 1 to
process control
(open cable end)
X connector
Preassembled cable
with SSI signal splitter
Safe outputs
Output:
Test request at OLM 2
Inputs: Test signal
Inputs: Sensor IDs
“Forward/Reverse”
OLM 2
OLM 1
Linear measurement sensor
OLM100 Hi
(with sign-of-life test)
Linear measurement sensor
OLM100 Hi
Figure 4: Wiring principle
From the connector plug on the FX3-MOC1 to the SSI signal splitter, the X-junction must
be contained within an electrical installation area.
OLM 1 and OLM 2 are numbered when the X-junction is connected. The connector plug
for the OLM 2 has a colored mark and must be connected to the linear measurement
sensor for which the bar code tape displays a higher position value. The connector plug
for OLM 1 does not have a mark.
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6 ELECTRICAL INSTALLATION
6.3
Safety controller pin assignment
Figure 5: Safety controller setup
The connection controller shown corresponds to the delivery state of a complete Safe
Linear Positioning system. Since the system can be extended on a modular basis,
inputs and outputs can be positioned on the XTIO module or on other modules (XTIO,
XTDI, XTDS).
WARNING
There is a risk of death or serious injury as diagnostics and shock resistance for the
protective device are not reliable.
b
b
26
Position inputs and outputs on different modules in such a way that they have the
same properties in terms of safety technology as the inputs and outputs of the
original module.
Adjust the current flow diagram accordingly (see "Safety controller pin assign‐
ment", page 26).
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ELECTRICAL INSTALLATION 6
Table 5: Modules of the safety controller
Module 0
Main module FX3-CPUx
Module 1
I/O module FX3-XTIO
Module 2
Motion control module FX3-MOC1
Module 3
I/O module FX3-XTIO
Module 1: inputs
Table 6: Function of the connections
Connection
Function
l1
KF100.1 test signal 1
l2
KF100.2 test signal 2
l3
BG100.1.1 OLM sensor ID 1
l4
BG100.2.1 OLM sensor ID 2
l5
B130 SLS request signal
l6
B130 SLS request signal
l7
SF200 emergency stop pushbutton
l8
SF200 emergency stop pushbutton
Module 1: outputs
Table 7: Function of the connections
Connection
Function
Q1
QA110.1 safety output (STO)
Q2
QA110.2 safety output (STO)
Q3
BG100.2.2 sensor 2 test request
Q4
KF130 stop request
Module 2: inputs
Table 8: Function of the connections
Connection
Function
Enc1
BG100.1 OLM sensor 1
Enc2
BG100.2 OLM sensor 2
Module 3: inputs
Table 9: Function of the connections
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Connection
Function
l1
SF210.1 reset button
l2
SF210.2 start button
l3
Vacant
l4
Vacant
l5
Vacant
l6
Vacant
l7
Vacant
l8
Vacant
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6 ELECTRICAL INSTALLATION
Module 3: outputs
Table 10: Function of the connections
6.4
Connection
Function
Q1
QA120.1 brake (optional)
Q2
QA120.2 brake (optional)
Q3
H210.1 “Reset required” light (optional)
Q4
H210.2 “Restart required” light (optional)
Interfaces and signals
The safety system has both safety interfaces and standard interfaces. The Flexi Soft
outputs that signal the safe state are considered to be safety interfaces, while those
used for test signals and the position value are considered to be standard interfaces.
6.4.1
Standard input interface: test signals
NOTE
The signals must be compatible with the inputs of the Flexi Soft XTIO module (see
"Technical data", page 78).
The position values of the sensors are compared with test signals from the non-safe
process controller to cover faults occurring at the same time in both channels of the
redundant dual-channel sensor system (plausibility check). The direction signals from
the drive system or process controller are used as test signals. In this case, the Flexi
Soft safety controller always anticipates a notification of a change to the movement
direction from the process in the form of the corresponding status of the test signals
immediately before the change is made.
The test signals must be generated independently of the position data of this safety
system (OLM sensor 1). The test signals must be transmitted to the Flexi Soft safety
controller via two separate signal cables.
Definition of test signals
• Test signal 1 active and test signal 2 active = standstill
• Test signal 1 active and test signal 2 inactive = forward movement
• Test signal 1 inactive and test signal 2 active = backward movement
• Test signal 1 inactive and test signal 2 inactive = “safe state” request
Table 11: Meaning of signals
Signal
Meaning
Active
24 V are applied to the input of the Flexi Soft controller.
Inactive
0 V are applied to the input of the Flexi Soft controller.
Forward
Movement is taking place in the direction of ascending position
values.
Backward
Movement is taking place in the direction of descending position
values.
Both signal cables must not be inactive at the same time, so the safe state is initiated
in this case. This allows for cable breaks and the like to be detected.
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ELECTRICAL INSTALLATION 6
WARNING
There is a risk of death or serious injury as diagnostics for the protective device are not
reliable.
In the event that position data that is not plausible or other safety-critical faults are
detected, the non-safe process controller must request the safe state by deactivating
both test signals.
Time requirements for test signals
The difference in time between the test signals from the process controller and the
movement status detected by the OLM 100 Hi sensors must not be more than
0.75 seconds.
NOTE
There may be availability issues if accelerations are less than 60 mm/s2. In this case,
the test signals can be delayed by as much as 650 ms.
Technical requirements
Technical data on the inputs can be found in the operating instructions for the Flexi Soft
controller.
6.4.2
SSI interface
The position value of OLM 1 is provided to the process controller via the SSI interface.
The process controller interface can either be an SSI master or an SSI listener. On that
basis, the SSI interface must be configured accordingly on the MOC module.
If the process controller is an SSI master, the MOC module must function as an SSI lis‐
tener.
If the process controller is an SSI listener, the MOC module must function as an SSI
master.
Requirements for the process controller SSI interface
The requirements for the SSI interface vary depending on the sensor unit in use.
Table 12: Requirements for the sensor unit with part number 1087575
Parameter
Requirement
Protocol frame
24 position data bits +1 error bit
Data decoding
Binary
Transmission rate (SSI master only)
100 kBaud ... 400 kBaud
Table 13: Requirements for the sensor unit with part number 1090629
Parameter
Requirement
Protocol frame
31 position data bits +1 error bit
Data decoding
Binary
Transmission rate (SSI master only)
100 kBaud ... 400 kBaud
If the process controller operates its SSI interface as a master, data packets must be
transmitted cyclically every 0 ms to 8 ms.
In order to guarantee that diagnostics are reliable, the transmission rates of the two SSI
interfaces must be set to different values. The interface for OLM 2 is set to 167 kBaud.
The process controller SSI interface requires a 120 ohm terminator.
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6 ELECTRICAL INSTALLATION
6.4.3
Signal for PDS (SR) - drive (safety-related)
This safety system provides output signals for the drive system of an application in
order to perform the SS1 and SS2 safe stop functions.
Output K100.1 / Q4 - KF130 stop request
This non-safe signal is necessary for a safe stop function with a monitored stop ramp.
The signal is active Low, meaning that 24 V DC are applied to the output when a stop
has not been requested and 0 V are applied when a stop has been requested.
The signal can be linked to a device that activates the stop ramp (e.g., process con‐
troller or drive).
NOTE
This signal does not necessarily have to be used.
If the signal is not used, the machine stops immediately upon the Enable torque output
signal by means of a safe torque off (STO) function without monitoring the stop ramp.
Output K100.1 / Q1+Q2 - QA110.x safety output (STO - safe torque off)
This safety signal includes a dual-channel output. The signal is active Low, meaning
that 24 V DC are applied to the output when a stop has not been requested and 0 V are
applied when the drive torque needs to be deactivated.
The safety output signal must be linked to a safe STO input of the drive. This STO input
forms part of the safety functions covered by this safety system and must comply with
the corresponding requirements (category 4, PL e as per EN ISO 13849-1 or SILCL3 as
per DIN EN 62061).
The STO function must be wired as shown in the operating instructions for the drive sys‐
tem. The wiring must fulfill the requirements for category 4, PL e as per EN ISO
13849-1.
NOTE
The dual-channel outputs switch simultaneously. If the STO input of the drive system
requires a complementary signal, an additional safety relay with “normally open” and
“normally closed” contacts must be put in place. This case will not be considered with
this safety system.
If the STO input of the drive system only has a single channel, additional measures
must be taken to ensure that the relevant safety requirements are complied with. This
case will not be considered with this safety system.
6.4.4
Signal for optional safe brake control
The manufacturer must use the risk assessment to determine whether a brake and in
turn the safe brake control (SBC) safety function are required. This safety system only
makes the brake control function possible.
The machine manufacturer is responsible for the technical and safety-related configura‐
tion of the brake and the corresponding hardware design.
If the risk assessment determines that a brake is needed, it must comply with the
requirements of category 4, PL e (EN ISO 13849-1). A fault in the brake must not lead
to the loss of the safety function. The respective specifications provided by the manu‐
facturer for the brake must be followed.
This safety system comes with the option of a dual-channel output for connecting an
external brake. The safe brake control (SBC) safety function can be implemented with
this brake. 24 V DC are applied to the output when the brake is released and 0 V are
applied when the brake function is activated.
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ELECTRICAL INSTALLATION 6
The brake’s safety values must guarantee that the safety level of the overall safety
function is PL e.
6.4.5
Safe SLS request signal
The safe signal source and the transmission path must comply with category 4, PL e. If
an external signal is not used, the function must be deactivated in the logic.
The dual-channel inputs for the SLS Request signal must always be set to High (24 V DC)
if there is no request for the speed to be limited or if an external signal is not used. If
safely limited speed has been requested, both inputs must be switched to Low (0 V).
Both channels for the safe SLS Request signal must change their status at the same
time, whereby the maximum permitted difference in time is 1 s.
6.4.6
Signal for emergency stop pushbutton
The Flexi Soft safety controller provides a dual-channel input signal for an SF200 emer‐
gency stop pushbutton.
Depending on the transport system being used within the application, a pushbutton
can be mounted directly on the vehicle and near to the rails. The signal path must
always correspond to category 4.
NOTE
The operating entity must press the emergency stop pushbutton at least every
six months to test that it is working properly. The device used for shutting down in an
emergency must meet the requirements of IEC 60947-5-5.
6.4.7
Signal for restart interlock
Manual reset
When a protective device requests a stop command, the stop status must apply until a
manual reset has been performed. A separate reset device (e.g., a pushbutton) must
be relied upon to perform this manual reset and must be in a position that allows for
the results of a restart to be overseen.
It must be possible for a falling signal edge, triggered by the reset device, to be
detected during processing. It should only be possible to reset when all safety functions
and protective devices are fully functional and active.
The reset device signal forms part of the safety functions. This means that it must have
one of the following properties:
•
•
Discrete wiring with the safety logic
Transmission via a safety bus system
Restarting must not bring about any movements or hazardous situations. The applica‐
tion is only permitted to accept a separate start command after a reset.
Starting and restarting
An automated restart must only be performed if there is no risk of a hazardous situa‐
tion.
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31
7 CONFIGURATION
7
Configuration
7.1
Structure and application of the chapter on configuration
The following chapters provide you with a full overview of the functionality of the soft‐
ware and guide you through the necessary adjustments step-by-step.
Some sections are optional for the user, depending on the intended purpose.
Modular extension and modification
If additional functions are to be added to the software, this is only possible outside of
the certified part of the software. For this purpose, APIs can be found in the safety
application software supplied by SICK. For further details on using these APIs for modu‐
lar extension and modification, see "Expanding and modifying the safety system",
page 49.
Functionality in detail
For a detailed description of the application software, please refer to "Contents of the
CPU logic", page 54 and "Contents of the motion control logic", page 64.
7.2
Requirements for software and firmware
Configuration of the functional safety system requires at least the following versions of
the software or firmware:
Table 14: Minimum versions
Minimum version
7.3
Flexi Soft Designer
≥ 1.9.0
Firmware FX3-CPUx
≥ V4.0
Firmware FX3-XTIO
≥ V3.0
Firmware FX3-MOC1
≥ V2.0
Configuration procedure
NOTE
The configuration of the software is described on the basis of the English-language Flexi
Soft Designer.
Information about configuration with Flexi Soft Designer can be found in the Flexi Soft
operating instructions in the Flexi Soft Designer configuration software.
The application software is already fully programmed and pre-configured for the func‐
tional scope of the safety system. The following steps just need to be taken to complete
the process:
•
•
•
•
•
•
•
32
Select the correct project file (see "Pre-configured project files", page 33)
Configure the SSI interface (see "Configuring the interface for BG100 motion sen‐
sor", page 35)
Configure the speed limits (see "Configuring speed limits", page 37)
Configure the position ranges (see "Configuring position ranges", page 40)
Assign the speed limits to the position ranges (see "Assigning maximum speeds to
the position ranges", page 41)
Configure safe cam (SCA) (see "Configuring safe cam (SCA)", page 42)
Optional: Configure stop ramps (see "Configuring stop ramps", page 45)
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The additional information provided in this chapter just offers an overview of the soft‐
ware.
7.3.1
Pre-configured project files
Pre-configured project files for the safety system are available under the following link:
www.sick.com/Safe_Linear_Positioning
Separate project files are available for both variants of the sensor and they have differ‐
ent sensor settings. In these project files, all configurable parameters are set to stan‐
dard values.
Aside from the project files provided, export files are available on the internet. These
correspond to the hardware configuration and logic of the project files, but can be
imported into any Flexi Soft CPU module (from firmware version 4.xx). The checksums
listed below result. After downloading or importing, it must be checked whether the
checksum of the project corresponds to the respective checksum indicated here. The
checksums change if modifications are made to the parameters or logic.
7.3.1.1
Project and export file for SSI protocol 24+1 bit (SAPPD3E-14AP003)
FX3-CPU0 with Flexi Soft project file ID no. 9288608
Table 15: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
Not assigned
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0xA126F159
Table 16: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0xD904FC86
Table 17: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0x771CA6AB
FX3-CPU1 with Flexi Soft export file “SSI master” ID no. 9288609
Table 18: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0x05D4F6D0
FX3-CPU1 with Flexi Soft export file “SSI listener” ID no. 9290537
Table 19: Checksum with possible pin assignment on FX3-MOC1 module
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MOC input E1
BG100.1 OLM sensor 1 as SSI listener 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0xABCCACFD
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7 CONFIGURATION
FX3-CPU2 with Flexi Soft export file “SSI master” ID no. 9288609
Table 20: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0x05D4F6D0
FX3-CPU2 with Flexi Soft export file “SSI listener” ID no. 9290537
Table 21: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0xABCCACFD
FX3-CPU3 with Flexi Soft export file “SSI master” ID no. 9288609
Table 22: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0x081D56C6
FX3-CPU3 with Flexi Soft export file “SSI listener” ID no. 9290537
Table 23: Checksum with possible pin assignment on FX3-MOC1 module
7.3.1.2
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 24+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 24+1 bit
Checksum
0xA6050CEB
Project and export file for SSI protocol 31+1 bit
FX3-CPU0 with Flexi Soft project file ID no. 9290043
Table 24: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
Not assigned
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0xDEF61431
Table 25: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0x06D9C02F
Table 26: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0xA8C19A02
FX3-CPU1 with Flexi Soft export file “SSI master” ID no. 9290044
Table 27: Checksum with possible pin assignment on FX3-MOC1 module
34
MOC input E1
BG100.1 OLM sensor 1 as SSI master 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0x40B50E17
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CONFIGURATION 7
FX3-CPU1 with Flexi Soft export file “SSI listener” ID no. 9290539
Table 28: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0xEEAD543A
FX3-CPU2 with Flexi Soft export file “SSI master” ID no. 9290044
Table 29: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0x40B50E17
FX3-CPU2 with Flexi Soft export file “SSI listener” ID no. 9290539
Table 30: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0xEEAD543A
FX3-CPU3 with Flexi Soft export file “SSI master” ID no. 9290044
Table 31: Checksum with possible pin assignment on FX3-MOC1 module
MOC input E1
BG100.1 OLM sensor 1 as SSI master 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0x4D7CAE01
FX3-CPU3 with Flexi Soft export file “SSI listener” ID no. 9290539
Table 32: Checksum with possible pin assignment on FX3-MOC1 module
7.3.1.3
MOC input E1
BG100.1 OLM sensor 1 as SSI listener 31+1 bit
MOC input E2
BG100.2 OLM sensor 2 as SSI master 31+1 bit
Checksum
0xE364F42C
Opening project file
1.
2.
3.
4.
5.
✓
Start Flexi Soft Designer.
Click on Project.
Click on Open.
Select the project file.
Click on Open.
The project file opens. The Hardware configuration view appears.
In the Configuration area, the entire hardware configuration of the Flexi Soft safety con‐
troller and the connected devices is displayed graphically.
7.3.2
Configuring the interface for BG100 motion sensor
The FX3-MOC1 Flexi Soft module provides the following inputs:
•
•
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Input ENC1 = OLM sensor 1
Input ENC2 = OLM sensor 2
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7 CONFIGURATION
BG100.1 OLM sensor 1 - SSI master
This element must be used when the process controller has an interface for an SSI
master. In this case, it is the MOC1 module that generates the clock rather than the
process controller providing it.
BG100.1 OLM Sensor 1 - SSI listener
This element must be used when the process controller has an interface for an SSI
master. In this case, the process controller provides the clock.
WARNING
There is a risk of death or serious injury as diagnostics for the protective device are not
reliable.
Different data transmission rates must be set for OLM sensor 1 and OLM sensor 2 for
diagnostic purposes. The transmission rate for OLM sensor 2 is 167 kBaud. It is recom‐
mended that the lowest possible data transmission rate is selected for OLM sensor 1
(100 kBaud).
b
Select the lowest possible data transmission rate for OLM sensor 1 (100 kBaud).
The ENC2 input is already set as SSI master and is used for internal plausibility checks.
The correct element (SSI master or SSI listener) must be dragged from the parking area
and dropped at the ENC1 input of the MOC1 module. Double-click on the SSI symbol to
open up the element settings.
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CONFIGURATION 7
NOTE
The user must not make any changes to the element settings.
7.3.3
Configuring speed limits
1.
2.
3.
✓
Move the mouse cursor to the Logic editor button.
Click on K110-2 / MOC1 - Logic editor.
Select the Position_Monitor logic page.
The view opens. The Position_Monitor page appears.
Figure 6: Position_Monitor page view
Position ranges can be set and monitored on this page. The two sensors provide sepa‐
rate status signals.
This page is protected with a password. Configurations must be set in the Position Moni‐
tor function block.
1.
2.
✓
Move the mouse cursor to the Position Monitor function block.
Double-click on the function block.
The view opens. The window containing the settings for the function block will
appear.
Figure 7: Settings window for Position Monitor function block
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7 CONFIGURATION
1.
2.
✓
Move the mouse cursor to the Speed limits button.
Click on the Speed limits button.
The view opens. The Speed limits window appears.
Figure 8: Speed limits settings window with sample values
7.3.3.1
Max. speed limit
WARNING
There is a risk of death or serious injury if the protective device is not working effec‐
tively.
b
Comply with the permitted speed.
The maximum permitted speed for this safety system is 4000 mm/s. The speed must
not exceed this limit.
If a lower maximum speed applies to the application in question, it must be configured
as the maximum speed limit.
7.3.3.2
Speed limits
Within the application, there may be requirements for safely limited speeds (SLS) owing
to the risk assessment (e.g., in areas where there are people or ahead of the end posi‐
tions of the rail system).
The following speed ranges can be configured for the safely limited speed (SLS) safety
function:
•
•
Standstill speed (default values set at the factory)
Speed limits 2-9
This means that up to 9 speed limits (including standstill speed) can be configured for
up to 10 speed ranges. The lowest speed limit (speed limit 1) is always the standstill
speed.
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The Speed ID indicates which speed range the current speed at the Motion in input corre‐
sponds to. Further information on this can be found in the Flexi Soft Designer operating
instructions.
Table 33: Speed at Motion in input
Speed at Motion in input
Meaning
Speed
ID
The speed is invalid or unreliable.
Invalid
0
One of the standstill conditions is met:
Standstill
1
No standstill and speed > standstill speed ≤
speed limit 2
Speed range 2
2
Speed > speed limit 2
Speed ≤ speed limit 3
Speed range 3
3
Speed > speed limit n-1
Speed ≤ speed limit n
Speed range n
n
Speed > speed limit 8
Speed ≤ speed limit 9
Speed range 9
9
Speed > speed limit 9
Speed range 10
10
•
•
The speed remains lower than the standstill
speed for at least as long as the accepted
standstill speed.
The standstill position tolerance has been
determined and not exceeded.
Special feature of speed ID 2
The lowest speed that can be monitored depends on which sensor variant is used. The
two sensor variants have a different speed acquisition resolution. The minimum speed
that is to be monitored within the application should be at least three times higher than
the speed acquisition resolution.
If this requirement is ignored, the result will be an availability issue rather than a safety
problem.
OLM linear measurement sensor (order no.: 1087575)
• Speed acquisition resolution = 25 mm/s
• Lowest speed that can be acquired = 25 mm/s
• Lowest speed that can be monitored = 75 mm/s
OLM linear measurement sensor (order no.: 1090629)
• Speed acquisition resolution = 3 mm/s
• Lowest speed that can be acquired = 3 mm/s
• Lowest speed that can be monitored = 9 mm/s
7.3.3.3
Speed filter
This function is used to enable the system to tolerate short-term increases or reduc‐
tions in speed. The Speed Filter parameter defines the extent to which any breach of the
relevant speed limit will be tolerated (filtered). The maximum length of the route that
the drive may continue to travel in spite of the fact that the applicable speed limit has
been exceeded is 10 mm (this is a default setting).
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7 CONFIGURATION
WARNING
There is a risk of death or serious injury if the stopping distance is calculated incor‐
rectly.
b
b
The default setting for the Speed Filter parameter is 10 mm and this must be
taken into account at the planning stage (see "Response times", page 80).
This value must not be changed.
As this is not a time-based filter, this function does not increase the response time.
Instead, the stopping distance will increase if there is a fault. The stopping distance is
increased accordingly with the default setting of 10 mm. This must be considered when
calculating the stopping distance.
7.3.4
Configuring position ranges
WARNING
There is a risk of death or serious injury as diagnostics for the protective device are not
reliable.
Value range monitoring is implemented in the safety system so that diagnostics can be
performed. For this reason, the minimum and maximum values of the bar code tape in
use should be configured at the configuration stage. 0 is not permitted as a minimum
value.
1.
2.
✓
In the settings for the Position Monitor function block, move the mouse cursor to the
Position Ranges button.
Click on the Position Ranges button.
The view opens. The Position Ranges window appears.
Figure 9: Position Ranges with sample values
The full position range for the application needs to be configured. The following should
be noted here:
•
•
40
Only the position range that is actually being used within the application should be
configured. In the example shown, only one bar code tape should be used from
the 100 mm position to 15,000 mm.
Ranges requiring a safely limited speed to be monitored must be defined.
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CONFIGURATION 7
WARNING
There is a risk of death or serious injury because the protective device cannot per‐
form the diagnostics function.
b
•
Always set a value greater than zero as the position ID because the position
0 mm is not permitted in this safety system for reasons relating to the diag‐
nostics.
If there are position ranges within the application that are not actually permitted,
these must also be defined.
The maximum possible measuring range of the respective sensor unit must be taken
into account too. Larger position values are not permitted.
Table 34: Maximum position range depending on sensor unit
Maximum position range
7.3.5
OLM100 Hi, part number
1087575
OLM100 Hi, part number
1090629
1,677 m
8,589 m
Assigning maximum speeds to the position ranges
1.
2.
✓
In the settings for the Position Monitor function block, move the mouse cursor to the
Speed-position-profile button.
Click on the Speed-position-profile button.
The view opens. The Speed-position-profile window appears.
A maximum permitted speed (speed ID) can be set for each position range in order to
implement a safely limited speed (SLS) function. To do this, use the mouse to click on
the maximum permitted speed limit for each position range. Permissible speed ranges
below the speed limit are shown in green.
Example:
Figure 10: Profile settings for speed/position
In this example, the speed ID 1-4 speed limits are assigned to the position ID 1-6 posi‐
tion ranges.
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7 CONFIGURATION
Position ID 1 is generally an impermissible/unavailable position range and its bar code
tape cannot be used because the 0 mm position, which is not permitted in this safety
system, is located within it. For this reason, speed ID 1 (standstill) has been assigned
here. The same applies to position ID 6 since its position range is beyond the maximum
bar code position that is actually being used.
WARNING
There is a risk of death or serious injury if the protective device is not working effec‐
tively.
b
7.3.6
Assign speed ID 1 (standstill) to impermissible position ranges.
Configuring safe cam (SCA)
In the speed-position-profile, the value of the Position CAM output can be defined for
each position range. This allows this output to be used to implement electronic cams.
Activated position cams are displayed in green.
Permitted position ranges must be configured as position cams. The position CAM out‐
put of the Position Monitor function block is set to logic High as long as the current posi‐
tion is within the permitted position range. If a position falls outside of this range, the
position CAM output is set to logic Low.
WARNING
There is a risk of death or serious injury if the protective device is not working effec‐
tively.
b
Do not configure position ranges as position cams if they are not permitted.
There are further configuration options with the safe cam function. For example, ranges
can be defined at the end positions, within which movement is only possible in the
direction of the permitted position range. This is shown in the following figure:
Figure 11: Safe cam setting range
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CONFIGURATION 7
The position ID 2-5 position ranges are available within the application. However, the
permitted range is limited to position ID 3 and 4 because they have been configured as
safe cams. If the end position is overrun (i.e., the application is in position ID 2 or 5)
owing to a fault, the application can only move at a reduced speed (speed ID 2) in the
direction of position ID 3 or 4 (safe direction - SDI).
Several profiles can be used and selected depending on the direction. Further informa‐
tion about the functional scope of safe cam can be found in the Flexi Soft Designer
operating instructions.
Storage and retrieval system application example
Speed reduction is always safely monitored in two stages before the end positions. The
position ID 2 and 8 position ranges function as a buffer in case it is not possible to slow
down enough owing to a fault. As the speed cannot be very high in this instance owing
to the fact that monitoring begins at position ID 4 and 6, the buffer zone does not have
to be very large.
Figure 12: Safe cam setting range for a storage and retrieval system
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7 CONFIGURATION
Figure 13: Speed/distance diagram for a storage and retrieval system:
Application example with a range with safely limited speed (SLS)
Within this application, the maximum speed is permitted in the position ID 2 and 4
position ranges. This area could, for example, be enclosed or somewhere it is generally
not possible for people to be present.
In the middle position range, position ID 3, only a safely limited speed (SLS) is permit‐
ted. This may be an assembly area where people work, for example.
Figure 14: Safe cam setting range for a range with a safely limited speed (SLS)
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7.3.7
Configuring stop ramps
The Safe Stop function block of the MOC module is used to trigger and monitor the safe
stop of a drive system. The drive has to be stopped in a controlled way. The braking
torque of the drive can be used to stop the drive more quickly than would be possible in
the case of an uncontrolled stop.
The Safe Stop function block initiates the stop ramp and monitors to check that the
speed reduction is within the permitted range. This corresponds to the SS1-r/SS2-r stop
functions as per IEC 61800-5-2 and stop category 1/stop category 2 as per
IEC 60204-1.
Monitoring of stop ramps is not configured within the default settings for the Flexi Soft
software project. This means that without any further configuration the safe torque off
(STO) stop function as per IEC 61800-5-2 or stop category 0 as per IEC 60204-1 is per‐
formed in the event of a stop request.
1.
2.
3.
✓
Move the mouse cursor to the Logic editor button.
Click on K110-2 / MOC1 - Logic editor.
Select the Safe_Stop logic page.
The view opens. The Safe_Stop page appears.
Figure 15: Safe Stop page view
Table 35: Inputs of the function block
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Input name
Function
Motion IN
This input receives the Motion signal from the Position Cross Check
function block. A fault is detected as soon as the position data
from the sensor is no longer reliable. This signal will trigger a safe
stop 2 (SS2) at the Safe Stop function block.
Safe Stop 1a
The SS1 request LowActive signal from the CPU logic is linked to this
input. If the signal switches to Low, a safe stop 1 (SS1) is initiated.
Safe Stop 2a
The SS2 request LowActive signal from the CPU logic is linked to this
input. If the signal switches to Low, a safe stop 2 (SS2) is initiated.
Safe Stop 2b
The PosMon Status signal (status of the Position Monitor function
block) is linked to this input. If the current position is not permitted
or if the speed exceeds the safe limit, this signal will be set to Low
and a safe stop 2 (SS2) will be initiated.
Reset
The reset signal comes from the CPU logic. A reset signal is
required following a safe stop 2 (SS2) or in order to reset the func‐
tion block after a fault has occurred.1
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7 CONFIGURATION
Input name
Function
Inhibit Motion bits reaction
The signal comes from component SAPP-FB Safe Position. The signal
prevents unintended switching off during the self-test of the safety
system.
1
The Safe Stop function block triggers a fault while the override function or Sensor2 test is active.
As this is a permitted status that is monitored, the stop request is not forwarded to the drive. In this case,
the Safe Stop function block detects a ramp fault. This is automatically reset by the software following an
override function or Sensor2 test once the function has been processed successfully.
Table 36: Outputs of the function block
7.3.7.1
Output name
Function
Enable torque
This safety signal deactivates the drive’s torque. The signal is
transmitted to the CPU logic and has an impact on the safe out‐
puts (dual-channel output signal switching device).
Enable brake
This safety signal switches off the energy supply for the optional
brake. The signal is transmitted to the CPU logic and has an
impact on the safe outputs (dual-channel output signal switching
device).
Stop request
This signal triggers the stop ramp of the drive. The signal is trans‐
mitted to the CPU logic and is forwarded either to the process con‐
troller or to the drive directly.
Safe Stop - Stop Ramps function block
1.
2.
✓
Move the mouse cursor to the Safe Stop function block.
Double-click on the function block.
The view opens. The window containing the settings for the function block will
appear.
The Stop Ramps function block monitors the actual reduction in speed until the drive
comes to a standstill. The ramp settings will depend on the application and the compo‐
nents in use (e.g., the drive).
Refer to the Flexi Soft Designer operating instructions for further details on how to con‐
figure safe ramp monitoring. The screenshot below shows the standard configuration,
with ramp monitoring deactivated.
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CONFIGURATION 7
Figure 16: Stop Ramps function block
7.3.7.2
Safe Stop settings - Standstill Monitoring function block
The Safe Stop function block includes a separate function block called Standstill Moni‐
toring.
This Standstill Monitoring function block is only used for the Safe Stop function. It is
used to determine when a ramp ends or to monitor the standstill position in the case of
a Safe Stop 2 function.
Figure 17: Standstill Monitoring function block
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7 CONFIGURATION
7.3.7.3
Safe Stop Types function block
Figure 18: Safe Stop Types function block
Table 37: Types of Safe Stop
Type
Function
Safe Stop Type 1
It is possible to define the number of inputs that can initiate a safe
stop 1 (SS1). A delay time can also be set using Off-delay for Enable
torque.
The Enable torque output is deactivated with this delay time after a
standstill has been detected.
Safe Stop Type 2
It is possible to define the number of inputs that can initiate a safe
stop 2 (SS2).
Stop Reset
This setting allows for an additional Reset input at the Safe Stop
function block.
NOTE
The stop ramp configuration must be checked thoroughly to ensure that it is correct.
The machine manufacturer is responsible for checking whether the application is in line
with the risk analysis and risk reduction strategy, and whether it conforms to all applica‐
ble standards and directives.
Otherwise, the operator of the machine will be put at risk.
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CONFIGURATION 7
7.4
Expanding and modifying the safety system
7.4.1
Configuring additional safety functions
Overview
Additional safety functions can be added to the safety system to trigger an SS1 or SS2.
Important information
DANGER
Additional safety functions are not part of this safety system.
The safety system may not function as intended after implementing additional safety
functions.
b
b
b
Only implement additional safety functions at your own risk.
Ensure that triggering of the safety function leads to appropriate behavior with
regards to resetting and restarting.
Ensure that the mechanisms are implemented correctly and that the safety func‐
tion is guaranteed.
Approach
1.
2.
3.
✓
Move the mouse cursor to the Logic editor button.
Click on Logic editor.
Click on the Interface logic page.
The view opens. The page appears.
Figure 19: Request Safe Stop function block
4.
5.
6.
Assign additional safety functions to the External_SS1 or External_SS2 jump
addresses.
Delete the link between static 1 and input 6 (for External_SS1) or input 7 (for Exter‐
nal_SS2).
Link the External_SS1 jump address to input 6 or External_SS2 to input 7 of the Rout‐
ing N:N function block.
Complementary information
•
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7 CONFIGURATION
Figure 20: Additional Safe Stop 1 requirement
•
Example: additional Safe Stop 2 requirement
Figure 21: Additional Safe Stop 2 requirement
Further topics
•
50
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CONFIGURATION 7
7.4.2
External and internal signal for activating the safely limited speed
1.
2.
3.
✓
Move the mouse cursor to the Logic editor button.
Click on Logic editor.
Click on the Interface logic page.
The view opens. The page appears.
In addition to the safely limited speed (SLS) function in the Position Monitor function
block in the MOC1 module, another such function can be activated in the CPU logic.
While any speed ID is possible in the Position Monitor function block, speed ID 2 is used
as the limit in this case.
Figure 22: Function block view - request for safely limited speed (SLS)
Table 38: Function of the inputs
Input name
Function
Input 1
External safe B130 SLS request signal (Low active).
If no external source is used for a safely limited speed (SLS)
request, B130 SLS request must be removed from input 1 and linked
to static 1 instead.
Input 2
static 0 at input 2 prepares for a request from an internal source
from the CPU logic (High active).
If an internal source is used for a safely limited speed (SLS)
request, static 0 must be removed and a High active signal used
instead.
Table 39: Function of the output
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Output name
Function
Output
The output is linked to the Bool to UI8 function block in the MOC1
module. If the output is set to logic Low, speed ID 2 is active. If the
output is set to logic High, speed ID 10 (maximum speed) is active.
The lowest speed ID (either from the Speed/Position Profile function
block or the Speed Enable ID input) always has priority.
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7 CONFIGURATION
No use of the external signal
If no external signal is used to activate the safely limited speed (SLS), the B130 SLS
request input operand at input 1 of the AND block must be deleted and static 1 con‐
nected instead.
The corresponding element at the I5 / I6 input of the K100.1 XTIO module can then be
deleted too in the hardware configuration area.
Use of an additional internal signal
If the safely limited speed (SLS) is supposed to be activated via an internal logic signal,
static 0 has to be deleted at input 2 of the AND block and the internal logic signal is to be
connected instead. The signal must be logic active High.
7.4.3
Configuring the override function
An override function may be required for some applications. This could be the case, for
example, if safety is guaranteed by another safety function at a particular moment (e.g.,
by a safety laser scanner) or if a brief position detection fault can be knowingly
accepted (e.g., if there is a code jump or relatively large expansion joint).
The pre-configured project file for Flexi Soft Designer is prepared for an override func‐
tion, but does not feature the logic for activating the override function. The user must
develop this for the specific application in question.
NOTE
The override function is not part of the safety system. The user is responsible for ensur‐
ing safe implementation.
The requirements for the override function result from the risk assessment that has to
be performed by the user. Proof must be provided that the override function meets
these requirements (e.g., with SISTEMA). The user also needs to verify and validate the
override function.
1.
2.
3.
✓
Move the mouse cursor to the Logic editor button.
Click on Logic editor.
Click on the Interface logic page.
The view opens. The page appears.
Figure 23: Function block view - override function requirement
4.
52
Replace Static 0 with a signal that has a logical High value when the override func‐
tion is requested. When the override function is requested, all position errors are
ignored.
If an override function is used, the Override request jump address must be used.
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CONFIGURATION 7
7.4.4
Controlling the safety outputs directly via PLC
Important information
DANGER
This safety system does not include the ability to control the safety outputs directly
using process signals.
Implementation of the adaptation described in this chapter makes you the manufac‐
turer of a safety system.
1.
2.
Carry out the adaptation of the safety system described here only subject to own
responsibility.
Comply with all manufacturer obligations for development and implementation of
a safety system.
Approach
This modification allows the PLC to switch the safety outputs in the safety system to a
safe state at any time. This does not circumvent the safety functions.
1.
2.
3.
✓
4.
Move the mouse cursor to the Logic editor button.
Click on Logic editor.
Click on the Interface logic page.
The view opens. The page appears.
Replace Static 1 with signals intended to control the individual outputs. This
involves the following assignment between the jump address and safety output:
Table 40: Assignment of jump address and safety output
Jump address
Safety output
Stop_request_PLC_ctl
K100.1 Q4 stop request
STO_PLC_ctl
K100.1 Q1 Q2 STO
Brake_PLC_ctl
K100.3 Q1 Q2 Brake
Figure 24: Function block view – Routing
Complementary information
Controlling the safety outputs directly can, for example, help to control the brake if this
is also to be used as a retaining brake
7.4.5
Use of internal status information
Overview
Jump addresses provide internal status information that can be used in the application.
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7 CONFIGURATION
Status information for external device monitoring (EDM)
Jump addresses that illustrate the status of the safety outputs can be found on the Safe
Outputs page. These can be used for retroactive implementation of external device mon‐
itoring.
Table 41: Assignment of jump addresses to the safety outputs
7.5
Jump address
Safety output
Stop_Request
K100.1 Q4 stop request
STO_enable
K100.1 Q1 STO
K100.1 Q2 STO
Brake_enable
K100.3 Q1 Brake
K100.3 Q2 Brake
Contents of the CPU logic
The logic editor contains the following pages:
Table 42: Logic editor overview
Page name
Contents
Disclaimer
Disclaimer and safety notes
Interface
Configuration of safe stop request, safely limited speed
(SLS) request, and override function request
Safe Position and Diagnostics
Diagnostics measures used to determine the safe posi‐
tion
Stop/reset/restart
Configuration of reset and restart
Safe Outputs
Configuration of safe stop
The logic editor uses the following safety application function blocks (SAPP-FBs):
•
•
•
•
•
•
Plausibility test SAPP-FB
Sensor2 test SAPP-FB
Sensor ID SAPP-FB
Safe Position 1 SAPP-FB
Safe Stop outputs SAPP-FB
Safe Stop reset SAPP-FB
The SAPP-FBs are protected with a password. The settings in the function blocks are
not displayed and cannot be changed.
7.5.1
Disclaimer page
This page contains the disclaimer, the version number, and a short description of the
application.
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CONFIGURATION 7
7.5.2
Interface page
Figure 25: Interface page view
The following function blocks are available on this page:
•
•
•
7.5.3
Safe stop request
Safely limited speed (SLS) request
Override function request
Safe Outputs page
Figure 26: Safe Outputs page view
The following function blocks are available on this page:
•
•
Safe Stop outputs SAPP-FB
Safe Stop reset SAPP-FB
NOTE
This page is protected with a password and cannot be configured.
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7 CONFIGURATION
7.5.3.1
Safe Stop outputs SAPP-FB function block
Figure 27: Function block view - Safe Stop outputs SAPP-FB
Table 43: Function of the inputs
Input name
Function
Sensor2_test _active
Jump address
Safe position
Jump address, logic OR, linked to the optional Override signal (jump
address)
SS1 Request LowActive
Jump address
SS2 Request LowActive
Jump address
Override Request
Jump address
Stop request
MOC1 input signal
Enable torque
MOC1 input signal
Enable brake
MOC1 input signal
Table 44: Function of the outputs
7.5.3.2
Output name
Function
KF130 stop request
Output/XTIO module
A non-safe signal that triggers the stop ramp of the drive.
QA110 Safety output
Dual-channel output/XTIO module,
Safety signal that deactivates the drive system’s torque.
QA120 Brake - optional
Dual-channel output/XTIO module
Safety signal that switches off the energy supply for the mechani‐
cal brakes (optional).
Override active
Jump address
Prepares the optional Override function. The logic required to acti‐
vate the Override function is not part of this safety system.
If an Override function is required, the user is responsible for safely
implementing it.
Safe Stop reset SAPP-FB function block
Figure 28: Function block view - Safe Stop reset SAPP-FB
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CONFIGURATION 7
Table 45: Function of the inputs
Input name
Function
SensTest reset SafeStop
Jump address
SS2 Request LowActive
Jump address
Override request
Jump address
Table 46: Function of the output
7.5.4
Output name
Function
Reset
Signal to the Safe Stop function block in the MOC1 logic
Safe Position and Diagnostics page
Figure 29: Safe Position and Diagnostics page view
This page contains diagnostics measures that are needed to determine the safe posi‐
tion.
The following safety application function blocks (SAPP-FBs) are required here:
•
•
•
•
Plausibility test SAPP-FB
Sensor2 test SAPP-FB
Sensor ID SAPP-FB
Safe Position SAPP-FB
This page is protected with a password and cannot be configured.
A message generator function block is also used on this page to generate notifications
relating to diagnostics for the specific application in question.
7.5.4.1
Plausibility test SAPP-FB function block
Figure 30: Function block view - Plausibility test SAPP-FB
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7 CONFIGURATION
The application-specific Plausibility testSAPP-FB function block checks whether the posi‐
tion data from the sensor is plausible.
The process control uses test signals to check whether the standstill and direction condi‐
tions read (from the SSI position data) are plausible.
In addition, the sensors generate their own standstill signal, which they transmit to the
Flexi Soft safety controller via the digital outputs (sensor ID signal). These standstill signals
are also used for the plausibility check.
Table 47: Function of the inputs
Input name
Function
Test signal 1
KF100.1 test signal 1 from the process control
Test signal 2
KF100.2 test signal 2 from the process control
Sensor2 test active
Sensor2_test active jump address from Plausibility test SAPP-FB
Sensor ID Standstill Status
Standstill from SensorID jump address from Sensor ID SAPP-FB
Sensor 1 Direction Status
Sensor 1 direction information from the MOC1 logic
Sensor 2 Direction Status
Sensor 2 direction information from the MOC1 logic
Sensor 1 Standstill Status
Sensor 1 standstill information from the MOC1 logic
Sensor 2 Standstill Status
Sensor 2 standstill information from the MOC1 logic
Table 48: Function of the output
7.5.4.2
Output name
Function
Plausibility test error
Result of the plausibility check
Sensor2 test SAPP-FB function block
The application-specific Sensor2 test SAPP-FB function block detects systematic faults
that occur on both sensors at the same time. In the case of this kind of fault, the posi‐
tion data can freeze the two sensors and output a static position. This would be inter‐
preted as a standstill.
Test procedure:
After a relatively long inactive phase, Flexi Soft sends a query signal to sensor 2 as a
test. The sensor then performs an internal test. Flexi Soft can use the data read at the
SSI interface to check that the test has been performed successfully and that the test
results coincide with the expectations.
Figure 31: Function block view - Sensor2 test SAPP-FB
Table 49: Function of the inputs
58
Input name
Function
Standstill Sensor 2
Sensor 2 standstill information from the MOC1 logic
SS1 request LowActive
SS1 request LowActive jump address from Sensor2 test SAPP-FB
SS2 request LowActive
SS2 request LowActive jump address from Sensor2 test SAPP-FB
Sensor2 _test_active
Sensor2_test_active jump address from Sensor2 test SAPP-FB output
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CONFIGURATION 7
Table 50: Function of the outputs
7.5.4.3
Output name
Function
Sensor2_test_active
Linked to Sensor2_test_active jump address.
SensTest reset SafeStop
Linked to SensTest reset SafeStop jump address.
Sensor2 test error
Linked to Sensor2 test error jump address, which is used for the Safe
Position SAPP-FB and Message generator.
Sensor spot light
Linked to the BG100.2.2 Sensor2 test digital output. This activates
the test on the sensor.
Sensor ID SAPP-FB function block
Both sensors supply defined signals (sensor ID 1 and ID 2 signals), which are evaluated
by this function block. This ensures that it is only possible to use sensor types that are
approved for this safety system. The signals from the two sensors are different so that
only sensors with the correct signal behavior can be used together.
The sensors generate further process information automatically. This information is
transmitted to Flexi Soft and then evaluated.
Figure 32: Function block view - Sensor ID SAPP-FB
Table 51: Function of the inputs
Input name
Function
Sensor ID 1
BG100.1.1 Sensor ID 1 input
Sensor ID 2
BG100.2.1 Sensor ID 2 input
These input signals are pulse width modulated.
Table 52: Function of the outputs
7.5.4.4
Output name
Function
Sensor ID error
Signal test result
Sensor ID Standstill Condi‐
tion
Standstill from Sensor ID jump address linked to the application-spe‐
cific Plausibility test SAPP-FB function block.
Safe Position function block
This function block collates requests for the evaluation of the safe position and gener‐
ates the Safe Position signal.
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7 CONFIGURATION
Figure 33: Function block view - Safe Position
Table 53: Inputs of the function block
Input name
Function
Position Monitor Status
Position Monitor Status input signal from the MOC1 logic
Position Cross Check Sta‐
tus
Position Cross Check Status input signal from the MOC1 logic
AbsPosReliability
AbsPosReliability input signal from the MOC1 logic
Plausibility test error
Plausibility test error jump address from Plausibility test SAPP-FB
Sensor2 test error
Sensor2_test_error jump address from Sensor2 test SAPP-FB
SensorID error
SensorID error jump address from SensorID error SAPP-FB
Sensor2 test active
Sensor2 test active jump address from Sensor2 test SAPP-FB
Table 54: Outputs of the function block
7.5.4.5
Output name
Function
Safe Position
Linked to Safe Position jump address. A stop is triggered by a logic
Low.
Inhibit Error Message
Linked to Inhibit Error Message jump address. This signal is logic
High when a permissible error occurs with the position data. The
position date is invalid when sensor2 test is active. In this case, the
Inhibit_Error_Message signal stops a false entry being made in the
fault diagnostics history.
Message Generator function block
The Message Generator function block evaluates up to eight inputs. If a signal edge is
detected at one of these inputs in accordance with the configuration, the function block
sets the associated output to High for the duration of the logic execution and adds a
(user-defined) text message to the diagnostics history.
It can be read using the Flexi Soft Designer diagnostics function in online mode.
NOTE
If the voltage supply to the Flexi Soft safety controller is interrupted, this text message
will be lost.
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CONFIGURATION 7
Figure 34: Function block view - Message Generator
Table 55: Assignment of messages to the inputs in use
Inputs
Logic active
Effect
1 and 2
High
The rising signal edge triggers the message.
3 and 4
Low
The falling signal edge triggers the message.
Figure 35: Configuration view - Message Generator
7.5.5
Stop/start/reset page
Figure 36: Stop/start/reset page view
This page is protected with a password and cannot be configured. The inputs of the
reset/restart function for SS1 and SS2 are linked to the “Interface” page via jump
addresses, i.e., the physical inputs are assigned on the “Interface” page. The outputs
are also linked to other parts of the safety application software via jump addresses and
internal signals.
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7 CONFIGURATION
This page contains the following function blocks:
•
•
•
7.5.5.1
Safe Stop 1: Reset and Restart
Safe Stop 2: Reset and Restart
User-defined function block used to control a light for two function blocks for reset‐
ting and restarting
Reset for Safe Stop 1 function block
Figure 37: Function block view - Reset for Safe Stop 1
With the Reset function block, the requirements of the safety application are fulfilled as
set out by the EN ISO 13849-1 standard for detecting a manual safety stop with a sub‐
sequent request to restart the application.
As soon as E_Stop is no longer set to High, Safe Stop 1 is initiated.
If the E_Stop input is set to High, the release condition has been met. A reset signal
(Reset_SS1) with a pulse duration of at least 100 ms sets the Enable output to High. This
is a release condition for the Restart function block.
The Enable and Reset required outputs are used in order to use the optional H210.1 Reset
required light by means of the user-defined Lamp reset/restart required function block.
7.5.5.2
Restart for Safe Stop 1 function block
The Restart function block allows for a graphical distinction to be made between the
function blocks.
As soon as the Release 1 input is no longer set to High, it initiates the Safe Stop 1 func‐
tion.
A valid reset sequence at the Reset function block is required in order for a restart to be
performed.
If the Release input is set to High, the release condition has been met. The Enable output
is set to High when a restart signal (Restart_SS1) lasts for a pulse duration of at least
100 ms.
The Enable output is linked to the MOC1 logic via an AND function block in order to initi‐
ate the Safe Stop 1 function with the Safe Stop function block. The output is also linked
to the SS1 Request LowActive jump address, which notifies other parts of the CPU logic
that a Safe Stop 1 request has been issued.
7.5.5.3
Triggering a Safe Stop 1 with additional safety functions
The Safe Stop 1 function can also be triggered by additional safety functions. The
AND function block connects additional safety functions via the Input 1 input, which is
linked to the External_SS1 jump address.
Further topics
•
•
62
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"Configuring additional safety functions", page 49
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CONFIGURATION 7
7.5.5.4
Reset for Safe Stop 2 function block
Figure 38: Function block view - Reset for Safe Stop 2
With the Reset function block, the requirements of the safety application are fulfilled as
set out by the EN ISO 13849-1 standard for detecting a manual safety stop with a sub‐
sequent request to restart the application.
As soon as the Safe Position and Override active jump addresses are no longer set to High,
the Safe Stop 2 function is initiated.
If the Reset_SS2 input is set to High, the release condition has been met. A reset signal
with a pulse duration of at least 100 ms sets the Enable output to High.
The Enable and Reset required outputs are used in order to use the optional H210.1 Reset
required light by means of the user-defined Lamp reset/restart required function block.
7.5.5.5
Restart for Safe Stop 2 function block
The Restart function block allows for a graphical distinction to be made between the
function blocks.
As soon as the Release 1 input is no longer set to High, the Safe Stop 2 function is initi‐
ated.
A valid reset sequence at the Reset function block is required in order for a restart to be
triggered.
If the Restart input is set to High, the release condition has been met. The Enable output
is set to High when a restart signal (Restart_SS2) lasts for a pulse duration of at least
100 ms.
The Enable output is linked to the MOC1 logic via an AND function block in order to initi‐
ate the Safe Stop 2 function with the Safe Stop function block. The output is also linked to
the Safe Stop 2 jump address, which notifies other parts of the CPU logic that a Safe Stop
2 request has been issued.
The Enable and Reset required outputs are used in order to use the optional H210.1 Reset
required light by means of the user-defined Lamp reset/restart required function block.
7.5.5.6
Triggering a Safe Stop 2 with additional safety functions
The Safe Stop 2 function can also be triggered by additional safety functions. The
AND function block connects additional safety functions via the Input 2 input, which is
linked to the External_SS2 jump address.
Further topics
•
•
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"Extension and modification", page 19
"Configuring additional safety functions", page 49
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7 CONFIGURATION
7.5.5.7
Function block for optional light
The Reset required or Restart required output of the Reset or Restart function block provides
a frequency of 1 Hz to indicate that the function block is anticipating a valid reset or
restart pulse.
As the light can be controlled using both the Safe Stop 1 function block and the Safe Stop
2 function block, the ratio between pulse and pause would be random if OR were used.
Figure 39: View of function block for optional light
7.6
Contents of the motion control logic
1.
2.
✓
7.6.1
Move the mouse cursor to the Logic editor button.
Click on K110.1 - MOC0[1] - Logic editor.
The view opens. The page appears.
Position_Cross_Check page
Figure 40: Position_Cross_Check page view
This page is protected with a password and cannot be configured.
The purpose of this function block is to cross-check the speed.
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CONFIGURATION 7
7.6.1.1
Position Cross Check function block
Figure 41: Function block view - Position Cross Check SAPP-FB
This function block compares position values from two different signal sources and
checks that the difference between the position values falls within the tolerance zone.
Table 56: Function of the inputs
Input name
Function
Sensor 1
BG100.1 OLM sensor 1 (at MOC1 input ENC1)
Sensor 2
BG100.2 OLM sensor 2 (at MOC1 input ENC2)
Inhibit_Error_ Message
This signal comes from the CPU logic and is set to High when a
permissible error occurs with the position data. The position data
is invalid when the sensor 2 test is active. The Inhibit_Error_Message
signal stops an entry being made in the diagnostics file in this
case.
Table 57: Function of the outputs
Output name
Function
Motion data cross checked The Motion data type adds additional diagnostics information to all
information provided by the motion sensors. If the diagnostics
(Motion data type):
information relates to both motion sensors, the motion data
becomes invalid as soon as there is a fault with one of the two
sensors.
7.6.1.2
Status
This output indicates whether or not the position cross-check was
successful (0 = not successful / 1 = successful). The signal is for‐
warded to the CPU logic.
AbsPosReliability
This output indicates whether or not the data from both sensors is
valid and reliable (0 = invalid / 1 = valid). The signal is forwarded
to the CPU logic.
Inhibiting the Diagnostics function block during internal tests
Figure 42: Function block view - Inhibit_Error_Message signal
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7 CONFIGURATION
The Inhibit_Error_ Message signal comes from the CPU logic and is set to High when a
permissible error occurs with the position data. The position data is invalid when the
sensor 2 test is active. As the Inhibit_Error_ Message signal is linked to the Inhibit‐
Diag.BG100.x diagnostics inputs of both sensors, the signal stops an entry being made
in the diagnostics file in this case.
7.6.2
Position_Monitor page
Figure 43: Position_Monitor page view
Position ranges can be set and monitored on this page. The two sensors provide sepa‐
rate status signals.
The application-specific Auxiliary Position Monitor SAPP-FB function block is protected with
a password. Configurations must only be set in the Position Monitor function block.
7.6.2.1
Function block for external safely limited speed requests (speed ID 2)
Figure 44: Function block for external safely limited speed requests (speed ID 2)
This function block converts a Boolean value (at input 1-4) to an integer (UINT8).
Table 58: Function of the inputs
66
Input number
Function
1 and 3
These inputs are linked to a Static 0 (Signal Low).
2
This input is linked to a Static 1 (Signal High).
4
This input is linked to a CPU logic signal. This means that the inte‐
ger at output 1 can have two values (depending on input 4).
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CONFIGURATION 7
Table 59: Function of the output
Output number
Function
1
Provides the decoded value as an integer.
Table 60: Possible values
Input 4 (23)
Input 3 (22)
Input 2 (21)
Input 1 (20)
Output 1
x
0
1
0
x +2
0
0
1
0
2
1
0
1
0
10
Output 1 is linked to the Speed Enable ID input of the Position Monitor function block. This
means that the signal from the CPU (input 4) activates either speed ID 2 (minimum
speed/speed ID 1 = 0) or speed ID 10 (maximum speed).
7.6.2.2
Auxiliary Position Monitor SAPP-FB function block (application-specific)
Figure 45: Function block view - Auxiliary Position Monitor SAPP-FB
The application-specific Auxiliary Position Monitor SAPP-FB function block generates status
information from sensor 2. The function block also prepares the Motion signal for the
Position Monitor function block, which must be configured by the user.
Table 61: Function of the inputs
Input name
Function
Sensor 1
BG100.1 OLM sensor 1 (at MOC1 input ENC1)
Sensor 2
BG100.2 OLM sensor 2 (at MOC1 input ENC2)
Static 1
Signal High for the function block
Table 62: Function of the outputs
Output name
Function
Motion out (Motion data type) The Motion data type adds additional diagnostics information to all
information provided by sensor 1. In this case, the diagnostics
information only relates to sensor 1.
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Sensor 2 Direction Status
The status bit of sensor 2 is forwarded to the CPU logic.
Sensor 2 Standstill Status
The status bit of sensor 2 is forwarded to the CPU logic.
Sensor 2 AbsPosValid
The position data from sensor 2 is checked to ensure that it is
valid (1 = valid/0 = invalid). The status bit is forwarded to the CPU
logic.
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7 CONFIGURATION
7.6.2.3
Position Monitoring function block
Figure 46: Function block view - Position Monitoring
The Position Monitor function block is the central module for monitoring all positions and
speeds within the application. It receives the Motion information from the leading sensor
1 via the Auxiliary Position Monitor SAPP-FB function block.
Table 63: Function of the input
Input name
Function
Motion In (Motion data
type)
The Motion data type adds additional diagnostics information to all
information provided by sensor 1. In this case, the diagnostics
information only relates to sensor 1.
Speed Enable ID
The maximum permitted speed range can be selected in the form
of an external integer using the Speed Enable ID input. If the current
speed at the Motion input is greater than the selected speed
range, the Monitor Status output is set to logic Low.
The value can be 2 (lowest speed) or 10 (highest speed) (see
"Position_Monitor page", page 66). It is guaranteed that the lowest
speed ID (either from Speed/Position Profile or Speed Enable ID)
always has priority.
Table 64: Function of the outputs
Output name
Function
Monitor Status
The Monitor Status output is set to High during fault-free operation.
It switches to Low if an active monitoring function detects a fault.
Within this application, this includes the combined status of the
following monitoring cases:
•
•
Position monitoring (safely limited position)
Speed monitoring (safely limited speed and maximum speed)
The Monitor Status is linked to the SCA - Safe CAM output. It is for‐
warded to the CPU logic and the PosMon Status jump address (for
use of the MOC1 logic).
68
Direction Status
The status bit of sensor 1 is forwarded to the CPU logic.
Standstill Status
The status bit of sensor 1 is forwarded to the CPU logic.
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CONFIGURATION 7
7.6.3
Output name
Function
Position CAM
This is the output for Safe CAM. It indicates a signal High when the
position is within the permitted range. The signal is linked to Moni‐
tor Status and triggers a stop when the current position is not within
the permitted range.
The SCA - Safe CAM diagnostics output marked in blue feeds the
signal from MOC1 to the CPU logic. This output should not be used
for safety signals owing to the long transmission time.
If the current position is not within the permitted range, an entry is
made accordingly in the fault history through the Message Generator
function block.
Speed Monitor Status
The Speed Monitor Status output is set to High during fault-free oper‐
ation. It switches to Low if the speed exceeds the permitted range.
Within this application, an entry is made accordingly in the fault
history through the Message Generator function block.
This logic is not safety-relevant. The Monitor Status signal takes care
of the safe switch-off process.
The Speed Monitor Status diagnostics output feeds the signal from
MOC1 to the CPU logic. This output should not be used for safety
signals owing to the short transmission time.
Safe Stop page
The Safe Stop function block of the MOC module is used to trigger and monitor the safe
stop of a drive system. The drive has to be stopped in a controlled way. The braking
torque of the drive can be used to stop the drive more quickly than would be possible in
the case of an uncontrolled stop.
Figure 47: Safe Stop page view
Inputs
• Motion IN
• Safe Stop 1a
• Safe Stop 2a
• Safe Stop 2b
• Reset
• Inhibit Motion bits reaction
Outputs
• Enable torque
• Enable brake
• Stop request
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7 CONFIGURATION
Table 65: Inputs of the function block
Input name
Function
Motion IN
This input receives the Motion signal from the Position Cross Check
function block. A fault is detected as soon as the position data
from the sensor is no longer reliable. This signal will trigger a safe
stop 2 (SS2) at the Safe Stop function block.
Safe Stop 1a
The SS1 request LowActive signal from the CPU logic is linked to this
input. If the signal switches to Low, a safe stop 1 (SS1) is initiated.
Safe Stop 2a
The SS2 request LowActive signal from the CPU logic is linked to this
input. If the signal switches to Low, a safe stop 2 (SS2) is initiated.
Safe Stop 2b
The PosMon Status signal (status of the Position Monitor function
block) is linked to this input. If the current position is not permitted
or if the speed exceeds the safe limit, this signal will be set to Low
and a safe stop 2 (SS2) will be initiated.
Reset
The reset signal comes from the CPU logic. A reset signal is
required following a safe stop 2 (SS2) or in order to reset the func‐
tion block after a fault has occurred.
The Safe Stop function block triggers a fault while the override
function or Sensor2 test is active.
As this is a permitted status that is monitored, the stop request is
not forwarded to the drive. In this case, the Safe Stop function
block detects a ramp fault. This must be reset following an over‐
ride function or Sensor2 test.
Inhibit Motion bits reaction
The signal comes from component SAPP-FB Safe Position. The signal
prevents unintended switching off during the self-test of the safety
system.
Table 66: Outputs of the function block
7.6.3.1
Output name
Function
Enable torque
This safety signal deactivates the drive’s torque. The signal is
transmitted to the CPU logic and has an impact on the safe out‐
puts (dual-channel output signal switching device).
Enable brake
This safety signal switches off the energy supply for the optional
brake. The signal is transmitted to the CPU logic and has an
impact on the safe outputs (dual-channel output signal switching
device).
Stop request
This signal triggers the stop ramp of the drive. The signal is trans‐
mitted to the CPU logic and is forwarded either to the process con‐
troller or to the drive directly.
Stop Ramps function block
The Stop Ramps function block monitors the actual reduction in speed until the drive
comes to a standstill. The ramp settings will depend on the application and the compo‐
nents in use (e.g., the drive).
Refer to the Flexi Soft Designer operating instructions for further details on how to con‐
figure safe ramp monitoring.
The screenshot below shows the standard configuration, with ramp monitoring deacti‐
vated.
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CONFIGURATION 7
Figure 48: Stop Ramps standard configuration
7.7
Notes on the Flexi Soft logic editor
7.7.1
Creating or deleting links
The logics in the Flexi Soft Designer mainly consist of the following elements:
•
•
•
Safety controller inputs
Safety controller outputs
Function blocks with inputs and outputs
Links connect these elements. Links are represented as lines. Every element contains
blue anchor points which represent the inputs and outputs of the elements. A link can
only be created between the anchor point on the right side of an element and the
anchor point on the left side of another element.
Creating link
1.
2.
✓
Click and hold the blue anchor point on the right side of an element.
Move and release the mouse cursor on the blue anchor point on the left side of an
element.
A link is created between 2 elements.
Deleting link
1.
2.
3.
✓
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Click on the link between 2 elements.
Press the Del pushbutton.
In the Delete page dialog box, click on the Yes button.
The link is deleted.
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7 CONFIGURATION
7.7.2
Jump addresses
A jump address consists of a source jump address and a destination jump address.
The destination jump address assumes the same value (High or Low) as the associated
source jump address without any delay time whatsoever – unless it is a loopback. Infor‐
mation on loopbacks can be found in the “Flexi Soft in the Flexi Soft Designer”
(8012998) operating instructions.
Jump addresses are an elegant option for implementing complex logic relationships.
Among other things, jump addresses are used to connect the various pages of logic
with each other.
7.7.2.1
Finding source and destination jump addresses that belong together
To find the corresponding destination jump address for a source jump address (or vice
versa), proceed as follows:
1.
2.
✓
3.
✓
7.7.2.2
Adding a new source jump address
1.
2.
3.
7.7.2.3
Drag the Add source jump address symbol from the toolbar on the left of the logic cre‐
ation page into the working range.
Enter a unique name in the Create jump mark dialog box.
Click on OK.
Adding a new destination jump address
1.
2.
3.
7.7.3
Right-click on the source or destination jump address.
Click Used on page.
A list of all pages containing elements of the jump address is displayed.
Click on the desired page.
The desired page is displayed. All elements of the jump address are highlighted in
color.
Drag the Add destination jump address symbol from the toolbar on the left of the logic
creation page into the working range.
Select the desired jump mark in the Select jump mark dialog box.
Click on OK.
Verification of the logic
After the required parameters have been configured, the logic has to be certified before
being transferred to the safety controller.
The manufacturer of the machine is responsible for the output connections and for the
logic verification.
7.7.4
Transfer configuration
b
72
Transmit configuration to the Flexi Soft main module (see operating instructions
8012998).
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COMMISSIONING 8
8
Commissioning
8.1
Safety
DANGER
Hazard due to lack of effectiveness of the protective device
b
b
Before commissioning the machine, make sure that the machine is first checked
and released by qualified safety personnel.
Only operate the machine with a perfectly functioning protective device.
DANGER
Dangerous state of the machine
During commissioning, the machine or the protective device may not yet behave as you
have planned.
b
Make sure that there is no-one in the hazardous area during commissioning.
Before commissioning can be performed, project planning, mounting, electrical installa‐
tion and configuration must be completed in accordance with this document.
8.2
Thorough check
Requirements for the thorough check during commissioning and in certain situations
The safety system and its application must be thoroughly checked in the following situa‐
tions:
•
•
•
•
Before commissioning
After changes to the configuration or the safety function
After changes to the mounting or the electrical connection
After exceptional events, such as after a manipulation has been detected, after
modification of the machine, or after replacing components
The thorough check ensures the following:
•
•
All relevant regulations are complied with and the safety system is effective in all
of the machine’s operating modes
The documentation corresponds to the state of the machine, including the protec‐
tive device
The thorough checks must be carried out by qualified safety personnel or specially qual‐
ified and authorized personnel and must be documented in a traceable manner.
1.
2.
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Effectiveness of the protective device for all operating modes selectable on the
machine in accordance with the checklist for initial commissioning and commis‐
sioning (see "Annex", page 86).
Make sure that the operating personnel has been instructed in the function of the
protective device before starting work on the machine. The instruction is the
responsibility of the machine operator and must be carried out by qualified per‐
sonnel.
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9 OPERATING THE COMPONENTS
9
Operating the components
NOTE
Information is included in the operating instructions for the components.
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MAINTENANCE OF THE COMPONENTS 10
10
Maintenance of the components
NOTE
Information is included in the operating instructions for the components.
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11 TROUBLESHOOTING
11
Troubleshooting
NOTE
Information is included in the operating instructions for the components.
11.1
Electromagnetic compatibility
The system may switch to the safe state if EMC levels are relatively high. Safety takes
priority over availability. If related problems arise, the user must take suitable mea‐
sures.
11.2
Exchange and repairs
The sensor unit, which consists of two OLM sensors and a mounting bracket, may only
be exchanged as a complete unit. Individual sensors may not be exchanged.
The sensor unit may only ever be repaired by the SICK Service team.
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DECOMMISSIONING 12
12
Decommissioning
12.1
Disassembly and disposal
The applicable national disposal regulations must always be followed. Efforts should be
made during the disposal process to recycle the constituent materials (particularly pre‐
cious metals).
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13 TECHNICAL DATA
13
Technical data
13.1
Data sheet
Table 67: Safe Linear Positioning data sheet
Safe Linear Positioning
SIL claim limit
SILCL3 (EN 62061)
Category
Category 4 (EN ISO 13849)
Performance level
PL e (ISO 13849-1)
PFHD
PFHD = 3.08 x 10-8
MTTFd of the safety system
High
TM (mission time)
20 years (EN ISO 13849)
Response time of the system
Max. 47.5 ms
Stopping distance extension
10 mm 1)
Resolution of the OLM100-1301/1401 mea‐
surement system (part number: 1087575)
0.1 mm
Resolution of the OLM100-1501/1601 mea‐
surement system (part number: 1090629)
0.01 mm
1,677 m
Maximum measuring range with
OLM100-1301/1401 (part number: 1087575)
8,589 m
Maximum measuring range with
OLM100-1501/1601 (part number: 1090629)
Maximum speed of the measurement system
4 m/s
Length of the SSI connection cable between
OLM 2 and the FX3-MOC1 input (direct con‐
nection)
Max. 50 m
(transmission rate < 400 kBaud)
Length of the SSI connection cable between
OLM 1 and the external process controller
(parallel infeed to FX3-MOC1)
Max. 50 m
(transmission rate < 400 kBaud)
Length of the SSI connection cable between
Max. 2 m
the splitter (coupling point) and the FX3-MOC1 (transmission rate < 400 kBaud)
input
Supply voltage UV
24 V DC (16.8 V DC ... 28.8 V DC) (SELV) 2)
Ambient operating temperature
Flexi Soft: -20 … +55 °C
OLM100 Hi: -30 … +55 °C
Storage temperature
–25 … +70 °C
Air humidity
10…95%, non-condensing
Permissible operating height
Max. 2,000 m above sea level (80 kPa)
Enclosure rating (EN 60529)
Flexi Soft: IP54
OLM100 Hi: IP65
Safe state
The safety-related semiconductor outputs are
in the OFF state.
Electromagnetic compatibility
EN 61000-6-2, EN 61000-6-4
Vibration resistance
EN 60068-2-6, EN 60068-2-64
Shock resistance
EN 60086-2-27
1)
2)
78
The user must use the overall response time and other application-specific parameters to calculate the
stopping distance. The user must then add another 10 mm on to the calculated stopping distance, which
apply owing to internal filters.
The external supply voltage must jumper a brief power failure of 20 ms as specified in IEC 60204-1. Suit‐
able power supply units are available as accessories from SICK.
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TECHNICAL DATA 13
13.2
XTIO module inputs
XTIO module
Input voltage HIGH
13 ... 30 V DC
Input voltage LOW
-5 ... +5 V DC
Input current HIGH
2.4 ... 3.8 mA
Input current LOW
-2.5 ... +2.1 mA
Input capacity
Max. 10 nF +10%
Switching current (when mechanical contacts
are connected)
14.4 mA with 5 V
3 mA with 24 V
Input reverse current in case of loss of ground connection
Hardware version < V1.10.0
Max. 20 mA
1.5 kΩ effective reverse resistance to voltage
supply
Hardware version ≥ V1.10.0
Max. 2 mA
Input pulse filter (pulses within these limits do not have any effect)
Pulse width
Max. 0.9 ms
Pulse period
Min. 4 ms
Further technical data can be found in the “Flexi Soft Modular Safety Controller Hard‐
ware” operating instructions.
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13 TECHNICAL DATA
13.3
Dimensional drawings
66 ±0.2
88 ±1
50 ±0.2
6 ±1)
206 ±0.2
47
190 ±0.2
47
47
Figure 49: Dimensional drawing for the OLM100 Hi on a mounting plate
13.4
Response times
Overrun for the entire system
The overrun for the entire system is made up of at least two phases.
T = t1 + t2
Table 68: Calculation of overrun for the entire system
80
Code
Meaning
T
Overrun for the entire system
t1
Maximum amount of time between the protective device being activated
and the OFF state of the output being reached.
t2
The maximum amount of stopping time required to end the dangerous sta‐
tus of the machine once the output signal from the protective device has
been switched to the OFF state. The response time of the machine’s control
system must be taken into consideration when calculating t2.
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TECHNICAL DATA 13
The default setting for the Speed Filter parameter is 10 mm and this must be taken into
account at the planning stage (see "Configuring speed limits", page 37).
WARNING
There is a risk of death or serious injury if the stopping distance is calculated incor‐
rectly.
b
Do not change the Speed Filter parameter.
Table 69: Explanation of calculation formula
T
t1
Overall stopping time
47.5 ms + TRampDelay + TPDS(RS)
=
t2
Sensor
MOC
input
Max. data
reception
interval
MOC logic
Flexi Soft
cycle time
Output
Drive
10 ms +
9 ms +
8 ms +
TRampDelay +
16 ms +
4.5 ms +
TPDS(SR)
TRampDelay
An additional TRampDelay delay time may be required depending on the drive system in
use. This delay time, which can be adjusted in Flexi Soft, delays the start of ramp moni‐
toring. The delay time must correspond to the response time of the drive.
TPDS(SR)
TPDS(SR) is the amount of time required by the drive system for a stop ramp. If after t1 the
acceleration is not great enough owing to a fault, the torque will be deactivated (safe
torque off, STO - stop). If the optional safe brake control (SBC) (QA120) is linked to Flexi
Soft, this will be activated too.
NOTE
If the stopping time with safe torque off (STO) and safe brake control (SBC) is greater
than in the case of the standard stop ramp, the higher value must be used for TPDS(SR).
13.4.1
Stopping time in the event of a drive fault
If the drive is faulty and the speed is not limited, the torque is deactivated and the
optional safe brake control (SBC) is activated.
T = t1 + t2
t1 = 47.5 ms + TRampDelay +47.5 ms
t2 = Tbrake
T = 95 s + TRampDelay + Tbrake
Table 70: Definition of operands
13.4.2
Code
Meaning
Tbrake
The amount of time the brake needs to stop movement.
TRampDelay
Additional delay time that may be necessary depending on the drive system
in use.
Flexi Soft cycle time
The cycle time of the Flexi Soft safety controller is dependent on the scope of the logic.
In this document, the stopping time is calculated on the basis of a standard cycle time
of 8 ms.
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13 TECHNICAL DATA
WARNING
There is a risk of death or serious injury due to the stopping/run-down time being too
long.
b
Double the cycle time (= 16 ms) to calculate the stopping/run-down time for the
entire system.
The CPU logic execution time may increase if additional safety functions are used.
Once the logic has been configured, the final calculation for the cycle time must be
used to calculate the stopping time.
13.4.3
Maximum data reception interval
The maximum data reception interval is an adjustable timeout period within which valid
position data must be received.
This timeout period can be configured using the Flexi Soft Designer. For this safety sys‐
tem, the value for the maximum data reception interval is set at 8 ms. If this time is
increased, the response time will be increased too accordingly.
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ORDERING INFORMATION 14
14
Ordering information
14.1
Safe Linear Positioning ordering information
SAPPD3E-14AP003 (part number 1028308)
Complete set with main module and all cables, 0.1 mm resolution, 25 bit SSI:
•
•
•
•
•
•
1 x FX3-CPU000000 main module (part number 1043783)
2 x FX3-XTIO84002 I/O module (part number 1044125)
1 x FX3-MOC100000 drive monitor (part number 1057833)
1 x FX3-MPL000001 system plug for FX3-CPU0 (part number 1043700)
1 x sensor unit, 0.1 mm resolution, 25 bit SSI (part number 1087575)
1 x X-junction (part number 2097764)
SAPPD3E-14AP004 (part number 1028313)
Complete set with main module and all cables, 0.01 mm resolution, 32 bit SSI:
•
•
•
•
•
•
1 x FX3-CPU000000 main module (part number 1043783)
2 x FX3-XTIO84002 I/O module (part number 1044125)
1 x FX3-MOC100000 drive monitor (part number 1057833)
1 x FX3-MPL000001 system plug for FX3-CPU0 (part number 1043700)
1 x sensor unit, 0.01 mm resolution, 32 bit SSI (part number 1090629)
1 x X-junction (part number 2097764)
SAPPD3E-14AP009 (part number 1096692)
Retrofitting set, but with all cables, 0.1 mm resolution, 25 bit SSI:
•
•
•
1 x FX3-MOC100000 drive monitor (part number 1057833)
1 x sensor unit, 0.1 mm resolution, 25 bit SSI (part number 1087575)
1 x X-junction (part number 2097764)
The main module and system plug must be ordered separately.
SAPPD3E-14AP010 (part number 1096693)
Retrofitting set, but with all cables, 0.01 mm resolution, 32 bit SSI:
•
•
•
1 x FX3-MOC100000 drive monitor (part number 1057833)
1 x sensor unit, 0.01 mm resolution, 32 bit SSI (part number 1090629)
1 x X-junction (part number 2097764)
The main module and system plug must be ordered separately.
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15 SPARE PARTS
15
Spare parts
Table 71: Spare parts
Name
Description
Part number
FX3-CPU000000
Main module
1043783
FX3-XTIO84002
I/O module
1044125
FX3-MOC100000
Drive monitor
1057833
FX3-MPL000001
System plug for FX3-CPU0
1043700
Table 72: Spare parts
84
Name
Part number
Sensor unit, resolution 0.1 mm, SSI 25 bit
1087575
Sensor unit, resolution 0.01 mm, SSI 32 bit
1090629
X-junction
2097764
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ACCESSORIES 16
16
Accessories
16.1
Connectivity
Table 73: Ordering data for connection cables for OLM sensors, straight male connector/straight
female connector
Part
Type code
Part number
Connection cable, 1 meter
YF2A28-010UA6M2A28
2096108
Connection cable, 2 meters
YF2A28-020UA6M2A28
2096105
Connection cable, 5 meters
YF2A28-050UA6M2A28
2096106
Connection cable, 10 meters
YF2A28-100UA6M2A28
2096109
Table 74: Ordering data for connection cables for OLM sensors, straight male connector/angled
female connector
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Part
Type code
Part number
Connection cable, 0.6 meters
DSL-1208-B0M6ASCO
6048801
Connection cable, 5 meters
DSL-1208-B05MASCO
6049328
Connection cable, 10 meters
DSL-1208-B05MASCO
6049329
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17 ANNEX
17
Annex
17.1
Checklist for initial commissioning and commissioning
This checklist should be retained and kept with the machine documentation to serve as
reference during recurring thorough checks.
This checklist is not a substitute for initial commissioning or periodic thorough checks
by qualified safety personnel.
17.1.1
Thorough check of the requirements specified in the operating instructions for the safety system
Ambient conditions
Table 75: Ambient conditions
Check sequence
Expected result
1.
Yes ⃞ No ⃞
Compliance with the requirements
specified in the operating instructions
for the safety system is confirmed.
The Flexi Soft system is in an environ‐
ment corresponding to enclosure rating
IP54 (EN 60529) (e.g., inside a control
cabinet).
Check the ambient conditions.
Result OK?
Mounting
Table 76: Mounting requirements
Check sequence
1.
2.
3.
Expected result
Result OK?
Compliance with the requirements
Check that the sensor system
specified in the operating instructions
has been mounted correctly in
terms of positioning and distance for the safety system is confirmed.
from bar code tape.
Check that the sensor system
and bar code tape are parallel to
one another.
Check the mounting conditions of
the Flexi Soft safety controller.
Yes ⃞ No ⃞
Electrical installation
Table 77: Requirements for the electrical wiring
Check sequence
Expected result
Result OK?
1.
Compliance with the requirements
specified in the operating instructions
for the safety system is confirmed.
An X-junction must be used to connect
the OLM sensors in all cases.
Yes ⃞ No ⃞
2.
Check the electrical wiring,
including the length of the
cables.
Check that the requirements for
electrical protection and current
limit have been met.
Table 78: Electrical requirements for the plausibility signals from the process channel
86
Check sequence
Expected result
Result OK?
1.
The electrical data for the plausibility
signals confirms compatibility with the
electrical data for the safe inputs that
are outlined in the operating instruc‐
tions for the Flexi Soft hardware.
Yes ⃞ No ⃞
Check that the plausibility signals
from the process controller are
electrically compatible with the
safe inputs of the Flexi Soft
safety controller (refer to the data
sheet).
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ANNEX 17
Table 79: Requirements for the SSI interface
Check sequence
1.
Expected result
Check the baud rates of both
Both SSI interfaces have different
OLM sensors in the Flexi Soft pro‐ transmission rates ranging from
gram and potentially also the
100 kBaud to 400 kBaud.
process controller.
Result OK?
Yes ⃞ No ⃞
Baud rate of OLM sensor 1:
Baud rate of OLM sensor 2 (standard value: 167 kBaud):
Configuration
Table 80: Definition of the permitted position values
Check sequence
1.
17.1.2
Expected result
Check the position ranges
The position ranges that are not per‐
entered in the Flexi Soft program. mitted (= not used) within the applica‐
tion have been determined and the
FX3-MOC1 module has been config‐
ured accordingly with the Flexi Soft
Designer software.
Result OK?
Yes ⃞ No ⃞
Thorough check of the hardware requirements
Drive system
Table 81: Drive system
Check sequence
1.
Expected result
Check that the drive’s safe torque Compliance with the requirements for
category 4, PL e (EN ISO 13849-1) is
off (STO) function and electrical
control comply with the require‐
confirmed.
ments of category 4, PL e (EN ISO
13849-1).
Result OK?
Yes ⃞ No ⃞
Brake
Table 82: Brake
Check sequence
Expected result
Result OK?
1.
Compliance with the requirements for
category 4, PL e (EN ISO 13849-1) is
confirmed or the risk assessment indi‐
cated that a brake is not required.
Yes ⃞ No ⃞
Check that the brake and electri‐
cal control comply with the
requirements of category 4, PL e
(EN ISO 13849-1).
External signal for requesting the safely limited speed (SLS)
Table 83: External signal for requesting the safely limited speed (SLS)
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Check sequence
Expected result
Result OK?
1.
Compliance with the requirements for
category 4, PL e (EN ISO 13849-1) is
confirmed or an external signal is not
used to request the safely limited
speed (SLS).
Yes ⃞ No ⃞
Check that the signal source and
electrical transmission path com‐
ply with the requirements of cate‐
gory 4, PL e (EN ISO 13849-1).
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17 ANNEX
Electrical installation
Table 84: Electrical installation
17.1.3
Check sequence
Expected result
1.
The requirements of the standard have Yes ⃞ No ⃞
been met.
Check that the electrical installa‐
tion work has been performed in
accordance with EN 60204-1
(IEC 60204-1).
Result OK?
Thorough check of the Flexi Soft configuration
Maximum speed
Table 85: Maximum speed
Check sequence
1.
2.
Expected result
Result OK?
Check that the maximum speed The maximum speed has been
for the safety system is 4 m/s.
adjusted in line with the application.
If a lower maximum speed is
required, configure this using the
MOC1 logic editor.
Yes ⃞ No ⃞
Safely limited speeds (SLS)
Table 86: Safely limited speeds (SLS)
Check sequence
Expected result
1.
Safely limited speeds (SLS) have been Yes ⃞ No ⃞
configured and the corresponding posi‐
tion ranges assigned (speed/position
matrix).
2.
Check that a maximum permitted
speed has been defined for each
position range that has been con‐
figured.
Set speed ID 1 (= standstill) for
position ranges that are not per‐
mitted.
Result OK?
Stop ramp
Table 87: Stop ramp
Check sequence
1.
Expected result
Result OK?
Check that the stop ramp has
The stop ramp has been configured in
been input in line with the spe‐
line with the specific application and
cific application and has been
taken into account accordingly.
taken into account when calculat‐
ing the stopping distance.
Yes ⃞ No ⃞
Increase to the response time through the “maximum data reception interval” para‐
meter
Table 88: Increase to the response time through the “maximum data reception interval” parame‐
ter
Check sequence
1.
88
Check that the maximum data
reception interval parameter in the
MOC1 logic editor has been
taken into account when calculat‐
ing the overall response time.
O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning
Expected result
Result OK?
The maximum data reception interval para‐ Yes ⃞ No ⃞
meter has been taken into account
when calculating the overall response
time.
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ANNEX 17
Increase to the response time through the “logic extension” parameter
Table 89: Increase to the response time through the “logic extension” parameter
17.1.4
Check sequence
Expected result
Result OK?
1.
The logic execution time has been
checked and taken into account when
calculating the overall response time
with a value of more than 8 ms.
Yes ⃞ No ⃞
Check that the logic execution
time has been taken into account
when calculating the overall
response time.
Thorough check of the Flexi Soft documentation
Configuration of the safety controller
Table 90: Configuration of the safety controller
Check sequence
Expected result
1.
•
Check the position ranges and
speed/position profile (in the
MOC1 logic editor).
•
•
Result OK?
The position ranges entered corre‐ Yes ⃞ No ⃞
spond to the target application.
Only the position ranges in use
have the CAM mark.
Position ranges that are not in use
and position 0 do not have the CAM
mark.
Thorough check of the response time
Table 91: Thorough check of the response time
Check sequence
Expected result
1.
•
Check the Flexi Soft CPU cycle
time with the Flexi Soft Designer
software.
•
Result OK?
If the cycle time is > 8 ms, the over‐ Yes ⃞ No ⃞
all response time for the Safe Lin‐
ear Positioning application must be
recalculated.
If the cycle time is 8 ms, the overall
response time provided in this doc‐
ument applies.
CPU cycle time value:
Verification of the Flexi Soft configuration
Table 92: Verification of the Flexi Soft configuration
Check sequence
Expected result
Result OK?
1.
•
Yes ⃞ No ⃞
Check that the Flexi Soft configu‐
ration has been verified correctly.
•
The tested Flexi Soft configuration
has been verified, which means
that the verification report has
been checked and approved.
The CV LED on the CPU lights up
continuously.
Documentation of the CRC checksum
Table 93: Documentation of the CRC checksum
Check sequence
Expected result
1.
The checksum of the verified Flexi Soft Yes ⃞ No ⃞
program has been determined.
Check the CRC checksum.
Result OK?
CRC:
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17 ANNEX
Documentation of the Flexi Soft project
Table 94: Documentation of the Flexi Soft project
Check sequence
Expected result
Result OK?
1.
•
Yes ⃞ No ⃞
Create Flexi Soft report.
•
17.1.5
Archiving of the verified Flexi Soft
program.
Checking and archiving of the Flexi
Soft report.
Thorough check on the process channel (standstill)
Evaluation of the test signals during standstill
NOTE
You must undo the manipulation on the safety system again after each individual test
sequence. Then you must reset the safety system and carry out a restart.
Table 95: Evaluation of the test signals during standstill
Check sequence
1.
Apply the test signal during
standstill.
Expected result
•
•
•
1.
2.
3.
1.
2.
3.
1.
2.
3.
17.1.6
Result OK?
Test signal 1 “forward” active (XTIO
input I1)
Test signal 2 “backward” active
(XTIO input I2)
No fault, system is in a functional
state (XTIO output Q4 "KF130 stop
request" is active)
Yes ⃞ No ⃞
Apply the test signal during
standstill.
Set test signal 1 “forward” to
inactive (XTIO input I1).
Set test signal 2 “backward” to
active (XTIO input I2).
The safety system switches to the safe
state (XTIO output Q4 "KF130 stop
request" is deactivated)
Yes ⃞ No ⃞
Apply the test signal during
standstill.
Set test signal 1 “forward” to
active (XTIO input I1).
Set test signal 2 “backward” to
inactive (XTIO input I2).
The safety system switches to the safe
state (XTIO output Q4 "KF130 stop
request" is deactivated)
Yes ⃞ No ⃞
Apply the test signal during
standstill.
Set test signal 1 “forward” to
inactive (XTIO input I1).
Set test signal 2 “backward” to
inactive (XTIO input I2).
The safety system switches to the safe
state (XTIO output Q4 "KF130 stop
request" is deactivated)
Yes ⃞ No ⃞
Thorough check on the process channel (forward movement)
Evaluation of the test signals during forward movement
NOTE
You must undo the manipulation on the safety system again after each individual test
sequence. Then you must reset the safety system and carry out a restart.
90
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ANNEX 17
Table 96: Evaluation of the test signals during forward movement
Check sequence
1.
Apply the test signal during for‐
ward movement.
Expected result
•
•
•
1.
2.
3.
1.
2.
3.
1.
2.
3.
17.1.7
Test signal 1 “forward” active (XTIO
input I1)
Test signal 2 “backward” inactive
(XTIO input I2)
No fault, system is in a functional
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2
"QA110.2 safety output (STO)" are
active)
Result OK?
Yes ⃞ No ⃞
Apply the test signal during for‐
ward movement.
Set test signal 1 “forward” to
active (XTIO input I1).
Set test signal 2 “backward” to
active (XTIO input I2).
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated)
Yes ⃞ No ⃞
Apply the test signal during for‐
ward movement.
Set test signal 1 “forward” to
inactive (XTIO input I1).
Set test signal 2 “backward” to
active (XTIO input I2).
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated)
Yes ⃞ No ⃞
Apply the test signal during for‐
ward movement.
Set test signal 1 “forward” to
inactive (XTIO input I1).
Set test signal 2 “backward” to
inactive (XTIO input I2).
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated)
Yes ⃞ No ⃞
Thorough check on the process channel (backward movement)
Evaluation of the test signals during backward movement
NOTE
You must undo the manipulation on the safety system again after each individual test
sequence. Then you must reset the safety system and carry out a restart.
Table 97: Evaluation of the test signals during backward movement
Check sequence
1.
Apply the test signal during back‐
ward movement.
Expected result
•
•
•
1.
2.
3.
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Apply the test signal during back‐
ward movement.
Set test signal 1 “forward” to
active (XTIO input I1).
Set test signal 2 “backward” to
active (XTIO input I2).
Test signal 1 “forward” inactive
(XTIO input I1)
Test signal 2 “backward” active
(XTIO input I2)
No fault, system is in a functional
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2
"QA110.2 safety output (STO)" are
active)
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated).
Result OK?
Yes ⃞ No ⃞
Yes ⃞ No ⃞
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17 ANNEX
Check sequence
Expected result
Result OK?
1.
Apply the test signal during back‐
ward movement.
Set test signal 1 “forward” to
active (XTIO input I1).
Set test signal 2 “backward” to
inactive (XTIO input I2).
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated).
Yes ⃞ No ⃞
Apply the test signal during back‐
ward movement.
Set test signal 1 “forward” to
inactive (XTIO input I1).
Set test signal 2 “backward” to
inactive (XTIO input I2).
The safety system switches to the safe
state (XTIO outputs Q1 "QA110.1
safety output (STO)" and Q2 "QA110.2
safety output (STO)" are deactivated).
Yes ⃞ No ⃞
2.
3.
1.
2.
3.
17.1.8
Thorough check of the safety functions
External signal for requesting the safely limited speed (SLS) (if external signal used)
NOTE
You must undo the manipulation on the safety system again after each individual test
sequence. Then you must reset the safety system and carry out a restart.
Table 98: External signal for requesting the safely limited speed (SLS)
Check sequence
Expected result
1.
A safe stop 2 (SS2) is initiated at a
Yes ⃞ No ⃞
speed > speed ID 2.
An automated restart is not performed.
Check that the external signal
source activates the SLS safety
function (outputs of the signal
source = 0 V).
Result OK?
Emergency stop
Table 99: Emergency stop
17.1.9
Check sequence
Expected result
1.
The emergency stop pushbutton is eas‐ Yes ⃞ No ⃞
ily accessible.
When actuated, a safe stop 1 (SS1) is
initiated.
If an optional brake is in use, the brake
function will be activated once a stand‐
still has been reached.
Resetting the emergency stop device
does not trigger a restart.
All emergency stop pushbuttons within
the application have to be checked.
Actuate the emergency stop
pushbutton.
Result OK?
Thorough check of faults on the transmission path
NOTE
You must undo the manipulation on the safety system again after each individual test
sequence. Then you must reset the safety system and carry out a restart.
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ANNEX 17
Interruption of connection to OLM sensor 1
Table 100: Interruption of connection to OLM sensor 1
Check sequence
1.
Expected result
Remove the plug connection from Switches to status:
OLM sensor 1.
XTIO output Q4 "KF130 stop request"
is deactivated.
Result OK?
Yes ⃞ No ⃞
Interruption of connection to OLM sensor 2
Table 101: Interruption of connection to OLM sensor 2
Check sequence
1.
Expected result
Remove the plug connection from Switches to status:
OLM sensor 2.
XTIO output Q4 "KF130 stop request"
is deactivated.
Result OK?
Yes ⃞ No ⃞
Interruption of connection to MOC1
Table 102: Interruption of connection to MOC1
Check sequence
1.
Expected result
Remove the plug connection from Switches to status:
the MOC1 module.
XTIO output Q4 "KF130 stop request"
is deactivated.
Result OK?
Yes ⃞ No ⃞
Interruption of connection for the “Sensor ID 1” signal
Table 103: Interruption of connection for the “Sensor ID 1” signal
Check sequence
1.
Expected result
Remove the plug connection from Switches to status:
the Flexi Soft input.
XTIO output Q4 "KF130 stop request"
is deactivated.
Result OK?
Yes ⃞ No ⃞
Interruption of connection for the “Sensor ID 2” signal
Table 104: Interruption of connection for the “Sensor ID 2” signal
Check sequence
1.
17.1.10
Expected result
Remove the plug connection from Switches to status:
the Flexi Soft input.
XTIO output Q4 "KF130 stop request"
is deactivated.
Result OK?
Yes ⃞ No ⃞
Thorough check for foreseeable misuse and manipulation
Mounting
Table 105: Bar code
Check sequence
Expected result
Result OK?
1.
•
Yes ⃞ No ⃞
Check that the bar code tape has
been applied properly, without
any tears or manipulation.
•
•
•
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Only the approved bar code tape
has been used.
The tape has been applied in line
with the requirements specified in
the OLM operating instructions.
There are no signs of the bar code
having been manipulated (e.g., for
test purposes).
The bar code tape is not contami‐
nated in any way.
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17 ANNEX
Table 106: Mounting
Check sequence
Expected result
Result OK?
1.
•
Yes ⃞ No ⃞
Check the mounting of the safety
system.
•
•
The sensor system has been
mounted in accordance with these
operating instructions.
The sensor system must be
mounted within a permissible dis‐
tance of the bar code tape
(80 mm-120 mm).
There are no signs of manipulation
as far as the mounting is con‐
cerned.
Electrical installation
Table 107: Cable laying
Check sequence
Expected result
1.
•
Check the cable laying.
•
•
•
•
Result OK?
Yes ⃞ No ⃞
The approved X-junction and, if
required, the permitted connection
cables from SICK are the only
options that can be used for electri‐
cally connecting the OLM sensors.
The X-junction is wired from the
FX3-MOC1 connector plug to the
SSI splitter within an electrical
installation area.
The maximum permitted lengths
have not been exceeded for cables.
The connector plugs for the OLM
sensors are mechanically secured
with tightened M12 threaded rings.
The connector plug for the FX3MOC1 is mechanically secured with
two screws (in the plug).
Product description
Table 108: Components
Check sequence
Expected result
1.
•
Check that only approved OLM
sensors with the safety controller
have been used.
•
•
Result OK?
Only the approved full OLM sensor Yes ⃞ No ⃞
system has been used.
Individual sensors have not been
exchanged. The sensor system may
only be exchanged as one whole
unit (i.e., a mounting bracket with
sensors mounted on it).
The sensor system is only operated
with a Flexi Soft safety controller.
Ambient conditions
Table 109: Surrounding area
94
Check sequence
Expected result
1.
•
Check the safety system for
manipulations in the surrounding
area.
O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning
Result OK?
There are no signs of manipulation Yes ⃞ No ⃞
in the surrounding area, e.g., a bar
code having been affixed in front of
the sensors or dazzle from ambient
light.
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ANNEX 17
17.1.11
Thorough check of the response time of the safety system within the target application
Response time of the safety system within the target application
Table 110: Response time of the safety system within the target application
Check sequence
Expected result
1.
The response time of the safety system Yes ⃞ No ⃞
within the target application is appro‐
priate.
Determine the response time of
the safety system within the tar‐
get application (e.g., by measur‐
ing the stopping time).
Result OK?
Comment:
17.1.12
Thorough check of the check intervals
Thorough check of the check intervals
Table 111: Thorough check of the check intervals
Check sequence
Expected result
Result OK?
1.
The check interval and responsible
party have been defined as follows:
Yes ⃞ No ⃞
2.
Set a check interval for regular
thorough checks and validation
of the safety system on the basis
of the risk assessment for the
application.
Specify a responsible party.
Check interval:
Responsible party:
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95
8020941/12O9/2019-08-05/en
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