Safety Controller CPU Module User`s Manual

Safety Controller CPU Module User`s Manual
2.3 Correct use
1 About this document
This document is the original manual.
WS0-CPU000200/WS0-CPU130202/WS0-CPU320202
Safety Controller CPU Module
User's Manual (Hardware)
Mitsubishi Electric Corporation
2-7-3 Marunouchi, Chiyoda-ku, Tokyo, Japan
Mitsubishi Electric Europe BV
Gothaer strasse 8, 40880 Ratingen, Germany
All rights reserved • Specified product properties and technical data do not
represent a guarantee declaration.
MODEL
WS-CPU-U-HW-E
MODEL CODE
13JZ91
IB(NA)-0800527ENG-B(1407)SICK
© 2014 MITSUBISHI ELECTRIC CORPORATION
Precautions regarding warranty and specifications
MELSEC-WS series products were jointly developed and manufactured
by Mitsubishi and SICK AG, Industrial Safety Systems, in Germany. Note
that there are some precautions regarding warranty and specifications of
MELSEC-WS series products.
<Warranty>
 The gratis warranty term of the product shall be for one (1) year after the
date of delivery or for eighteen (18) months after manufacturing,
whichever is less.
 The onerous repair term after discontinuation of production shall be for
four (4) years.
 Mitsubishi shall mainly replace the product that needs a repair.
 It may take some time to respond to the problem or repair the product
depending on the condition and timing.
<Specifications>
 General specifications of the products differ.
MELSEC-WS
MELSEC-Q
MELSEC-QS
Operating ambient
temperature
-25 to 55°C*1
0 to 55°C
0 to 55°C
Température
-25 à 55°C*1
0 à 55°C
0 à 55°C
ambiante de
fonctionnement
Operating ambient
10 to 95%RH
5 to 95%RH
5 to 95%RH
humidity
Storage ambient
-25 to 70°C
-25 to 75°C
-40 to 75°C
temperature
Storage ambient
10 to 95%RH
5 to 95%RH
5 to 95%RH
humidity
*1: When the WS0-GCC100202 is included in the system, operating
ambient temperature will be 0 to 55°C.
*1: Avec un module WS0-GCC100202 inclus dans le système, la
température ambiante de service est de 0 à 55°C.
 EMC standards that are applicable to the products differ.
MELSEC-Q,
MELSEC-WS
MELSEC-QS
EMC standards
EN 61000-6-2, EN 55011
EN 61131-2
1.1 Documentations for the MELSEC-WS system
This manual describes the mounting of the CPU module of a MELSECWS safety controller.
Mounting of the MELSEC-WS network modules (WS0-GETH and WS0GCC1), safety I/O modules (WS0-XTIO and WS0-XTDI) and the relay
output module (WS0-4RO) is described in separate manuals.
The installation, configuration and commissioning of the MELSEC-WS
safety controller are described in the "Safety Controller User’s Manual"
and "Safety Controller Setting and Monitoring Tool Operating Manual".
Title
Safety Controller User’s Manual
Safety Controller Ethernet Interface
User’s Manual
Safety Controller CC-Link Interface
User’s Manual
Safety Controller Setting and Monitoring
Tool Operating Manual
Number
WS-CPU-U-E
(13JZ32)
WS-ET-U-E
(13JZ33)
WS-CC-U-E
(13JZ45)
SW1DNNWS0ADR-B-O-E
(13JU67)
1.2 Function of this document
This manual instructs the technical staff of the machine manufacturer
and/or of the machine operator on the safe operating of the CPU module
of the MELSEC-WS safety controller.
In addition mounting protective devices also requires specific technical
skills which are not detailed in this documentation.
This manual does not provide instructions for operating the machine in
which the safety controller is, or will be, integrated. Information of this kind
will be found in the manuals for the machine.
2 On safety
This chapter deals with your own safety and the safety of the equipment
operators.
 Please read this chapter carefully before beginning with the installation.
2.1 Qualified safety personnel
The MELSEC-WS safety controller may only be installed by qualified
safety personnel.
Qualified safety personnel are defined as persons who …
 have undergone the appropriate technical training and
 who have been instructed by the responsible machine operator in the
operation of the machine and the current valid safety guidelines and
 have access to the MELSEC-WS manuals and have read and
familiarized themselves with them and
 have access to the manuals for the protective devices (e.g. light
curtains) connected to the safety controller and have read and
familiarized themselves with them.
2.2 Applications of the device
The MELSEC-WS safety controller is a configurable controller for safety
applications. It can be used
 in accordance with IEC 61508 to SIL 3
 in accordance with IEC 62061 to SILCL 3
 in accordance with EN/ISO 13849-1 up to Performance Level e
The degree of safety actually attained depends on the external circuit, the
realization of the wiring, the parameter configuration, the choice of the
pick-ups and their location at the machine.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser
scanners, safety switches, sensors, emergency-stop buttons) are
connected to the safety controller and are linked logically. The
corresponding actuators of the machines or systems can be switched off
safely via the switching outputs of the safety controller.
The MELSEC-WS safety controller fulfils the
requirements of Class A (industrial applications) in
ATTENTION accordance with the "Interference emission" basic
specifications!
Le contrôleur de sécurité MELSEC-WS a été conçu en
conformité aux exigences des appareils de Classe A
(applications industrielles) pour ce qui concerne les
spécifications de base dans le domaine des
"émissions d'interférences" !
The MELSEC-WS safety controller is therefore only
suitable for use in an industrial environment and not for
private use.
Le contrôleur de sécurité MELSEC-WS peut donc s'utiliser
dans un environnement industriel mais n'a pas été prévu
pour un usage domestique.
The MELSEC-WS safety controller may only be used within specific
operating limits (voltage, temperature, etc., refer to the technical data and
to the section "Application areas of the device"). It may only be used by
qualified safety personnel and only at the machine at which it was
mounted and initially commissioned by qualified safety personnel in
accordance with the "Safety Controller User’s Manual".
The modules of the MELSEC-WS safety controller conform to Class A,
Group 1, in accordance with EN 55011. Group 1 encompasses all the ISM
devices in which intentionally generated and/or used conductor-bound RF
energy that is required for the inner function of the device itself occurs.
Mitsubishi Electric Corporation accepts no claims for liability if the
equipment is used in any other way or if modifications are made to the
device, even in the context of mounting and installation.
UL/CSA applications:
 Use 60°C/75°C conductors.
 The terminal tightening torque must be 5-7 lbs in.
 To be used in a Pollution Degree 2 environment only.
 Memory plug and CPU module shall be supplied by an isolating power
source protected by an UL248 fuse, rating 42.4VDC which is the
maximum voltage requirements of UL508.
 The safety functions are not evaluated by UL. The approval is
accomplished according to UL508, general use applications.
Applications UL/CSA:
 Utiliser des conducteurs 60°C/75°C.
 Le couple de serrage des bornes doit être de 5-7 lbs in.
 À utiliser uniquement en environnement polluant de degré 2.
 La prise mémoire et le module CPU doivent être alimentés à partie
d'une source isolée protégé par un fusible UL248, d'un' tension
nominale de 42,2V cc, ce qui est le maximum admissible pour UL508.
 Les fonctions de sécurité n'ont pas été évaluées par UL. L'agrément a
été accordé selon UL508 pour applications universelles.
2.4 General protective notes and protective measures
Observe the protective notes and measures!
Respecter les consignes de sécurité et mesures de
ATTENTION protection !
Please observe the following items in order to ensure
proper use of the MELSEC-WS safety controller.
Pour garantir une utilisation correcte du contrôleur de
sécurité MELSEC-WS, veuillez observer les points
suivants.
 When mounting, installing and using the MELSEC-WS safety controller,
observe the standards and directives applicable in your country.
 The national rules and regulations apply to the installation, use and
periodic technical inspection of the MELSEC-WS safety controller, in
particular:
– Machinery Directive 2006/42/EC
– EMC Directive 2004/108/EC
– Provision and Use of Work Equipment Directive 2009/104/EC
– Low-Voltage Directive 2006/95/EC
– Work safety regulations/safety rules
 Manufacturers and owners of the machine on which a MELSEC-WS
safety controller is used are responsible for obtaining and observing all
applicable safety regulations and rules.
 It is imperative that the notices, in particular the test notices of the
manual must be observed.
 The tests must be carried out by qualified safety personnel or specially
qualified and authorized personnel and must be recorded and
documented to ensure that the tests can be reconstructed and retraced
at any time by third parties.
2.5 Disposal
Disposal of unusable or irreparable devices should always occur in
accordance with the applicable country-specific waste-disposal regulations
(e.g. European Waste Code 16 02 14).
3 Conditions of use for the product
(1) Although MELCO has obtained the certification for Product's
compliance to the international safety standards IEC 61508, EN 9541/ISO 13849-1 from TUV Rheinland, this fact does not guarantee that
Product will be free from any malfunction or failure. The user of this
Product shall comply with any and all applicable safety standard,
regulation or law and take appropriate safety measures for the system
in which the Product is installed or used and shall take the second or
third safety measures other than the Product. MELCO is not liable for
damages that could have been prevented by compliance with any
applicable safety standard, regulation or law.
(2) MELCO prohibits the use of Products with or in any application
involving, and MELCO shall not be liable for a default, a liability for
defect warranty, a quality assurance, negligence or other tort and a
product liability in these applications.
1) power plants,
2) trains, railway systems, airplanes, airline operations, other
transportation systems,
3) hospitals, medical care, dialysis and life support facilities or
equipment,
4) amusement equipment,
5) incineration and fuel devices,
6) handling of nuclear or hazardous materials or chemicals,
7) mining and drilling,
8) and other applications where the level of risk to human life, health
or property are elevated.
4 Product description
4.1 CPU modules WS0-CPU0, WS0-CPU1 and WS0CPU3
The CPU modules WS0-CPU0, WS0-CPU1 or WS0-CPU3 are the central
process unit of the entire system in which all the signals are monitored
and processed logically in accordance with the configuration stored in the
memory plug. The outputs of the system are switched as a result of the
processing, whereby the FLEXBUS+ backplane bus serves as the data
interface.
The memory plug has to be ordered separately, refer to the "Safety
Controller User’s Manual".
The CPU modules further more have an RS-232 interface with the
following functions:
 Transferring the configuration from the MELSEC-WS Setting and
Monitoring Tool to the memory plug or the connected SICK EFIcompatible device
 Uploading the configuration from the memory plug or the connected
SICK EFI-compatible device to the MELSEC-WS Setting and
Monitoring Tool
 Online monitoring of the MELSEC-WS safety controller
The WS0-CPU1 and WS0-CPU3 modules have two more EFI interfaces.
If SICK EFI-compatible devices are connected, a functional extension at
the sensors is then possible by simple means.
The WS0-CPU3 module has following interfaces as well.
 USB interface for the settings and diagnostics using the MELSEC-WS
Setting and Monitoring Tool
 Flexi Line interface that enables safety communications between
MELSEC-WS safety controllers
4.2 Display elements
WS0-CPU0 and WS0-CPU1 modules
4.2.4 Displays of the LINE LED (only WS0-CPU3)
LINE LED
Meaning
○
Flexi Line is not set and not operating.
● green
Flexi Line is operating.
☀ green (1Hz)
Flexi Line is waiting for an adjacent station.
☀ green (2Hz)
Perform teaching.
☀ red/green (2Hz)
Set Flexi Line.
☀ red (1Hz)
An error has occurred on Flexi Line.
● red
Flexi Line is stopped because of an major
error.
4.2.1 Displays of the MS LED (module status)
MS LED
Meaning
Supply voltage lies outside range
○
A self test is being carried out or the system
☀ red/green (1Hz)
is being initialized
System is in Stop state
☀ green (1Hz)
Identify (e.g. for Flexi Link)
☀ green (2Hz)
System is in Run state
● green
Invalid configuration
☀ red (1Hz)
Critical error in the system, possibly in this
module. Application is stopped. All outputs
☀ red (2Hz)
are switched off.
Critical error in the system, possibly in
another module. Application is stopped. All
● red
outputs are switched off.
Symbol meaning:
Wiring of the emergency stop pushbuttons, start switches, stop switches,
and reset switches
 Dual-channel wiring (with test pulse outputs)*1
4.3 Terminal assignment
Affectation des bornes
4.3.2 Terminal assignment of memory plugs WS0-MPL0 and WS0MPL1
Affectation des bornes de prise mémoire WS0-MPL0 et WS0MPL1
Terminal
Assignment
Borne
Affectation
A1
24VDC
A2
5 Mounting/Dismantling
The MELSEC-WS safety controller is only suitable for
mounting in a control cabinet with at least IP 54
ATTENTION degree of protection.
While supply voltage is applied, modules must not be
plugged to nor be removed from the MELSEC-WS
safety controller.
Le contrôleur de sécurité MELSEC-WS ne peut être
installé que dans une armoire de commande avec un
degré de protection IP 54 ou mieux.
Quand la tension d'alimentation est appliquée, les
modules ne doivent pas être enfichés sur ou retirés du
contrôleur de sécurité MELSEC-WS.
5.1 Mounting the modules
4.3.1 Pin assignment of RS232 interface
Affectation des broches d'interface RS232
Plug/socket
Pin
Signal
Fiche/prise
Broche
Signal
Reserved
1
En réserve
2
RxD
GND (Internally electrically
connected with connection A2
of the CPU module)
3
GND (Raccordé
électriquement à l'intérieur sur
connexion A2 du module
CPU)
4
TxD
WS0-CPU3 module
4.4 Wiring example
0VDC
*1: Use the following terminal combinations for dual-channel input wiring.
WS0-XTIO: ((I1 and X1) (I2 and X2)), ((I3 and X1) (I4 and X2)),
((I5 and X1) (I6 and X2)), ((I7 and X1) (I8 and X2))
WS0-XTDI: ((I1 and X1) (I2 and X2)), ((I3 and X3) (I4 and X4)) to
((I7 and X7) (I8 and X8))
*2: Connect an emergency stop pushbutton (with dual-channel equivalent
switching contacts for direct operation) between the I1 to I8 (input)
terminals and the X1 and X2 (test pulse output) terminals.
*3: Connect an emergency stop pushbutton (with dual-channel equivalent
switching contacts for direct operation) between the I1 to I8 (input)
terminals and the X1 to X8 (test pulse output) terminals.
*1: Utiliser les combinaisons de bornes ci-après pour le câblage d'entrée
double-voie.
WS0-XTIO: ((I1 and X1) (I2 and X2)), ((I3 and X1) (I4 and X2)),
((I5 and X1) (I6 and X2)), ((I7 and X1) (I8 and X2))
WS0-XTDI: ((I1 and X1) (I2 and X2)), ((I3 and X3) (I4 and X4)) à
((I7 and X7) (I8 and X8))
*2: Raccorder un bouton-poussoir d'arrêt d'urgence (avec contacts de
commutation équivalente sur double canal pour actionnement direct)
entre les bornes I1 à I8 (entrée) et les bornes X1 et X2 (sortie
d'impulsions d'essai).
*3: Raccorder un bouton-poussoir d'arrêt d'urgence (avec contacts de
commutation équivalente sur double canal pour actionnement direct)
entre les bornes I1 à I8 (entrée) et les bornes X1 à X8 (sortie
d'impulsions d'essai).
 In a MELSEC-WS safety controller, the CPU module is positioned at the
far left and the two optional network modules follow directly. Only then
do the safety I/O modules follow. The WS0-4RO module has to be
mounted at the far right.
 The modules are located in a 22.5mm wide modular system for 35mm
DIN rails to IEC/EN 60715.
 The connection between the modules is effected by means of the plug
connection integrated in the housing.
 Mount the modules in accordance with EN 50274
 Ensure that suitable ESD protective measures are also taken during
mounting. Otherwise the FLEXBUS+ backplane bus may be damaged.
 Take suitable measures to ensure that foreign matter does not enter the
connector openings, in particular that of the memory plug.
 Make sure that the voltage supply of the MELSEC-WS safety controller
is switched off.
 Hang the device onto the DIN rail (1)).
 Ensure that the earthing spring contact is positioned correctly (2)). The
earthing spring contact of the module must contact the DIN rail
securely to allow electrical conductivity.
 Snap the module onto the DIN rail by pressing it lightly in the direction
of the arrow (3)).
○: LED Off, ●: LED Lights up, ☀: LED Flashes
4.2.2 Displays of the CV LED (configuration status)
CV LED
Meaning
Configuration in progress
○
Storing of configuration data in the non☀ yellow (2Hz)
volatile memory
Unverified configuration
☀ yellow (1Hz)
Valid configuration
● yellow
4.2.3 Displays of the EFI LEDs (only WS0-CPU1 and WS0-CPU3)
EFI LED (EFI1 or EFI2)
Meaning
OK
○
Waiting for integration of any SICK EFIcompatible device or Flexi Link station after
● red
power up
Error, e.g.:
 Any expected SICK EFI-compatible device
or Flexi Link station not found within 3
minutes
 Integration check failed
☀ red (1Hz)
 Communication interruption
 SICK EFI-compatible device address
conflict
 Flexi Link ID conflict
Identify, (e.g. for Flexi Link)
☀ red (2Hz, alternating)
 If there are several modules, slide the modules together individually in
the direction of the arrow until the side plug connection latches in.
 Install the end clips on the left and right.
5.2 Steps for dismantling the modules
 Remove the removable terminals with wiring and the end clips.
 If there are several modules, slide the modules away from each other
individually in the direction of the arrow until the side plug connection is
separated.
 Press the module downwards at the rear (1)) and remove it from the
DIN rail in the direction of the arrow while keeping it pressed down (2)).
6 Electrical installation
De-energize the entire system!
Mettez le système entièrement hors tension !
ATTENTION The system could start up unexpectedly while you are
connecting the devices.
Le système pourrait être mis en marche par inadvertance
pendant qu'on connecte les dispositifs.
Observe the relevant safety standards!
Observez les normes de sécurité pertinentes!
All safety related parts of the installation (cabling,
connected sensors and actuators, configuration settings,
EDM) must be according to the relevant safety standards
(e.g. IEC 62061 or EN/ISO 13849-1).
Tout matériel ou logiciel ayant des implications de sécurité
(câblage, capteurs et actionneurs à raccorder,
paramétrages de configuration, EDM) doivent être
conformes aux normes de sécurité applicables (par
exemple, IEC 62061 ou EN/ISO 13849-1).
 The MELSEC-WS safety controller fulfils the EMC requirements in
accordance with the basic specification IEC 61000-6-2 for industrial use.
 Carry out the electrical installation in accordance with EN 60204-1
 To ensure full electromagnetic compatibility (EMC), the DIN rail has to
be connected to functional earth (FE).
 The voltage supply of the devices must be capable of buffering brief
mains voltage failures of 20ms as specified in IEC 60204-1.
 The voltage supply has to fulfil the regulations for extra-low voltages
with safe separation (SELV, PELV) in accordance with IEC 60664 and
EN 50178 (equipment of electrical power installation with electronic
devices).
 You must connect all the modules of the MELSEC-WS safety controller,
the connected protective devices as well as the voltage supply/ies with
the same 0VDC (GND).
 All connected pick-ups and downstream controllers as well as wiring
and installation have to fulfil the required safety characteristics.
 If a module is replaced the correct terminal assignment has to be
guaranteed, for example by labelling or suitable cable routing.
 For further information that is to be taken into consideration when the
MELSEC-WS safety controller is used, refer to the "Safety Controller
User’s Manual" and "Safety Controller Setting and Monitoring Tool
Operating Manual".
7 Configuration and commissioning
Do not commission without a check by qualified
safety personnel!
Ne pas procéder à la mise en service sans qu'un
ATTENTION personnel de sécurité qualifié ait effectué un
contrôle.
Before initial commissioning of a system using a
MELSEC-WS safety controller, it must be checked and
released by qualified safety personnel. Document the
result of the safety check.
La première mise en service d'un système utilisant un
contrôleur de sécurité MELSEC-WS ne doit être
effectuée qu'après contrôle et sur autorisation délivrée
par un personnel qualifié. Les résultats du contrôle de
sécurité doivent être dûment documentés et suivis.
The MELSEC-WS safety controller can be configured by the Setting and
Monitoring Tool connected to the RS-232 interface or USB interface (only
WS0-CPU3 module) of a CPU module, or the port of an Ethernet interface
module.
Note  The Setting and Monitoring Tool is required to configure and
commission the MELSEC-WS safety controller.
 The system configuration of the complete MELSEC-WS safety
controller is stored in the memory plug. The system does not
have to be reconfigured when a module is replaced.
 For the diagnostics after module replacement with the higher
version (for instance, upgraded from V1.11.0 to V2.01.0), the
Setting and Monitoring Tool version 1.7.0 is required.
Power supply unit (A1, A2) via memory plug WS0-MPL0 or
WS0-MPL1
8 Technical data
WS0-CPU0
Safety-related parameters
This information relates to an ambient temperature of +40°C, which is
normally used for the statistical calculation of the values.
Safety Integrity Level
SIL claim limit
Category
Performance Level
PFHd
PFHd for Flexi Line
station*1
WS0-CPU0
WS0-CPU1/3
SIL3 (IEC 61508)
SILCL3 (IEC 62061)
Category 4 (EN/ISO 13849-1)
PLe (EN/ISO 13849-1)
1.07 × 10-9
1.69 × 10-9
CPU1: CPU3: 0.40 × 10-9
TM (mission time)
20 years (EN/ISO 13849-1)
*1 Applies for a CPU module WS0-CPU3 that is used exclusively for
routing information via Flexi Line.
General data
Protection class
Enclosure rating
Ambient temperature in
operation
Température ambiante
de fonctionnement
Storage temperature
Humidity
Climatic conditions
Operating altitude
Vibration resistance
Shock resistance
Continuous shock
Single shock
Electromagnetic
compatibility
Number of EFI
interfaces
Number of Flexi Line
interfaces
Data interface
Configuration interface
Cross-section of
connecting wires
Taille des fils de
raccordement
EFI or Flexi Line
connection method
Cross-section of EFI
connecting wires
Dimensions
(W × H × D)
Weight
WS0-CPU0
III (IEC 61140)
IP20 (IEC 60529)
WS0-CPU1/3
-25 ... +55°C
-25 à +55°C
-25 ... +70°C
10% ... 95%, non-condensing
55°C, 95% relative humidity (IEC 61131-2),
No corrosive gases
Max. 2000 m above sea level (80 kPa)
5-150 Hz/1g (EN 60068-2-6)
10-500 Hz/3gRMS (IEC 60068-2-64)
10g, 16ms (IEC 60068-2-27)
30g, 11ms (IEC 60068-2-27)
Class A (IEC 61000-6-2, EN 55011)
0
0
2
CPU1: 0
CPU3: 2
Backplane bus (FLEXBUS+)
CPU1: RS-232
RS-232
CPU3: RS-232,
USB2.0 (mini b)
Single-core or finely stranded:
1 × 0.14 … 2.5 mm2 (26 to 13 AWG) or 2 ×
0.14 … 0.75mm2 (26 to 18 AWG)
Finely stranded with wire end ferrules:
1 × 0.25 … 2.5mm2 (23 to 13 AWG)or 2 ×
0.25 … 0.5mm2 (23 to 20 AWG)
Monobrin ou fine torsade:
1 × 0,14 … 2,5mm2 (26 à 13 AWG) ou 2 ×
0,14 … 0,75mm2 (26 à 18 AWG)
Fine torsade avec manchon d'extrémité EN
46228:
1 × 0,25 … 2,5mm2 (23 à 13 AWG) ou 2 ×
0,25 … 0,5mm2 (23 à 20 AWG)
Dual level spring
clamp terminals
Single-core or finely
stranded:
0.2 … 1.5 mm2 (24 to
15 AWG)
Finely stranded with
wire end ferrule:
0.25 … 1.5mm2 (23 to
15 AWG)
22.5 × 96.5 ×
22.5 × 101.7 ×
120.8mm
120.8mm
111g (+/- 5%)
119g (+/- 5%)
Supply voltage
Supply voltage
UL/CSA applications
Type of supply
voltage
Overvoltage categoly
Power consumption
Switch-on time
WS0-CPU1/3
24VDC (16.8 ... 30VDC)
24VDC
PELV or SELV
The current of the power supply unit that
supplies the CPU module has to be limited to a
maximum of 4A – either by the power supply
unit itself or by a fuse
II (IEC61131-2)
Max. 2.5W
Max. 18s
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