Sick Safe Stationary Machine Operating instructions

Sick Safe Stationary Machine Operating instructions
OPERATING INSTRUCTIONS
Safe Stationary Machine
Example application
Described product
Safe Stationary Machine – Example application
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........................................................................
5
1.1
1.2
1.3
1.4
1.5
Purpose of this document........................................................................
Scope.........................................................................................................
Target groups and structure of these operating instructions................
Further information...................................................................................
Symbols and document conventions......................................................
5
5
5
6
6
Safety information............................................................................
7
2.1
2.2
2.3
General safety notes................................................................................
Intended use.............................................................................................
Requirements for the qualification of personnel....................................
7
7
7
Product description...........................................................................
9
3.1
3.2
3.3
3.4
4
4.2
4.3
4.4
Manufacturer of the machine..................................................................
4.1.1
Risk assessment.....................................................................
4.1.2
Safety functions.......................................................................
4.1.3
Implementation of the safety functions.................................
Integrating the equipment into the electrical control.............................
4.2.1
Block diagram and circuit diagram.........................................
4.2.2
Requirements for components...............................................
Calculation of the performance level......................................................
Operating entity of the machine..............................................................
14
14
14
16
18
18
19
22
22
Configuration..................................................................................... 23
5.1
5.2
5.3
5.4
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9
9
9
10
10
10
11
11
11
12
13
Project planning................................................................................ 14
4.1
5
Example application.................................................................................
Components..............................................................................................
3.2.1
Project file................................................................................
3.2.2
SISTEMA files...........................................................................
Application description.............................................................................
Structure and function.............................................................................
3.4.1
Interlocking...............................................................................
3.4.2
Drive monitoring and standstill control..................................
3.4.3
Operating modes.....................................................................
3.4.4
Emergency stop.......................................................................
3.4.5
Safe state of the machine.......................................................
Overview....................................................................................................
Hardware configuration of the Flexi Soft safety controller.....................
Logic programming for the MOC..............................................................
5.3.1
Logic programming page 1.....................................................
5.3.2
Stationary Machine page of the logic programming.............
Easy Application configuration assistant................................................
5.4.1
Machine parameters...............................................................
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23
24
25
25
26
27
27
3
CONTENTS
5.5
5.6
6
Necessary components for Safe Stationary Machine............................
50
Accessories...............................................................................................
51
Annex.................................................................................................. 52
9.1
9.2
4
49
Accessories........................................................................................ 51
8.1
9
Thorough check........................................................................................
Ordering information........................................................................ 50
7.1
8
29
36
36
37
40
41
41
41
42
43
46
48
Commissioning.................................................................................. 49
6.1
7
5.4.2
Application parameters...........................................................
5.4.3
Summary..................................................................................
Further configuration options in Expert mode........................................
5.5.1
Speed comparison...................................................................
5.5.2
Speed monitoring....................................................................
5.5.3
Safe stop..................................................................................
Logic programming for the CPU...............................................................
5.6.1
Service mode page..................................................................
5.6.2
Automatic mode page..............................................................
5.6.3
Stop signals page.....................................................................
5.6.4
From/to FX3-MOC0 page.........................................................
5.6.5
Drive control page....................................................................
Checklist for initial commissioning and commissioning........................
Extending the number of axes.................................................................
52
55
10
List of figures..................................................................................... 58
11
List of tables....................................................................................... 59
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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 Safe Stationary Machine example application.
These operating instructions must be made available to everyone who works with the
example application.
Read these operating instructions carefully and ensure that you have understood the
contents completely before working with the example application.
1.2
Scope
These operating instructions are valid for the Safe Stationary Machine example applica‐
tion.
These operating instructions are included with SICK part number 8020942 (all availa‐
ble language versions of the operating instructions).
NOTICE
These operating instructions do not describe:
•
•
•
•
The Flexi Soft safety controller
How to program the Flexi Soft safety controller
The necessary sensors and safety switches, and how to implement, mount, and
install them
The machine and its drive (which is protected by means of the
Flexi Soft safety controller)
Further information can also be found in the following documents:
Table 1: Available documents
1.3
Document
Title
Part number
Operating instructions
Flexi Soft modular safety con‐
troller hardware
8012999
Operating instructions
Flexi Soft in the
Flexi Soft Designer configura‐
tion software
8012998
i10 Lock
Operating instructions
i10 Lock safety locking device 8010025
Operating instructions
E100 enabling switch
8010034
Operating instructions
ES21 emergency stop push‐
button
8012498
Operating instructions
ER12 reset pushbutton
8016415
Operating instructions
DFS60S Pro safe encoder
8016866
Mounting instructions
DFS60 Core incremental
encoder
8018427
Mounting instructions
DBS60 incremental encoder
8017140
Competence brochure
Guide for Safe Machinery
8008007
Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
opers (planners, developers, designers).
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1 ABOUT THIS DOCUMENT
The structure of these operating instructions is based on the life cycle phases of the
Safe Stationary Machine example application: project planning, configuration, and com‐
missioning.
1.4
Further information
www.sick.com
The following information is available via the Internet:
■
■
■
1.5
This document in other languages
Operating instructions and mounting instructions of suitable SICK components for
the Safe Stationary Machine example application
Guide for Safe Machinery (“Six steps to a safe machine”)
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
6
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.
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SAFETY INFORMATION 2
2
Safety information
2.1
General safety notes
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
2.2
Please read this document carefully and make sure that you understand the con‐
tent fully before working with the device.
Follow all safety notes in this document.
Intended use
Safe Stationary Machine is an example application.
DANGER
Hazard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
If you do decide to use the Safe Stationary Machine example application, you must
observe the following points:
•
•
•
The example application is an incomplete solution.
The example application may only be used in an industrial environment where the
specified standards apply.
The example application will only satisfy the requirements of the Machinery Direc‐
tive if additional steps are completed successfully. These include having the entire
system verified by the qualified safety personnel (see "Requirements for the quali‐
fication of personnel", page 7) responsible for implementing the example appli‐
cation in a machine or plant.
The example application may only be used in accordance with the product descrip‐
tion (see "Product description", page 9).
Certain requirements must be met before you can use the Safe Stationary Machine
example application:
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
b
b
2.3
Carry out a risk assessment (see "Risk assessment", page 14).
Select suitable components (see "Requirements for components", page 19).
Verify and validate the safety functions (see "Commissioning", page 49).
Observe the product or C-type standards (as a basic principle, these take higher
priority than the content of these operating instructions).
Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and
serviced by qualified safety personnel only.
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2 SAFETY INFORMATION
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.
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.
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
Example application
Safe Stationary Machine is an example application. It illustrates how you can use the
Flexi Soft safety controller to implement a safe solution on stationary machines.
In addition to using the various Safe Stationary Machine components, you must also
adapt them as appropriate for the specific machine.
3.2
Components
The Safe Stationary Machine example application consists of the following compo‐
nents:
•
•
•
•
3.2.1
SISTEMA file for a safety encoder
Demo_FX3-MOC0_Stationary_Machine_3_DFS60Spro_E148770_V03.ssm
SISTEMA file for two non-safe encoders
Demo_FX3-MOC0_Stationary_Machine_3_E117073_V04.ssm
Project file for Flexi Soft Designer
Demo_FX3-MOC0_Stationary_Machine_CPU0_E117072_V07.fsp
A file that can be imported if a CPU other than the CPU0 is used
Demo_FX3-MOC0_Stationary_Machine_E117072_V07.fsi
Project file
The project file should be opened in Flexi Soft Designer. It contains the following com‐
ponents:
•
•
•
Hardware configuration
Logic programming for the CPU
Logic programming for the FX3-MOC0
Hardware configuration
The hardware configuration contains the structure of the Flexi Soft system plus hard‐
ware modules and the configuration for the inputs, outputs, and connected elements.
NOTICE
The Safe Stationary Machine example application will only work if the elements config‐
ured in the hardware configuration are connected accordingly.
Logic programming for the CPU and Drive Monitor FX3-MOC0
The logic programming for the CPU incorporates the programming for the following: two
operating modes, the safe stop signals, and communication with the FX3-MOC0 and
EDM.
Drive Monitor FX3-MOC0 features its own logic programming. This relies on the Station‐
ary Machine Easy Application.
Stationary Machine Easy Application
An Easy Application is a function block that has been specially prepared by SICK ready
for use. It has its own logic page and its own configuration dialog. In addition, it
includes automatic calculations for interdependent configuration parameters and addi‐
tional plausibility checks.
Easy Applications make it easier to configure standard applications.
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3 PRODUCT DESCRIPTION
3.2.2
SISTEMA files
The SISTEMA software assistant provides assistance when assessing controller safety
within the context of EN ISO 13849-1.
The two SISTEMA files for either one safety encoder or for two non-safe encoders allow
you to assess what performance level can be achieved.
3.3
Application description
The Safe Stationary Machine example application enables the closed-off hazardous
area of a machine to be accessed safely. It ensures that the machine is stationary
before access to the closed-off hazardous area becomes possible. Alternatively, access
to the hazardous area can also be enabled if the machine is put into a defined safe
state (e.g. maintenance mode with limited speed).
During a safety-related stop or after the machine is switched on, the machine is pre‐
vented from restarting unexpectedly. The machine can only be restarted once the
access point to the hazardous area has been closed and locked, and the machine has
been reset. An emergency stop function is also integrated.
3.4
Structure and function
NOTICE
The Safe Stationary Machine example application requires the protective devices to be
structured in a particular way and to perform specific functions.
The primary safety concept is that people and the machine must be physically sepa‐
rated. This means that people are not allowed to enter or reach into the hazardous area
while the machine is in a dangerous state.
The main safety elements consist of physical guards (perimeter safeguards, covers)
and movable guards (doors, flaps).
Figure 1: Example structure and function
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PRODUCT DESCRIPTION 3
ß
9
M
2
3
A
1
8
S
4
5
6
7
Figure 2: Structure required
3.4.1
1
Flexi Soft safety controller
2
Operating mode selector switch for Automatic and Service operating modes
3
Control switches for resetting the protective device and restarting the machine (reset and
restart)
4
Control switch for unlocking the safety door or machine cover
5
Enabling switch for Service operating mode
6
Emergency stop pushbutton
7
Safety locking device and safety switch for monitoring and interlocking the safety door or
machine cover
8
Two non-safe encoders or one safety encoder
9
Drive with Drive-Enable, Brake, and Safe Torque Off (STO) functions
ß
Physical guard
Interlocking
The Safe Stationary Machine example application features dual-channel protective
device interlocking:
1
2
Safety locking device: The monitored locking pin is only able to move if the safety
door or machine cover is closed (prevents pin from being moved into the locking
position unintentionally).
Safety switch: If the safety door or machine cover is opened, a safety switch
is actuated.
To open the safety door or machine cover, it is necessary to actuate the control switch
for unlocking the safety door or machine cover.
3.4.2
Drive monitoring and standstill control
Two non-safe encoders or one safety encoder are/is used to monitor the drive. The
speed is monitored by Drive Monitor FX3-MOC0.
Drive standstill is controlled by the Flexi Soft safety controller using the FX3-XTIO mod‐
ule. This involves using the Drive-Enable, Brake, and STO drive functions.
3.4.3
Operating modes
The Safe Stationary Machine example application features two operating modes. An
operating mode selector switch is used to switch between the operating modes. Switch‐
ing between the operating modes brings the machine to a controlled stop.
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3 PRODUCT DESCRIPTION
Automatic operating mode
In Automatic operating mode, the safety locking device prevents anyone from entering
the hazardous area while the machine is running. Once the machine has been stopped
and the standstill has been detected by the Flexi Soft safety controller, the safety lock‐
ing device can be unlocked and the safety door can be opened. The safety door is also
monitored by means of a safety switch.
The following sequence starts the machine in Automatic operating mode:
1.
2.
3.
Close the safety door.
Reset the protective device.
Restart the machine.
Service operating mode
Service operating mode allows the hazardous area to be accessed at any time. How‐
ever, in this mode, the machine is only allowed to run at reduced speed. The safety
functions have to be disabled manually for a limited time. The machine parameters are
monitored. When you switch to Service operating mode, it triggers a controlled machine
stop.
The following sequence starts the machine in Service operating mode:
1.
2.
3.
✓
Reset the protective device.
Press and hold the enabling switch.
Restart the machine.
The machine runs at reduced speed.
As soon as you release the enabling switch, the machine stops.
The following sequence starts the machine again:
1.
2.
Press and hold the enabling switch.
Restart the machine.
Switching to Automatic operating mode at the end of the service work
Switching between the operating modes brings the machine to a controlled stop.
The following sequence starts the machine in Automatic operating mode:
1.
2.
3.
3.4.4
Close the safety door.
Reset the protective device.
Restart the machine.
Emergency stop
The emergency stop function puts a stop to the dangerous state of the machine. Differ‐
ent sequences must be followed to restart the machine depending on which operating
mode is selected.
In Automatic operating mode:
1.
2.
3.
Unlock the emergency stop pushbutton.
Reset the protective device.
Restart the machine.
In Service operating mode:
1.
2.
3.
4.
12
Unlock the emergency stop pushbutton.
Reset the protective device.
Press and hold the enabling switch.
Restart the machine.
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PRODUCT DESCRIPTION 3
3.4.5
Safe state of the machine
When the machine is in the safe state, the safety outputs are switched off. The machine
is and remains switched off. The machine switches to the safe state in the following cir‐
cumstances:
•
•
•
•
•
•
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A connection between an encoder and the safety controller has been interrupted.
The voltage supply to an encoder or to the safety controller has been interrupted.
A fault (discrepancy, short-circuit, etc.) has been detected on the connected safety
switches or on the operating mode selector switch.
The external device monitoring has detected a fault.
The two connected encoders are unable to provide plausible output signals within
the configured discrepancy time.
The safety program of the safety controller requires a safety function to be per‐
formed, e.g.:
° When the emergency stop pushbutton is pressed
° When the enabling switch is released in Service operating mode
° If the speed in Service operating mode is too high
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4 PROJECT PLANNING
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
4.1.1
Before the Safe Stationary Machine example application can be used, a risk
assessment must be carried out. Check that the machine meets the requirements
for the Safe Stationary Machine example application.
Comply with the applicable national regulations derived from the application (e.g.,
work safety regulations, safety rules, or other relevant safety guidelines).
Risk assessment
The manufacturer must check whether the Safe Stationary Machine example is suitable
for its specific application case (risk assessment).
In any event, additional work is always necessary before the Safe Stationary Machine
example application can be used, e.g. final configuration of the safety controller.
The manufacturer has the following duties:
•
•
•
Carrying out a risk assessment
Verifying and validating the safety functions
Integrating the individual components in accordance with the appropriate stand‐
ards
NOTICE
In addition to the identified risks, please note that machine-specific C-type standards
may contain special requirements. These must be observed.
NOTICE
For the purpose of the Safe Stationary Machine example application and the descrip‐
tion below, it has been assumed that a performance level of PL d is required in accord‐
ance with EN ISO 13849-1.
4.1.2
Safety functions
Identification of hazards
It is essential to take account of all potential hazards that might be posed by a rotating
drive or by movement.
•
•
•
•
•
•
•
•
•
14
Cutting
Crushing
Shearing
Stabbing
Drawing-in or trapping
Entanglement
Impact
Impact from broken parts
Impact from ejected chips
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PROJECT PLANNING 4
Definition of safety functions
This section describes how technical measures can be implemented to minimize the
risks associated with the relevant machine.
1
M
7
6
2
3
A
5
S
4
8
Figure 3: Safety functions
1
00 – Permanently preventing access
2
01 – Preventing unexpected start-up
3
03 – Disabling safety functions manually and for limited time
4
04 – Temporarily preventing access
5
05 – Monitoring machine parameters
6
06 – Combining or switching safety functions
7
10 – Initiating a stop
8
99 – Emergency stop
Table 2: Definition of safety functions
Safety function
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Code
Description
Permanently preventing 00
access
Access to a hazardous point is prevented by means of
mechanical covers, barriers, or obstacles (referred to as phys‐
ical guards).
Preventing unexpected
start-up
01
After the “Initiating a stop” function is triggered or the
machine is switched on, deliberate actions are required to put
the machine into operation. These actions include manually
resetting a protective device to prepare for restarting the
machine.
Disabling safety func‐
tions manually and for
a limited time
03
Protective devices sometimes have to be disabled to enable
setup work or process monitoring in Service operating mode.
However, in order for the machine to be operated with the
protection disabled, the enabling switch has to be actuated.
Further risk minimization measures should be implemented.
Temporarily preventing
access
04
Access to a hazardous point is prevented until the machine is
in a safe state.
Monitoring machine
parameters
05
In some applications, it is necessary to monitor various
machine parameters for safety-related limits. If a limit is
exceeded, suitable measures are initiated (e.g., stop, warning
signal).
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4 PROJECT PLANNING
4.1.3
Combining or switching 06
safety functions
A machine can adopt various states or work in various operat‐
ing modes. Within this context, different safety measures may
be effective or different safety functions may be coupled
together. Measures must be implemented to ensure that the
required level of safety is always achieved. The process of
switching between operating modes, or the selection and
adjustment of different safety measures, is not allowed to
lead to a dangerous state.
Initiating a stop
10
A safety-related stop function places the machine in a safe
state on demand (e.g., if a person approaches). To reduce the
required stopping time, it may be advisable to implement a
stop function which complies with stop category 1 (IEC
60204-1-2-9). Additional safety functions may be necessary
to prevent an unexpected restart.
Emergency stop
99
Emergency stop is a supplementary protective measure; it is
not a primary means of reducing risk.
The safety level of this function must be defined
based on the risk assessment for the machine. In particular,
influencing environmental factors (e.g., vibrations, method of
actuation, etc.) must be considered.
Implementation of the safety functions
If the Safe Stationary Machine example application is used, the safety functions descri‐
bed below must be implemented:
Access protection with standstill monitoring
It is only possible to enter the hazardous area if the Flexi Soft safety controller has
detected that the machine is at a standstill. The safety locking device keeps the safety
door locked while the machine remains in motion.
Safety functions that must be implemented:
•
•
SF04: Temporarily preventing access
SF99 Emergency stop
Setup mode at limited speed
In certain situations (setup, maintenance), the presence of people in the machine's
hazardous area cannot be avoided. In such situations the risk must be reduced by low‐
ering the speed of the machine and making sure that the machine can only move when
an enabling switch is actuated. The actual command that starts the machine must
come from an additional control switch.
The enabling switch must take the form of a three-position switch. Enabling is only
active in position 2. In positions 1 and 3, the drive receives a stop command from the
safety controller and stops the movement.
Following a valid start sequence, the machine speed is monitored by Drive Monitor FX3MOC0. If the monitor detects a speed that is higher than the permissible speed, the
safety controller switches off the drive.
Safety functions that must be implemented:
•
•
•
SF03: Disabling safety functions manually and for a limited time
SF05: Monitoring machine parameters
SF99 Emergency stop
Safe stop
A safe stop is used to shut down a drive in a controlled manner while monitoring the
stop.
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PROJECT PLANNING 4
This may be triggered by an emergency stop pushbutton, for example, or may occur if
the safety controller detects that the speed is too high.
The stop ramp of a drive system is not usually safe. For this reason, the FX3-MOC0
“Safe stop” function block monitors the actual reduction in speed until the drive comes
to a standstill.
The FX3-MOC0 “Safe stop” function block supports two stop states as defined in
IEC 61800-5-2 and IEC 60204-1. The difference between the two relates to the end of
the stop ramp. In the case of the safe stop 1 (SS1) function, the drive system torque is
switched off once the drive has come to a standstill.
NOTE
The safe stop 1 function corresponds to a controlled stop in accordance with
IEC 60204-1, stop category 1.
By contrast, the torque remains enabled in the case of the safe stop 2 (SS2) function,
but the standstill condition is nevertheless monitored. This enables the drive to act as a
stop control.
NOTE
The safe stop 2 function corresponds to a controlled stop in accordance with
IEC 60204-1, stop category 2.
The stop responses that have to be achieved are:
•
•
•
•
•
Safe stop 1 (stop category 1), after the emergency stop pushbutton is pressed
Safe stop 2 (stop category 2), if a speed is detected that is higher than the maxi‐
mum speed
Safe stop 2 (stop category 2), after the enabling switch is released
Safe stop 2 (stop category 2), after switching to a different operating mode
Safe stop 2 (stop category 2), if the safety door is opened in Automatic operating
mode but no machine standstill has been detected (e.g., if the locking device is
broken)
Safety functions that must be implemented:
•
•
SF10: Initiating a stop
SF01: Preventing unexpected start-up
Calculation of stopping times
The stopping times of the various safety functions depend on the response times of the
sensors, the actuators, and the communication path between the Flexi Soft safety con‐
troller, the actuator, and – where applicable – the process control. For details of how to
calculate stopping times, see the “Calculation of response times” section of the
“Flexi Soft modular safety controller hardware” operating instructions (part no.
8012999).
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4 PROJECT PLANNING
4.2
Integrating the equipment into the electrical control
4.2.1
Block diagram and circuit diagram
K4 Brake
2
M
K4.1 Readback Brake
ENC1 ENC2
K2 Drive-Enable
K2.1 Readback Drive-Enable
K3 STO
1
3
K3.1 Readback STO
4
S4-1/2
S
A
S6
S5
S8
K1 Locking on safety door
5
S3 Locking monitoring
S2
S7 Safety switch
S1
Figure 4: Block diagram
1
Safety controller
2
Drive
3
Drive control
4
Operating elements
5
Locking device and interlocking
+24 V DC
S1
A1
A1
Flexi Soft
CPU0
FE
Flexi Soft
MOC0
I1
S3
S2
I2
I3
I4
I5
S5
I6
X1
FE
Flexi Soft XTIO
FE
A2
A2
I7
I8
Q1
I1
Q2
Q3
Q4
X2
S6
I2
S7
I3
I4
X1
X2
X3 X4
FE
Flexi Soft XTDI
I5
I6
I7
I8
X5
X6
X7
X8
S8
S4
-1
S4
-2
K2.1 K3.1 K4.1
Connection cable
(Part no. 2067798)
K1
K2
K3
Connection cable
(Part no. 2067800)
C3
C4
C3
Splitter Box
Encoder Box
NC2
NC2
NC1
VS
Uout
GND
0V
C-
ENC1
C+
K4
NC1
VS
Uout
GND
0V
FE
C1
ENC2
C-
FE
C1
C+
B-
B-
Sin-
B-
B+
B+
Sin+
B+
A-
A-
Cos-
A-
A+
A+
Cos+
A+
0 V DC
FE
E180120/01/2017-05-12
Figure 5: Example circuit diagram
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PROJECT PLANNING 4
Table 3: Switching elements
4.2.2
Element
Function
Tag name in
Flexi Soft Designer
S1
Emergency stop pushbut‐ S1 E-Stop
ton
Dual-channel
S2
Enabling switch
S2 Enabling switch
Dual-channel
S3
Locking device monitor‐
ing
S3 Locking monitoring
Dual-channel
S4-1/2
Operating mode selector
switch
S4-1 Automatic mode
S4-2 Service mode
e.g., in the form of a keyoperated (break-beforemake) switch
S5
Reset pushbutton
S5 Reset
Single-channel
S6
Restart button
S6 Start
Single-channel
S7
Safety switch
S7 Safety switch
S8
Control switch for unlock‐ S8 Open door
ing the door
Single-channel
K1
Unlocking solenoid of
safety locking device
K1 Locking on safety
door
Single-channel
K2
Drive contactor
K2 Drive-Enable
Single-channel
K3
STO contactor
K3 STO
Single-channel
K4
Brake contactor
K4 Brake
Single-channel
K2.1
Drive EDM
K2.1 Readback DriveEnable
Single-channel
K3.1
STO EDM
K3.1 Readback STO
Single-channel
K4.1
Brake EDM
K4.1 Readback Brake
Single-channel
ENC1
Encoder 1
A/B incremental, HTL
24 V, 2 pairs of outputs
A/B incremental encoder
ENC2
Encoder 2
Sine-cosine, 1 Vss
Sine-cosine encoder
Comments
Dual-channel
Requirements for components
NOTICE
The manufacturer that integrates the Safe Stationary Machine example application into
its machine is responsible for the selection and use of the components.
All devices must be operated as per their technical specifications.
The operating instructions for the components must be observed.
Any application that relies on the Safe Stationary Machine Easy example application
can only meet the requirements for category 3, performance level d under
EN ISO 13849-1 if the selected components are sufficient to achieve this category and
PL.
Safety locking device and interlocking
Various types of switch can be selected to serve as a safety locking device and inter‐
lock. They must conform to EN ISO 14119 and EN 60204-1.
Emergency stop pushbutton
Various types of switch can be selected to serve as an emergency stop pushbutton.
They must conform to EN ISO 13850 and EN 60204-1.
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4 PROJECT PLANNING
Enabling switch
Various types of switch can be selected to serve as an enabling switch. These must con‐
form to EN 60947-5-8 and EN 60204-1.
Reset
The reset function and the reset pushbutton must be designed to meet the require‐
ments of IEC 60204-1.
Start
The start function and the restart button must be designed to meet the requirements of
IEC 60204-1.
Operating mode selector switch
The operating mode selector switch must conform to ISO 12100:2010 and
IEC 60204-1.
Control switch for unlocking the door
The control switch for unlocking the door must conform to IEC 60204-1.
Encoders
Various types of encoder or motor feedback system can be selected to serve as encod‐
ers.
Non-safe encoders are not designed and manufactured in accordance with safety
standards. If non-safe encoders are used, they must be implemented in a structure that
meets the requirements for category 3.
The structural design must ensure that an individual mechanical fault is not capable of
impairing the detection capabilities of both encoders.
If category 3 safety encoders are used, category 3 can still be achieved with only one
category 3 safety encoder.
The following requirements apply to encoders in general:
•
Encoders must feature a suitable measurement principle.
Safety encoders are subject to the following additional requirements:
•
•
•
The safety encoder must be mounted and implemented in accordance with the
safety encoder instructions.
The safety encoder must be operated as per its technical specifications.
The use of a safety encoder calls for overdimensioning of the mechanical coupling
and mounting to eliminate the risk of mechanical faults.
Additional requirements for non-safe encoders
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.
The fact that standard encoders are being used outside of their defined scope of appli‐
cation means that the machine manufacturer has particular responsibilities.
b
20
Heed and follow the notes/instructions below.
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PROJECT PLANNING 4
The operating condition requirements are application-specific and must be defined by
the machine manufacturer. The machine manufacturer must assess how well the Safe
Stationary Machine example application functions under these operating conditions
(EMC, vibration, etc.). The technical specifications in the user manual for the relevant
components can be used for reference. These values are typical or limit values.
If the operating limits of the Safe Stationary Machine example application are outside
the component operating limits, if values are missing, or if you are unable to assess the
performance/capabilities of the components, you must not implement the Safe Station‐
ary Machine example application. In this case, please contact your local SICK sales
office or service partner. They will be able to help clarify the situation by offering con‐
sulting and engineering services.
If the components do meet the operating condition requirements, you must also assess
whether the selected combination of components plus the Flexi Soft safety controller
are capable of detecting, handling, and overcoming systematic faults and faults with a
common cause. The measures used to address the systematic faults and faults with a
common cause must be incorporated into the software assistant for evaluating safetyrelated machine controllers (e.g., SISTEMA).
In addition, the machine manufacturer must assess whether the claims about the
safety features of the Safe Stationary Machine example application actually meet the
requirements of EN ISO 13849 and the other applicable standards within the context of
the application.
The machine manufacturer that implements the encoders must put measures in place
to counter systematic faults and faults with a common cause.
•
•
•
•
•
•
The structural design must ensure that an individual mechanical fault is not capa‐
ble of impairing the capabilities of both encoders.
The encoders must be mounted so that if a mechanical breakage occurs on one of
the components it does not break the mechanical connection of both encoders.
Use suitable wiring to ensure that an individual fault does not result in the loss of
both encoder signals.
Different types of encoder must be used as non-safe encoders:
° Different measuring techniques
° Different interface technologies
° Different resolutions
Put measures in place to detect loss of voltage, overvoltage, and undervoltage.
Put measures in place to avoid the effects of ambient conditions (e.g., tempera‐
ture, moisture, vibration, electromagnetic interference).
Additional requirements
Any faults on encoders and switches, terminals, or the safety controller must be
detected. The following types of fault have to be detected:
•
•
•
Short-circuits
Wire breaks
Mechanical breakages
The safety functions are performed by the Flexi Soft safety controller. To ensure that
they are performed properly, the selected actuators and drives must meet the require‐
ments of the example application described in these operating instructions.
For instance, the STO input of a drive must be sufficient to achieve PL d within the con‐
text of the example application described. The cabling must also be appropriate.
The STO input or other signals (for example) may have to be wired in different ways
depending on the encoders, switches, and drive. In this case, the instructions of the
drive or encoder manufacturer must be observed.
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4 PROJECT PLANNING
4.3
Calculation of the performance level
The performance level can be calculated with the SISTEMA files that form part of the
Safe Stationary Machine example application.
File “Demo_FX3-MOC0_Stationary_Machine_3_E117073_V04.ssm” is based on an
application with two non-safe encoders.
File “Demo_FX3- MOC0_Stationary_Machine_3_DFS60Spro_E148770_V03.ssm” is
based on an application with one safety encoder.
The machine manufacturer that implements the Safe Stationary Machine example
application must decide which measures must be taken to counter faults with a com‐
mon cause. These measures must be selected in the SIMSTEMA project file for each
user-defined sub-system.
Figure 6: Example screenshot from the SISTEMA software assistant
In addition, the correct values must be entered for the components used. For the pur‐
pose of the product suggestions presented in these operating instructions, you can
select the following values:
•
•
•
Non-safe encoder DBS60E-S4EA05000: MTTFD = 300 years
Non-safe encoder DFS60B-S4NA01024: MTTFD = 300 years
Reset pushbutton ER12-SB3C4S01: B10d = 1 × 106
The servomotor used in the examples must be adapted for the actual application.
4.4
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
22
If changes are made to the configuration of the Safe Stationary Machine example
application, the protective function may be impaired. Therefore, the effectiveness
of the protective devices must be checked after any change to the configuration.
The person carrying out the change is also responsible for maintaining the protec‐
tive function.
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CONFIGURATION 5
5
Configuration
5.1
Overview
DANGER
Hazard due to lack of effectiveness of the protective device
Hazard due to unexpected starting of the machine
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.
Do not use the Safe Stationary Machine example application unless the following
requirements have been met:
•
•
•
The risk assessment has revealed that the example is suitable for the application
concerned.
The performance level is sufficient.
The hardware components have been selected and used in accordance with the
project planning chapter.
NOTE
This chapter describes the project file for the Flexi Soft safety controller that has been
supplied together with the example application.
It does not describe the processes of creating and modifying a project.
For information about how to open a project in Flexi Soft Designer or how to transfer a
system configuration, please refer to the operating instructions titled “Flexi Soft in the
Flexi Soft Designer Configuration Software” (part number 8012998).
The project file for the example application consists of the hardware configuration, the
logic programming for the MOC, and the logic programming for the CPU.
Hardware configuration
The hardware configuration comprises the following modules:
•
•
The modules of the Flexi Soft safety controller (FX3-CPU0, FX3-MOC0, FX3-XTIO,
and FX3-XTDI)
The elements wired to the module connections (locking device, encoder(s), emer‐
gency stop pushbutton, etc.)
Logic programming for the MOC
The logic programming for the MOC comprises the following pages:
•
•
•
I/O matrix and I/O summary, which contain various items of information
Page 1, which contains the Stationary Machine Easy Application and an additional
Speed comparison function block
Stationary Machine, which contains the function blocks and connections that make
up the Stationary Machine Easy Application
Logic programming for the CPU
The logic programming for the CPU comprises the following pages:
•
•
•
•
•
•
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I/O matrix, I/O summary, and Info, which contain various items of information
Service mode for the Service operating mode
Automatic mode for the Automatic operating mode
Stop signals for generating safe stop signals
From/to FX3-MOC0 to enable data exchange between the CPU and MOC
Drive control for EDM
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5 CONFIGURATION
5.2
Hardware configuration of the Flexi Soft safety controller
Hardware configuration with two encoders
Figure 7: Hardware configuration with two encoders
On delivery, there are two non-safe encoders connected to the input of the FX3-MOC0.
Hardware configuration with one encoder
Alternatively, you can use a single safety encoder.
Figure 8: Hardware configuration with one encoder
To enable this, you must change the hardware configuration in Flexi Soft Designer by
connecting one safety encoder to the input of the FX3-MOC0.
NOTE
For information about how to change the hardware configuration in
Flexi Soft Designer, please refer to the operating instructions titled “Flexi Soft in the
Flexi Soft Designer Configuration Software” (part number 8012998).
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CONFIGURATION 5
5.3
Logic programming for the MOC
5.3.1
Logic programming page 1
Page 1 of the logic programming contains the Stationary Machine Easy Application. The
logic programming varies according to what type of hardware is used and what hard‐
ware settings have been configured in the Flexi Soft hardware configuration (see "Hard‐
ware configuration of the Flexi Soft safety controller", page 24).
Stationary Machine Easy Application with two encoders
Figure 9: Logic programming with two encoders
The example application already contains the logic programming for two encoders.
Stationary Machine Easy Application with one encoder
Figure 10: Logic programming with one encoder
If you wish to use one safety encoder, you must adapt the logic programming accord‐
ingly.
The safety encoder should only be connected to one FX3-MOC0 connection. In the logic
programming, the encoder signal must be connected to the Motion 1 and Motion 2
inputs of the Easy Application.
NOTE
For information about how to change the logic programming in
Flexi Soft Designer, please refer to the operating instructions titled “Flexi Soft in the
Flexi Soft Designer Configuration Software” (part number 8012998).
Additional speed comparison function block
On Page 1 of the drive logic there is an additional Speed comparison function block under‐
neath the Stationary Machine Easy Application.
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5 CONFIGURATION
The parameters of this function block must be configured in accordance with the set‐
tings for the Speed comparison function block within the Stationary Machine Easy Applica‐
tion.
If the following parameters have been config‐
ured in the speed comparison function block
within the Stationary Machine Easy Applica‐
tion:
•
•
•
•
•
•
•
•
•
•
•
•
5.3.2
Absolute tolerance threshold for speed
difference
Limit 1, relative speed difference
Absolute tolerance threshold for speed
difference
Limit 1, relative speed difference
Limit 2, relative speed difference
Max. time limit 2
Absolute tolerance threshold for speed
difference
Limit 1, relative speed difference
Limit 2, relative speed difference
Max. time limit 2
Limit 3, relative speed difference
Max. time limit 3
Copy the values of the following parameters
across to the additional speed comparison
function block:
–
•
•
•
•
•
•
Absolute tolerance threshold for speed
difference
Limit 1, relative speed difference
Absolute tolerance threshold for speed
difference
Limit 1, relative speed difference
Limit 2, relative speed difference
Max. time limit 2
Stationary Machine page of the logic programming
The Stationary Machine page contains the function blocks that make up the Easy Applica‐
tion. It contains the connections between the function blocks, and the connections to
the inputs and outputs.
Figure 11: Function blocks of the Stationary Machine Easy Application
The function block inputs and outputs that are shown in gray are deactivated. They
have not been configured in the respective function block.
The input and output addresses that are shown in white have not been connected to
the CPU logic programming.
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CONFIGURATION 5
NOTE
If SSI encoders are used, the two inputs called Enable limit 2 and Enable limit 3 will be
available. These inputs can be used to allow higher discrepancies between the two
encoder signals. The inputs must be connected to a CPU output or to Logic 1.
5.4
Easy Application configuration assistant
The Stationary Machine Easy Application makes it easier to configure the
Flexi Soft safety controller with Drive Monitor FX3-MOC0. This is because it reduces the
number of parameters that need to be configured. The internal parameters are calcu‐
lated automatically on the basis of the configured application parameters. If necessary,
the parameters can also be adjusted manually in Expert mode.
NOTICE
To enable subsequent verification of the application, the parameters must always be
checked in Expert mode.
Figure 12: Configuration assistant – Overview
The first page provides an overview of the parameters for the Stationary Machine Easy
Application.
The configuration assistant makes a distinction between machine parameters and
application parameters.
5.4.1
Machine parameters
The images in the center show typical mechanical couplings. The diagrams to the right
of the coupling illustrations show the respective motion behavior.
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5 CONFIGURATION
Figure 13: Machine parameters
1.
2.
3.
4.
28
For the type of motion, choose between Linear and Rotary.
Select the unit for the speeds.
Select the Type of mechanical coupling.
Where applicable, enter a delay/damping time.
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CONFIGURATION 5
5.4.2
Application parameters
Encoders
Figure 14: Encoders in the configuration assistant
The Encoders page of the configuration assistant shows the following:
•
•
How to connect the encoders to the Drive Monitor in the Flexi Soft Designer hard‐
ware configuration
How to connect the encoders to the Easy Application in the Drive Monitor logic edi‐
tor
NOTE
The encoder parameters can be configured in the hardware configuration. As well as
selecting the encoder resolution, you can (for example) also configure the gear factor or
the machine factor.
1.
✓
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Double-click the encoder symbol at the Drive Monitor FX3-MOC connection.
A configuration assistant appears on the Measurement system scaling tab of the Ele‐
ment settings window.
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5 CONFIGURATION
Automatic error reset
Figure 15: Automatic error reset in the configuration assistant
The following options must be configured for the Automatic error reset function:
•
•
Other primary protective devices are present to prevent access to the hazardous area.
No suppression of error response and self-repair of errors
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
30
Do not configure any other options.
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CONFIGURATION 5
Speed monitoring
Figure 16: Speed monitoring in the configuration assistant
Use the Speed monitoring page of the configuration assistant to configure the following
parameters:
•
•
•
•
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The Standstill speed that is to be accepted as a standstill
The Standstill monitoring position window within which positional changes are to be
accepted as a standstill
The Setup and maintenance speed limit for the Service operating mode (Speed ena‐
bled 2 active)
The Maximum speed limit for the Automatic operating mode (Speed enabled 3
active)
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5 CONFIGURATION
Response time for stop request
Figure 17: Response time for stop request in the configuration assistant
Use the Response time for stop request page of the configuration assistant to configure
how long the machine should take to respond to a stop request from the
Flexi Soft safety controller.
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CONFIGURATION 5
Ramp speed transitions
Figure 18: Ramp speed transitions in the configuration assistant
Use the Ramp speed transitions page of the configuration assistant to configure a ramp for
the transition from a monitored speed to a lower speed.
The following parameters are required:
•
•
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Change in speed
Duration of change in speed
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5 CONFIGURATION
Stop ramps
Figure 19: Stop ramps in the configuration assistant
Use the Stop ramps page of the configuration assistant to configure a safe stop for a
drive system. This means that the drive has to be shut down in a controlled manner.
The stop ramp of a drive system is not usually safe. For this reason, the FX3-MOC0 Safe
stop function block monitors the actual reduction in speed until the drive comes to a
standstill.
The following parameters are required:
•
•
34
Change in speed
Duration of change in speed
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CONFIGURATION 5
EDM (external device monitoring)
Figure 20: EDM (external device monitoring) in the configuration assistant
The EDM (external device monitoring) page of the configuration assistant shows an example
of how to create EDM function blocks in the CPU logic editor.
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5 CONFIGURATION
5.4.3
Summary
Figure 21: Summary in the configuration assistant
The Summary page provides a summary of the relevant parameters.
Check these parameters for plausibility.
5.5
Further configuration options in Expert mode
Further configuration options are displayed in Expert mode.
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CONFIGURATION 5
The three configurable function blocks of the Easy Application are described below (the
two function blocks called BoolToUI8 and UI8ToBool are not configurable).
The function block parameters are calculated by the Easy Application.
As part of the verification process, the function blocks are shown in the report together
with their parameters. Consequently, these must be checked during verification.
5.5.1
Speed comparison
Figure 22: Speed comparison function block (CrossCheck_StMa)
The Speed comparison function block compares the signals of both connected encoders.
This function is one of the requirements that must be met in order to achieve a per‐
formance level of PL d with non-safe encoders or to achieve a level of PL e with safety
encoders.
The following parameters are configured for the Speed comparison function block:
•
•
•
•
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Units
Inputs
° Manual reset activated
° Automatic reset not activated
Speed comparison mode = speed comparison with sign activated
Speed comparison limits: The settings are dependent on the encoders used.
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5 CONFIGURATION
Speed comparison limits with incremental encoders
Figure 23: Speed comparison limits with incremental encoders
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CONFIGURATION 5
Speed comparison limits with SSI encoders
Figure 24: Speed comparison limits with SSI encoders
In the SSI master hardware configuration, you can set a data reception interval of
between 4 and 100 ms. The configured data reception interval must be greater than or
equal to the encoder transmission interval.
NOTE
Particularly if SSI encoders are used, further limits may have to be configured (this may
be necessary due to possible differences between the encoders, for example).
DANGER
If SSI encoders are used, the following parameters must be configured for Enable limit
3:
•
•
Limit 3, relative speed difference 100%
Max. time limit 3 = 8 ms
Errors are detected with a delay time of 8 ms.
Result
The Motion result of the Speed comparison function block directly affects the Motion inputs
of the Speed monitoring and Safe stop function blocks.
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5 CONFIGURATION
Additional parameters
•
•
5.5.2
Propagation delay compensation
The propagation delay compensation setting is dependent on the application. It is
not normally activated.
Speed output mode
Configured as the greater of the two speeds from Motion 1 or Motion 2
Speed monitoring
Figure 25: Speed monitoring function block (SpeedMonitor_StMa_1)
The Speed monitoring function block monitors the speed of the drive. Details of the speed
to be monitored are transferred by the CPU using Speed enable ID Bit 0 to 2 (by default, Bit
3 is not used).
As the CPU supplies binary data, these bits have to be converted into UINT8 format via
the upstream BoolToUI8 function block.
Reduced speeds
The following speeds are configured by default:
•
•
•
Standstill speed = 1 mm/s corresponds to speed ID 1
Reduced speed = 10 mm/s corresponds to speed ID 2
Max. speed = 6,000 mm/s corresponds to speed ID 3
These values may vary depending on the configuration set in the Easy Application con‐
figuration assistant.
Ramps
A speed transition is also configured for ramps. This is necessary to prevent the func‐
tion block status from switching directly to LOW when the enabling switch is actuated in
Service operating mode.
Up to three further ramps can be configured. For details, see the operating instructions
titled “Flexi Soft in the Flexi Soft Designer Configuration Software” (part number
8012998).
Result
The Monitoring status, Direction status, and Speed status ID output signals are forwarded to
the CPU.
As the CPU requires binary data, the speed status ID must be converted into the follow‐
ing binary data items via the downstream UI8ToBool function block: Speed status ID Bit 0
to 2 (by default, Bit 3 is not used).
If an error is detected (encoder error, excessively high speed, etc.), the Monitoring status
output switches to LOW.
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CONFIGURATION 5
5.5.3
Safe stop
Figure 26: Safe stop function block (SafeStop_StMa)
A LOW signal at the Safe stop 2a input triggers the SS2 function.
The SS2 function can also be triggered via the CPU (Safe stop 2 signal) with the Safe stop
2b input if, for example, the safety door is opened.
If the Safe stop 1a input switches to LOW (e.g., because of an emergency stop), the SS1
function is triggered. This signal comes from the CPU (Safe stop 1).
The Enable torque, Enable brake, and Request stop output signals of the Safe stop function
block are forwarded to the CPU.
In the event of a malfunction or a stop request, these outputs control the safe stop
sequence for the drive.
The following parameters are configured by default:
•
•
Delay time until start of ramp: 32 ms
Speed offset for stop ramps: 5 mm/s
These values may vary depending on the configuration set in the Easy Application con‐
figuration assistant.
5.6
Logic programming for the CPU
5.6.1
Service mode page
The Service mode page is used to implement the Service operating mode.
Operating mode selector switch
Figure 27: Logic for the operating mode selector switch
This program section contains the Operating mode selector switch function block. Depend‐
ing on the status of the inputs, this switches either the Auto_switch or the Service_switch
jump address to HIGH.
In addition, the function block monitors the physical operating mode selector switch for
short-circuits, cable breaks, etc.
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41
5 CONFIGURATION
Reset and restart sequence for Service mode
Figure 28: Reset and restart sequence for Service mode
This program section implements the processes for resetting the protective device and
starting/restarting the machine. The output of the Reset function block switches to HIGH
if the following criteria are met:
•
•
•
•
The EDM_Error jump address is set to HIGH (no EDM error).
The Service_switch jump address is set to HIGH (operating mode selector switch set
to Service mode).
The S1 E-Stop input is set to HIGH (no emergency stop has been pressed).
The S5 Reset input is briefly set to HIGH (after reset button is pressed).
Following the reset, the machine can be started if the following criteria are met:
•
•
The Enabling switch input is set to HIGH (after enabling switch is actuated).
The S6 Start input is briefly set to HIGH (after restart button is pressed).
The process of starting the machine also triggers the Service_SS2_reset jump address.
5.6.2
Automatic mode page
The Automatic mode page is used to implement the Automatic operating mode.
Reset and restart sequence for Automatic mode
Figure 29: Reset and restart sequence for Automatic mode
The output of the Reset function block switches to HIGH if the following criteria are met:
•
•
•
•
42
The EDM_Error jump address is set to HIGH (no EDM error).
The Auto_switch jump address is set to HIGH (operating mode selector switch set to
Automatic mode).
The S1 E-Stop input is set to HIGH (no emergency stop has been pressed).
The S7 Safety switch input is set to HIGH (safety door closed).
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CONFIGURATION 5
•
•
The S5 Reset input is briefly set to HIGH (after reset button is pressed).
The output of the OR function block is set to HIGH.
If jump address Speed 1 = Standstill (machine stationary) and input S8 Open door are
both set to HIGH (button for opening door has been pressed), the output of the OR
function block is set to LOW.
Following the reset, the machine can be started if the following criteria are met:
•
•
The S3 Locking monitoring input is set to HIGH (the safety door is closed and the
locking device is locked).
The S6 Start input is briefly set to HIGH (after restart button is pressed).
If the Automatic OK signal switches to HIGH, it triggers the Automatic_SS2_reset jump
address.
Locking device opening or closing
Figure 30: Locking device opening or closing
This program section ensures that the safety door can only be opened (Locking jump
address set to HIGH) if the following criteria are met:
•
•
The controller has detected that the machine is at a standstill (jump address
Speed 1 = Standstill is set to HIGH).
The switch for opening the door has been actuated (the S8 Open door input is set to
HIGH).
The Edge detection function block is used to prevent the door from being opened unin‐
tentionally.
The Automatic ready signal of the program section called Reset/Restart sequence for auto‐
matic mode is used to perform the reset. The signal is set to HIGH if the following criteria
are met:
•
•
5.6.3
All the criteria are met for the enable inputs of the Reset function block.
The S5 Reset input is briefly set to HIGH (after reset button is pressed).
Stop signals page
The Stop signals page is used to implement safe stop signals SS1 and SS2. These are
routed to the drive logic on the From/to FX3-MOC0 program page (see "From/to FX3MOC0 page", page 46).
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5 CONFIGURATION
Safe stop signal SS1
Figure 31: Safe stop signal SS1
Safe stop signal SS1 is triggered when an S1 E-Stop signal is generated by a connected
emergency stop pushbutton. This means that SS1 switches to LOW when the emergency
stop pushbutton is pressed (normally closed). The following conditions have to be met
before jump address SS1 can switch to HIGH and the machine can start up:
•
•
No emergency stop has been triggered at S1 E-Stop by the emergency stop push‐
button.
The enable output of the Restart function block is set to HIGH.
The second input of the AND function block is used to monitor a reset/restart sequence.
This prevents unexpected start-up following an emergency stop. If the following enable
conditions are met, a restart is performed:
•
•
The output of the Reset function block is set to HIGH (reset conditions met).
The S6 Start input is briefly set to HIGH (after restart button is pressed).
If the following enable conditions are met, the output of the Reset function block
switches to HIGH:
•
•
•
The S1 E-Stop input is set to HIGH (no emergency stop has been triggered).
The No_movement_24h jump address is set to HIGH.
The S5 Reset input is briefly set to HIGH (after reset button is pressed).
Safe stop signal SS2
Figure 32: Safe stop signal SS2
Safe stop signal SS2 is triggered if the conditions are not met for either Automatic
mode or Service mode.
If one of the following conditions is met, the SS2 jump address switches to HIGH:
•
•
44
The conditions for either Automatic mode or Service mode are met.
The SS1 jump address is set to LOW.
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CONFIGURATION 5
Resetting of safe stop signal SS2
Figure 33: Resetting of safe stop signal SS2
If either of the function blocks AND 1 or AND 3 provides a HIGH signal, the SS2_reset
jump address switches to HIGH.
If each of the following conditions is met, the output of the AND 1 function block
switches to HIGH:
•
•
If all the conditions are met for the restart sequence in Automatic operating mode
(see "Automatic mode page", page 42), jump address Automatic_SS2_reset switches
to HIGH.
If the operating mode selector switch is set to Automatic, jump address Auto_Switch
changes to HIGH.
If each of the following conditions is met, the output of the AND 3 function block
switches to HIGH:
•
•
If all the conditions are met for the restart sequence in Service operating mode
(see "Service mode page", page 41), jump address Service_SS2_reset switches to
HIGH.
If the operating mode selector switch is set to Service, jump address Service_Switch
changes to HIGH.
Standstill time monitoring
Figure 34: Standstill time monitoring
As soon as the drive logic detects a standstill, a Clock generator function block starts run‐
ning with a clock of 2 s. These clock pulses are counted by the Counter function block
until the configured value of 43,201 is reached.
A value of 43,200°×°2 s = 86,400 s corresponds to 24 h.
Once the value of 43,201 has been reached, the No_movement_24h jump address
switches to LOW.
Thanks to the standstill time monitoring function, the protective device has to be reset
if the machine remains stationary for more than 24 hours.
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5 CONFIGURATION
5.6.4
From/to FX3-MOC0 page
The From/to FX3-MOC0 page controls signal transfer between the CPU and the FX3MOC0.
Conversion of binary data to 1-of-n
Figure 35: Conversion of binary data to 1-of-n
This program section is used to convert the binary speed information that the logic pro‐
gramming makes available for the MOC. The function block called Binary decoder con‐
verts the information into a 1-of-n code.
The two bits at Input A and Input B are used to switch outputs 1, 2, or 3 to HIGH.
Output 1 indicates an error, which causes the No_information jump address to switch to
HIGH.
In the event of a speed of V = 0 (standstill), jump address Speed 1 = Standstill switches to
HIGH at Output 2.
By default, Input C is not wired in the Easy Application. If further reduced speeds are
configured in the Easy Application, inputs A, B, and C can be used to convert additional
speeds.
Speed enable ID
Figure 36: Speed enable ID
This program section is used to determine the speed in accordance with the operating
mode.
Based on whether the system has been switched to Service mode or to Automatic
mode, the Speed enable ID is generated at outputs A and B of the Binary encoder function
block. This affects the respective inputs of the Stationary Machine Easy Application.
At this point, the logic programming can be adapted if further reduced speeds are
required.
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CONFIGURATION 5
Routing of jump addresses SS1, SS2, and SS2_reset
Figure 37: Routing of jump addresses SS1, SS2, and SS2_reset
The three jump addresses SS1, SS2, and SS2_reset are routed to the Stationary Machine
Easy Application using the Routing function block.
Additional limits of the “Speed cross check” function block
Figure 38: Additional limits of the “Speed cross check” function block
If additional limits are configured for the Speed cross check function block in the drive
logic, the two final program sections on the page are required as well.
In the logic programming for the MOC, there is an additional Speed cross check function
block underneath the Stationary Machine Easy Application. If Expert mode is used to config‐
ure additional limits (Limit 2 or Limit 3) in the Stationary Machine Easy Application, the sig‐
nals at the OR function block inputs are of relevance.
This delays when a discrepancy limit can next be activated. As a result, a limit cannot
be triggered repeatedly.
The delay time that has to be set in the Switch-on delay 4 and 5 function blocks is the
time that has been configured for the corresponding limit in the drive logic.
A longer time must be configured for the switch-on delays than for the switch-off delays.
This makes it possible to define a period when the limit cannot be reselected. We rec‐
ommend configuring the switch-on delays so that they are twice as long as the switchoff delays.
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47
5 CONFIGURATION
5.6.5
Drive control page
EDM function blocks
Figure 39: EDM function blocks
On the Drive control page, there are four EDM function blocks for monitoring the following
shutdown signals:
•
•
•
•
K3 STO
K4 Brake
K2 Drive-Enable
K1 Locking on safety door
Output 1 of each EDM function block must be connected to the relevant output of the
FX3-XTIO module.
Verify the functions before transferring the program to the safety controller. A value of
500 ms has been configured for the maximum feedback delay. This value has been cal‐
culated from the system response time, including the logic execution time and the sig‐
nal propagation delay.
The K3 STO and K4 Brake shutdown signals have to be connected directly from Drive
Monitor FX3-MOC0 to the outputs of the FX3-XTIO module.
The EDM function blocks are used to monitor the switching behavior of the external
contactors by comparing the control signals with the feedback signals from the external
contactors. If these two signals fail to switch in a non-equivalent manner, a fault on the
external contactor is assumed to exist.
Example: If the Stop request signal of Drive Monitor FX3-MOC0 is set to HIGH and the
conditions for an operating mode are met, K2 Drive-Enable is also set to HIGH. If the K2
Drive-Enable signal switches from HIGH to LOW, a controlled stop is triggered.
EDM errors
Figure 40: EDM errors
The signals are combined in the EDM_Error jump address within the bottom program
section.
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COMMISSIONING 6
6
Commissioning
6.1
Thorough check
Requirements for the thorough check during commissioning and in certain situations
The Safe Stationary Machine example application and its use must be thoroughly
checked in the following cases:
•
•
•
•
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 manipulation has been detected, after the
machine has been modified, or after components have been replaced
The thorough check ensures the following:
•
•
All relevant regulations are complied with and the example application is effective
in all of the machine’s operating modes.
The documentation accurately reflects the state/condition of the machine, includ‐
ing the protective device
The thorough checks must be carried out by qualified safety personnel or specially
qualified and authorized personnel, and must be documented in a traceable manner.
1.
2.
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Check the effectiveness of the protective device for all operating modes selectable
on the machine in accordance with the checklist for initial commissioning and
commissioning (see "Annex", page 52).
Make sure that the operating personnel have been briefed on the function of the
protective device before they start work on the machine. The machine operator
has overall responsibility for the briefing, which must be carried out by qualified
personnel.
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49
7 ORDERING INFORMATION
7
Ordering information
7.1
Necessary components for Safe Stationary Machine
Table 4: Part numbers of the components for the Flexi Soft safety controller
Part
Description
Part number
Flexi Soft safety controller
FX3-MPL000001
System plug for FX3-CPU0 or FX3-CPU1
Screw terminals
1043700
FX3-CPU000000
Main module
1043783
FX3-XTIO84002
I/O module
8 safe inputs, 4 safe outputs, plug-in dual-level
spring terminals
1044125
FX3-XTDI80002
I/O module
8 safe inputs, plug-in dual-level spring termi‐
nals
1044124
FX3-MOC000000
Drive Monitor
For connecting two encoders
1062344
NOTE
Safe Stationary Machine requires the following additional components:
1 safety encoder or 2 incremental encoders
1 emergency stop pushbutton
1 reset pushbutton
1 enabling switch
1 electro-mechanical safety switch
1 safety locking device
SICK offers appropriate components in many different variants. The following table lists
some of the individual variants as examples. Details of further variants can be found at
www.sick.com.
Table 5: Part numbers of additional components required
Part
Description
Part number
Encoders
DBS60E-S4EA05000
Incremental encoder
1072523
DFS60B-S4NA01024
Incremental encoder
1070475
DFS60S-S40K01024
Safety encoder
1069520
ES21-SA10F1
Emergency stop pushbutton/complete device
6036148
ER12-SB3C4S01
Reset pushbutton
6034585
E100-A2A22C05A
Enabling switch
6021917
Safety command devices
Electro-mechanical safety switches
i12-SB213
Safety switches with separate actuator
6025059
Safety locking device
6022580
Safety locking devices
i10-M0233 Lock
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ACCESSORIES 8
8
Accessories
8.1
Accessories
Table 6: Part numbers for Drive Monitor FX3-MOC accessories
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Part
Description
Part number
–
Connecting cable for all encoder connection
boxes, shielded, twisted pair, one 15-pin Micro
D-Sub, straight, one 15-pin HD D-Sub, 2 m
2067798
–
Extension cable for motor feedback splitter box
FX3-EBX3, shielded, twisted pair, one 9-pin DSub, one 15-pin HD D-Sub, 2 m
2067800
FX3-EBX3
Motor feedback splitter box for FX3-MOCx
2068728
FX3-EBX4
Dual encoder connection box for FX3-MOCx
2068729
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9 ANNEX
9
Annex
9.1
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.
Table 7: Tests in Automatic and Service operating modes
Step
Test sequence
Expected result
Result OK?
1
1.
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Use S8 Open door to unlock
the door but keep the door
closed.
Activate S5 Reset followed
by S6 Start.
The door unlocks (K1 HIGH).
The door locks again when S5
Reset is activated (K1 LOW).
The drive starts when S6 Start is
activated.
Yes ⃞ No ⃞
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Use S8 Open door to unlock
the door.
Open the door (safety lock‐
ing device actuator is pulled
out).
Activate S5 Reset followed
by S6 Start.
The door unlocks (K1 HIGH).
S5 Reset and S6 Start have no
effect.
The drive does not start.
Yes ⃞ No ⃞
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Activate S5 Reset and S6
Start.
Activate S1 E-Stop.
Reset S1 E-Stop.
Activate S5 Reset followed
by S6 Start.
The drive starts when S5 Reset
Yes ⃞ No ⃞
and S6 Start are activated.
The drive performs a safe stop 1
(SS1) when S1 E-Stop is acti‐
vated.
If S1 E-Stop is reset, the drive
starts after S5 Reset and S6 Start
are activated.
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Activate S5 Reset followed
by S6 Start.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
The drive starts when S5 Reset
Yes ⃞ No ⃞
and S6 Start are activated.
The drive performs a safe stop 2
(SS2) when S4-2 Service mode is
activated.
If S5 Reset, the S2 Enabling
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
2.
3.
2
1.
2.
3.
4.
3
1.
2.
3.
4.
5.
4
1.
2.
3.
4.
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ANNEX 9
Step
Test sequence
Expected result
5
1.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Activate S5 Reset followed
by S6 Start.
If S5 Reset, the S2 Enabling
Yes ⃞ No ⃞
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
The drive performs a safe stop 2
(SS2) when S4-1 Automatic mode
is activated.
The drive starts when S5 Reset
and S6 Start are activated.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
Release the S2 Enabling
switch.
Press and hold the S2 Ena‐
bling switch, and then acti‐
vate S6 Start.
If S5 Reset, the S2 Enabling
Yes ⃞ No ⃞
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
The drive performs a safe stop 2
(SS2) when the S2 Enabling
switch is released.
If the S2 Enabling switch and S6
Start are activated in the correct
order, the drive starts running at
reduced speed.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Use S8 Open door to unlock
the door.
Open the door (safety lock‐
ing device actuator is pulled
out, S7 Safety switch is
deactivated).
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
Activate S1 E-Stop.
The door unlocks (K1 HIGH).
Yes ⃞ No ⃞
If S5 Reset, the S2 Enabling
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
The drive performs a safe stop 1
(SS1) when S1 E-Stop is acti‐
vated.
The door remains unlocked (K1
HIGH).
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
Activate S1 E-Stop.
Release the S2 Enabling
switch.
Reset S1 E-Stop.
Press and hold the S2 Ena‐
bling switch, and then acti‐
vate S6 Start.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
If S5 Reset, the S2 Enabling
Yes ⃞ No ⃞
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
The drive performs a safe stop 1
(SS1) when S1 E-Stop is acti‐
vated.
Nothing happens when the S2
Enabling switch and S6 Start are
activated. The machine remains
off.
If S5 Reset, the S2 Enabling
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
2.
3.
4.
6
1.
2.
3.
4.
7
1.
2.
3.
4.
5.
8
1.
2.
3.
4.
5.
6.
7.
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Result OK?
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53
9 ANNEX
Step
Test sequence
Expected result
9
1.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Activate S5 Reset. Then
press and hold the S2 Ena‐
bling switch. After that, acti‐
vate S6 Start.
Increase the speed of the
machine so that it exceeds
the maximum limit permit‐
ted in Service operating
mode.
If S5 Reset, the S2 Enabling
Yes ⃞ No ⃞
switch, and S6 Start are activated
in the correct order, the drive
starts running at reduced speed.
K2 Drive-Enable switches to High.
The drive performs a safe stop 2
(SS2).
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Activate S5 Reset followed
by S6 Start.
Operate the machine at
maximum speed.
When the machine is run‐
ning at maximum speed,
activate S1 E-Stop (emer‐
gency stop pushbutton).
The drive starts when S6 Start is Yes ⃞ No ⃞
activated.
The drive performs a safe stop 1
(SS1) when S1 E-Stop is acti‐
vated.
K3 STO switches to LOW when the
end of the stop ramp is reached
(standstill).
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Activate S5 Reset followed
by S6 Start.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
The drive starts when S6 Start is
activated.
The drive performs a safe stop 2
(SS2) when S4-2 Service mode is
activated.
K3 STO remains set to HIGH.
Yes ⃞ No ⃞
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Configure a slower stop
ramp in the drive control
than in the FX3-MOC0 logic
programming.
Activate S5 Reset followed
by S6 Start.
Operate the machine at
maximum speed.
When the machine is run‐
ning at maximum speed,
activate S1 E-Stop (emer‐
gency stop pushbutton).
The drive starts when S6 Start is
activated.
The drive performs a safe stop 1
(SS1) when S1 E-Stop is acti‐
vated.
K3 STO switches to LOW before
the end of the stop ramp is
reached.
Yes ⃞ No ⃞
2.
3.
10
1.
2.
3.
4.
11
1.
2.
3.
12
1.
2.
3.
4.
5.
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Result OK?
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ANNEX 9
Step
Test sequence
Expected result
Result OK?
13
1.
The drive starts when S6 Start is
activated.
The drive performs a safe stop 2
(SS2) when S4-2 Service mode is
activated.
K3 STO switches to LOW before
the end of the stop ramp is
reached.
Yes ⃞ No ⃞
2.
3.
4.
5.
9.2
Set the operating mode
selector switch to S4-1 Auto‐
matic mode.
Configure a slower stop
ramp in the drive control
than in the FX3-MOC0 logic
programming.
Activate S5 Reset followed
by S6 Start.
Operate the machine at
maximum speed.
Set the operating mode
selector switch to S4-2 Serv‐
ice mode.
Extending the number of axes
Figure 41: Application with several axes
Industrial environments are frequently home to applications that have several drives
operating in different axes. The Safe Stationary Machine example application can be
extended to accommodate such scenarios.
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55
9 ANNEX
Safety concept
DANGER
The procedure described below for extending the number of axes is merely intended as
a rough guide.
b
If the Safe Stationary Machine example application is actually extended, a sepa‐
rate risk assessment must be carried out.
A copy of the original SFxx safety functions is required for each axis you add (see
"Safety functions", page 14 ). Here, xx represents the respective code (01, 02, ..., 99).
An index of “1” is appended to the original SFxx safety function (e.g., SF01.1, SF02.1,
and so on). Whenever a further copy is made, the index is incremented accordingly,
e.g., SF01.2, SF01.3, ..., SF01.n (n = number of axes).
The structure of the safety functions is based on subsystems. These are categorized as
follows: trigger (T), condition (C), logic (L), or response (R). The encoders (T or C), the
MOC logic (L), and the STO/Brake drive control (R) for each axis must be configured in
accordance with the axes that are added. If all axes are controlled simultaneously, the
STO/Brake block can remain unchanged.
SISTEMA
In line with the details described above, the associated SFxx.n safety functions must be
added in the software assistant and evaluated.
Hardware of the Flexi Soft safety controller
An extra FX3-MOC0 with two encoders must be added for each additional axis. This
applies when a performance level of d or e is required. In the case of a lower perform‐
ance level or if sine-cosine encoders are used, the situation may be different (see asso‐
ciated documentation).
In order to control each axis, it is necessary to have three extra safe outputs (Drive-Ena‐
ble, Brake, STO) plus the associated EDM functions. Consequently, one FX3-XTIO mod‐
ule is required per additional axis.
Logic programming for the MOC
The same logic is required by each FX3-MOC0. This logic must be individually config‐
ured for the respective drive based on the speeds, stop ramps, etc., that apply during
operation.
Logic programming for the CPU
On the Service mode page, you must increase the number of inputs for the Reset function
block by the number of additional axes. The EDM error information for the additional
axes must be connected to these additional inputs.
On the Automatic mode page, you must increase the number of inputs for the Reset func‐
tion block by the number of additional axes. The EDM error information for the addi‐
tional axes must be connected to these additional inputs. The Speed 1 = Standstill jump
address of each individual axis must be connected to the AND function block for the
door interlocking and to the OR function block for the reset/restart sequence. To enable
this, the number of inputs on the AND and OR function blocks must be increased by one
for each additional axis. The inputs of the OR function block must be inverted.
56
O P E R A T I N G I N S T R U C T I O N S | Safe Stationary Machine
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Subject to change without notice
ANNEX 9
On the Stop signals page, the final program section called Standstill monitoring must be
duplicated for each additional axis. The function block settings must be kept the same
as on the original network except that the Speed 1 = Standstill jump address of the addi‐
tional axis/axes must be connected instead of the Speed 1 = Standstill jump address of
the first axis.
The duplication of the Standstill monitoring program section results in multiple No_move‐
ment_24h_x jump addresses. So that all these jump addresses can be connected, the
number of inputs on the Reset function block within the Safe stop 1 signal generation pro‐
gram section must be increased by the number of additional axes.
The From/to FX3-MOC0 page must be duplicated for each additional axis.
The structure of the function blocks and jump addresses must be identical on each of
these new pages. Each input or output signal must be connected to the associated sig‐
nal of the MOC logic programming for the additional axis. Where applicable, the set‐
tings of the function blocks in the last two program sections must be aligned with the
settings in the MOC logic programming for the additional axis.
The Drive control page must be duplicated for each additional axis. The structure of the
function blocks and jump addresses must be identical on each of these new pages. The
only exception is that the fourth EDM function block is not required. All the inputs and
outputs of the three remaining EDM function blocks must be connected to the relevant
hardware inputs and outputs or to the signals of the MOC logic programming for the
additional axis. The number of inputs on the AND function block must be reduced by
one (no input for the EDM_Locking jump address).
8020304/2017-07-26 | SICK
Subject to change without notice
O P E R A T I N G I N S T R U C T I O N S | Safe Stationary Machine
57
10 LIST OF FIGURES
10
List of figures
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
58
Example structure and function.................................................................................10
Structure required.......................................................................................................11
Safety functions.......................................................................................................... 15
Block diagram............................................................................................................. 18
Example circuit diagram.............................................................................................18
Example screenshot from the SISTEMA software assistant....................................22
Hardware configuration with two encoders.............................................................. 24
Hardware configuration with one encoder................................................................24
Logic programming with two encoders......................................................................25
Logic programming with one encoder....................................................................... 25
Function blocks of the Stationary Machine Easy Application.................................. 26
Configuration assistant – Overview...........................................................................27
Machine parameters.................................................................................................. 28
Encoders in the configuration assistant................................................................... 29
Automatic error reset in the configuration assistant................................................30
Speed monitoring in the configuration assistant..................................................... 31
Response time for stop request in the configuration assistant.............................. 32
Ramp speed transitions in the configuration assistant........................................... 33
Stop ramps in the configuration assistant................................................................34
EDM (external device monitoring) in the configuration assistant........................... 35
Summary in the configuration assistant...................................................................36
Speed comparison function block (CrossCheck_StMa)...........................................37
Speed comparison limits with incremental encoders.............................................. 38
Speed comparison limits with SSI encoders............................................................ 39
Speed monitoring function block (SpeedMonitor_StMa_1).................................... 40
Safe stop function block (SafeStop_StMa)............................................................... 41
Logic for the operating mode selector switch........................................................... 41
Reset and restart sequence for Service mode.........................................................42
Reset and restart sequence for Automatic mode.................................................... 42
Locking device opening or closing............................................................................. 43
Safe stop signal SS1.................................................................................................. 44
Safe stop signal SS2.................................................................................................. 44
Resetting of safe stop signal SS2..............................................................................45
Standstill time monitoring..........................................................................................45
Conversion of binary data to 1-of-n........................................................................... 46
Speed enable ID......................................................................................................... 46
Routing of jump addresses SS1, SS2, and SS2_reset............................................ 47
Additional limits of the “Speed cross check” function block................................... 47
EDM function blocks...................................................................................................48
EDM errors.................................................................................................................. 48
Application with several axes.....................................................................................55
O P E R A T I N G I N S T R U C T I O N S | Safe Stationary Machine
8020304/2017-07-26 | SICK
Subject to change without notice
LIST OF TABLES 11
11
List of tables
1.
2.
3.
4.
5.
6.
7.
8020304/2017-07-26 | SICK
Subject to change without notice
Available documents.....................................................................................................5
Definition of safety functions.....................................................................................15
Switching elements.....................................................................................................19
Part numbers of the components for the Flexi Soft safety controller..................... 50
Part numbers of additional components required................................................... 50
Part numbers for Drive Monitor FX3-MOC accessories........................................... 51
Tests in Automatic and Service operating modes.................................................... 52
O P E R A T I N G I N S T R U C T I O N S | Safe Stationary Machine
59
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