Emerson PACSystems VersaSafe IC220SDL963 User Manual Download Page 1

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User Manual

GFK-2843A

Jan 2020

PACSystems

VersaSafe

ENHANCED SAFETY LOGIC MODULE, SAFE OUTPUT 24VDC, 8
POINTS USER MANUALS
VersaPoint

MODULE: IC220SDL963

Summary of Contents for PACSystems VersaSafe IC220SDL963

Page 1: ...User Manual GFK 2843A Jan 2020 PACSystemsTM VersaSafeTM ENHANCED SAFETY LOGIC MODULE SAFE OUTPUT 24VDC 8 POINTS USER MANUALS VersaPointTM MODULE IC220SDL963 ...

Page 2: ...4 Housing dimensions 9 2 5 Connection options for actuators depending on the parameterization 12 2 6 Local diagnostic and status indicators 12 2 7 Safe state 14 2 7 1 Operating state 14 2 7 2 Error detection in I O devices 14 2 7 3 Device errors 15 2 7 4 Parameterization errors 16 2 8 Process data words 16 2 9 Programming data configuration data 16 2 9 1 Local bus 16 2 9 2 Other bus systems or net...

Page 3: ... off delay for stop category 1 33 Chapter 6 Connection examples for safe outputs 35 6 1 Explanation of the examples 35 6 2 Notes on the protective circuit for external re lays contactors freewheeling circuit 36 6 3 Measures required to achieve a specific safety integrity level 37 6 4 Single channel assignment of safe outputs 39 6 5 Two channel assignment of safe outputs 42 Chapter 7 Startup and va...

Page 4: ...system 67 A 1 The VersaSafe system 67 A 1 1 VersaSafe technology maximum flexibility and safety 67 A 1 2 Overview of VersaSafe system features 68 A 1 3 Differences in VersaSafe systems depending upon which module with integrated safety logic is used 68 A 2 System topology 70 A 2 1 General topology 70 A 2 2 Network and controller requirements 71 A 2 3 Safe input and output devices 71 A 2 4 Cross co...

Page 5: ... Parameterization or configuration errors 90 A 11 3 Communication errors 90 A 11 4 I O errors 91 A 11 5 Application errors 91 A 12 Startup and restart 92 A 12 1 Startup restart following power up 92 A 12 2 Restart after triggering a safety function 92 A 13 Memory sizes for the safety logic 92 Appendix B checklists 94 B 1 Checklists for the VersaSafe system 95 B 1 1 Planning 95 B 1 2 Configuration ...

Page 6: ...intenance The information is supplied for informational purposes only and Emerson makes no warranty as to the accuracy of the information included herein Changes modifications and or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein It is understood that Emerson may make changes modifications or improvements to the equipment ref...

Page 7: ...ease observe all the safety notes included in this section Requirements Knowledge of the following is required The target system e g PROFIBUS PROFINET The standard control system The VersaSafe system see Appendix A The components used in your application The VersaPoint product range Operation of the software tools used Safety regulations in the field of application Qualified personnel In the conte...

Page 8: ... carry out any repairs Repair work may not be carried out on the safety module In the event that an error cannot be removed please contact Emerson immediately engage a service engineer or send the faulty module directly to Emerson Do not open the housing security seal It is strictly prohibited to open the safety module housing In order to prevent the manipulation of the safety module and to detect...

Page 9: ...rding to DIN EN 60664 1 If you expect surge voltages in the system which exceed the values defined in surge voltage category II take into consideration additional measures for voltage limitation Installation and configuration Please observe the instructions for installing and configuring the system see Documentation on page 6 WARNING Depending on the application incorrect installation and upgrades...

Page 10: ...Please also refer to Achievable safety depending on the modules used on page 89 Check hardware and parameterization Carry out a validation every time you make a safety related modification to your overall system Use your test report to ensure that The safe devices are connected to the correct safe sensors and actuators The safe input and output devices have been parameterized correctly The safety ...

Page 11: ...and in such a way as to avoid errors You must observe all information in this manual as well as in the documents listed in Documentation on page 6 In particular only use the module according to the technical data and ambient conditions specified in Technical data and ordering data on page 58 and onwards Within a VersaSafe system the safety module can be used to achieve safety functions with the fo...

Page 12: ...ed VersaPoint product range GFK 2736 Automation terminals of the VersaPoint product range configuration and installation Documentation for the Network Interface Unit NIU used 1 8 Abbreviations used Table 1 Abbreviations used Abbreviation Meaning Standard Example SIL Safety integrity level IEC 61508 2 SIL 2 SIL 3 SIL CL SIL claim limit EN 62061 SIL CL 3 Cat Category EN ISO 13849 1 Cat 2 Cat 4 PL Pe...

Page 13: ...nsmission speed of the VersaPoint local bus can be set to 500 kbaud or 2 Mbaud on the safety module using switches Use the same transmission speed throughout an VersaPoint station The module has a 10 pos DIP switch which is used to set the island number The module has four safe positive switching digital outputs for two channel assignment or eight safe positive switching digital outputs for single...

Page 14: ...including hardware firmware firmware version designation not shown 3 Switch for setting the transmission speed 4 Switch for setting the island number 5 Potential jumper 6 Diagnostic and status indicators for assignment and meaning see Local diagnostic and status indicators on page 12 7 VersaPoint connector for assignment see Terminal point assignment on page 19 8 Terminal points 9 Marking field ...

Page 15: ...ng dimensions Figure 2 Housing dimensions in mm 2 5 Safe digital outputs The safety module has safe positive switching digital outputs which can be used as follows For two channel assignment Four two channel outputs For single channel assignment Eight single channel outputs ...

Page 16: ...tallation see Connection examples for safe outputs on page 35 For information on parameterization please refer to Parameterization of the safe outputs on page 31 Diagnostics Diagnostics are provided via both the local diagnostic indicators and the diagnostic messages which are transmitted to the controller For information on the diagnostic messages of the outputs please refer to Safe digital outpu...

Page 17: ...tection time is 20 ms Important Please refer to Single channel assignment of safe outputs on page 39 and Two channel assignment of safe outputs on page 42 for additional information Only use appropriately qualified actuators Use reliable components These include for example Control contactors according to EN 60947 4 1 Power contactors Relays with forcibly guided contacts according to DIN EN 50205 ...

Page 18: ...outputs Observe the requirements of the standards with regard to the external wiring and the actuators to be used to achieve a SIL SIL CL Cat PL see Measures required to achieve a specific safety integrity level on page 37 Output OUT0 to OUT3 Output parameterization Single channel Two channel Test pulses Any ON OFF Achievable category SIL 2 SIL CL 2 Cat 3 PL d SIL 3 SIL CL 3 Cat 4 PL e For connect...

Page 19: ...ization was not accepted ON Hardware fault The output drivers are reset there is no communication to the satellites Or Impermissible switch position The module will respond to certain impermissible switch positions by entering the failure state immediately after power up UM Green LED Monitoring the supply voltage UM OFF Communications power not present or firmware has not started up yet Flashing a...

Page 20: ...be entered in the following cases 1 Operating state 2 Error detection in I O devices 3 Device errors 4 Parameterization errors 5 Error detection during safe communication 2 8 1 Operating state In the operating state the outputs can enter states 1 or 0 In general state 0 is the safe state WARNING Loss of the safety function possible due to undetected accumulation of errors Also evaluate the diagnos...

Page 21: ...oller see Safe digital output errors on page 51 Serious errors All serious errors that can result in the loss of or adversely affect the safety function cause the entire module to enter the safe state The FS LED on the safety module is permanently on The following errors result in the safe state Serious hardware faults in the internal circuit User errors Module overload Module overheating Faulty s...

Page 22: ...Parameterization errors on page 53 2 9 Process data words The module occupies 24 words in the VersaPoint system Use electronic device descriptions GSD GSDML in order to use the module in various networks 2 10 Programming data configuration data 2 10 1 Local bus Operating mode IC220SDL963 ID code ABhex 171dec Length code 18hex 24dec Input address area Application specific Output address area Applic...

Page 23: ...Supply voltage UL Supply the 24 V supply voltage UBK U24V at a bus coupler or a suitable power terminal The 7 5 V voltage UL is generated from this 24 V supply voltage in the bus coupler or power terminal It is supplied to the safety module via the VersaPoint potential jumper UL WARNING Loss of the safety function when using unsuitable power supplies Please note for the voltage supply at the bus c...

Page 24: ...ly voltage UM actuators on page 61 The maximum current carrying capacity for the main circuit UM is 8 A total current with the segment circuit that is not used in the safety terminal This current carrying capacity can be reduced if certain terminals are used Please refer to the information in the terminal specific data sheets If the limit value of the potential jumpers UM and US is reached total c...

Page 25: ...k according to IEC 61326 3 1 A DC distribution network is a DC power supply network which supplies a complete industrial hall with DC voltage and to which any device can be connected A typical system or machine distribution is not a DC distribution network For devices that are provided for a typical system or machine distribution the DC connections are viewed and tested as I O signals according to...

Page 26: ...ut 0 channel 1 0 1 2 1 OUT0_Ch2 Output 0 channel 2 0 2 1 2 Not used 2 2 Not used 1 3 0 V GND Channel 1 and channel 2 2 3 0 V GND Channel 1 and channel 2 1 4 FE 2 4 FE Table 5 Terminal point assignment for connector 2 Terminal point Signal Channel assignment LED 3 1 OUT1_Ch1 Output 1 channel 1 1 1 4 1 OUT1_Ch2 Output 1 channel 2 1 2 3 2 Not used 4 2 Not used 3 3 0 V GND Channel 1 and channel 2 4 3 ...

Page 27: ...ED 7 1 OUT3_Ch1 Output 3 channel 1 3 1 8 1 OUT3_Ch2 Output 3 channel 2 3 2 7 2 Not used 8 2 Not used 7 3 0 V GND Channel 1 and channel 2 8 3 0 V GND Channel 1 and channel 2 7 4 FE 8 4 FE WARNING Loss of functional safety due to parasitic voltages Connect the ground of the actuator to the ground terminal point of the corresponding output on the VersaPoint connector An external ground may not be use...

Page 28: ...while the power is connected Before assembling or removing the module disconnect the power to the module and the entire VersaPoint station and ensure that it cannot be switched on again Make sure the entire system is reassembled before switching the power back on Observe the diagnostic indicators and any diagnostic messages The system may only be started provided neither the station nor the system...

Page 29: ... switch The DIP switches are located on the left hand side of the safety module Figure 6 DIP switches A Switch for setting the transmission speed B Switch for setting the address island number Important The numbers located directly on the 10 position DIP switch should be ignored When using this switch please refer only to the laser etched numbers on the plastic housing he module 2 pos DIP switch T...

Page 30: ...al information on addressing please refer to VersaSafe address assignment on page 76 Note Malfunction during mixed operation During simultaneous use of IC220SDL953 and IC220SDL963 on a controller make sure that the island number of the IC220SDL963 system is 8 This should be checked during overall validation of the system Use switches 9 to 5 to set the island number An island always consists of the...

Page 31: ...nnectors from the safety terminal and the adjacent connectors from the neighboring VersaPoint terminal on the left This prevents the potential routing knife contacts and the keyway featherkey connections from being damaged Hold the safety module perpendicular and snap it onto the DIN rail 7 5 mm in height Important Ensure that all featherkeys and keyways on adjacent terminals are securely interloc...

Page 32: ...le remove the connectors from the safety module and the adjacent connector from the neighboring VersaPoint terminal on the left Remove connectors Remove the connector by pressing the back shaft latching A and levering off the connector B Figure 9 Removing the connector Remove base Release the base by pressing on the front and back snap on mechanisms A and pull it out perpendicular to the DIN rail ...

Page 33: ...ed before switching the power back on The system may only be started provided the system does not pose a hazard 4 2 1 Electrical installation of the VersaPoint station Electrical installation of the VersaPoint station includes the following Connecting the bus system to the VersaPoint station Connecting the supply voltages for the VersaPoint station Carry out electrical installation for the VersaPo...

Page 34: ...e only involves connecting the actuators The actuators are connected via VersaPoint connectors Wire the connectors according to your application For the terminal point assignment please refer to Terminal point assignment on page 19 For wiring proceed as follows Strip 8 mm off the cable Important VersaPoint wiring is normally done without ferrules However it is possible to use ferrules If using fer...

Page 35: ...oval and electrical installation 29 Insert the assembled connectors in the corresponding module slot see Terminal point assignment on page 19 Mark all connections to prevent connections to the VersaPoint connectors being mixed up see GFK 2736 user manual ...

Page 36: ...fe island Set the same island number both in VersaConf Safety and on the module Important For additional information on the island number please refer to VersaSafe address assignment on page 76 Set this address via the DIP switches prior to assembling the safety module see Setting the DIP switches on page 23 Parameterization and configuration of the module Parameterization and configuration determ...

Page 37: ...y integrity levels SIL SIL CL Cat PL Two channel If the outputs are operated via two channels the following fixed assignment applies OUT0_Ch1 to OUT0_Ch2 OUT1_Ch1 to OUT1_Ch2 OUT2_Ch1 to OUT2_Ch2 OUT3_Ch1 to OUT3_Ch2 Single channel If two channel operation in the external wiring of the outputs is not required the outputs can be parameterized in such a way that they operate independently of one ano...

Page 38: ...ily enabled for test purposes Please observe the notes below this table Enable Disabled Enabled Disabled default value the corresponding safe output is operated exclusively according to the safety logic Enabled enable is active the safe output data is output after being ANDed with the Data_LPSDO process data item Section A 4 See also Enable principle on page 80 Test pulses Note Note on test pulses...

Page 39: ...ation of the switch off delay the time until the outputs are actually switched off can vary Table 10 Switching off of the outputs according to the trigger event and the parameterization Switch off of outputs Influence of parameterized switch off delay Switch off of outputs By the controller Yes Once the parameterized switch off delay has elapsed After a bus error Yes Once the parameterized switch ...

Page 40: ... are switched off immediately without delay In this case only stop category 0 is supported For the switch off operation please take into consideration the following The switch off operation can be interrupted by switching the output on again The switch off delay is not guaranteed if a reparameterization or download is initiated Carry out a validation every time the parameterization is modified ...

Page 41: ...ion If a message is transmitted to the controller in the event of an error the message is specified in the tables For information on the relevant error code possible solutions and information as to whether acknowledgment is required please refer to Section Errors messages and removal on page 50 Typical parameterization The table illustrates an example of all the parameters for the specified assign...

Page 42: ...e specified SIL SIL CL Cat PL WARNING Disregarding this warning may lead to the loss of the safety function An external voltage may not be supplied in an output e g via cross circuits These errors can adversely affect the operation of the module or even destroy the module and therefore result in the loss of the safety function Therefore these errors must be prevented Install the connecting cables ...

Page 43: ... can be achieved is specified for each connection example Important Please also refer to Section Achievable safety depending on the modules used on page 89 SIL SIL CL Important Use the relevant standard to determine the probability of failure in your application according to IEC 61508 2 SIL and EN 62061 SIL CL When the SIL SIL CL is specified the module takes up 1 of the specified SIL SIL CL Table...

Page 44: ...actuators on page 10 Please note that mechanical failure of the switching device can result in the loss of the safety function Prevent the welding of contacts on the connected contactors or safety relays with appropriate protection against overcurrent and surge voltage All errors that cannot be detected can result in the loss of the safety function Take appropriate measures to prevent such errors ...

Page 45: ...gnment of the outputs a two channel actuator must be used The two channel operation of the actuator with the corresponding connection is represented on a gray background The failure detection time is 20 ms This means that high pulses of this width can occur in the event of an error If the application responds to these pulses use the two channel assignment of the outputs K1 R and K2 R represent the...

Page 46: ...pulses to improve device diagnostics If the test pulses for the actuator are faulty they can be disabled In this case test the switching capability of the outputs at regular intervals Device diagnostics and behavior of the module in the event of an error Table 14 Single channel test pulses enabled Error type Dete ction Diagnosti cs Loss of SF Remark Error in the actuator Despite being disabled the...

Page 47: ...rload OUTx No The error is detected in the ON state The output is disabled safe state The module cannot be switched on again with an edge from 0 to 1 until the error has been removed and acknowledged WARNING Unexpected machine startup An operator acknowledgment leads to a positive edge and can therefore result in the outputs being re enabled Typical parameterization Parameterization Parameterized ...

Page 48: ... relay readback contacts Connect these contacts via safe digital inputs Evaluate the readback and therefore the state of the switching elements in your safety logic WARNING Loss of safety function Connect the actuator ground directly to terminal point GND of the safety module An external ground may not be used The failure detection time is 20 ms This means that high pulses of this width can occur ...

Page 49: ... they can be disabled In this case test the switching capability of the outputs at regular intervals Device diagnostics and behavior of the module in the event of an error Table 15 Two channel Error type Detect ion Diagnos tics Loss of SF Remark Error in the actuator Despite being disabled a switching No None No No loss of the safety function as the second switching element of the two channel actu...

Page 50: ... pulses have been disabled test the circuit and the external wiring at regular intervals by enabling the outputs Short circuit Output to ground Or output to FE Yes Short circuit or overload OUTx No The error is detected in the ON state The output is disabled safe state The module cannot be switched on again with an edge from 0 to 1 until the error has been removed and acknowledged WARNING Unexpect...

Page 51: ...meterized as Remark Channel 1 Channel 2 Test pulses output disabled in software test impulses output switched off Enabled Enabled According to the Value range of switch off delay for stop category 1 and Switch off delay for stop category 1 parameters in this example the switch off delay is 30 x 1 s 30 s ...

Page 52: ...dress island number Setting the DIP switches on page 23 Install the safety module within the VersaPoint station Assembly removal and electrical installation on page 22 Connect the bus system and supply voltage cables to the GFK 2736 user manual or documentation for the bus coupler VersaPoint station Wire the outputs according to your application Assembly removal and electrical installation on page...

Page 53: ...nd electrical installation on page 22 Implement data flow between the standard control system and the safety modules and between the safety modules themselves IC220SDL963 system handling in various control systems on page 80 Download the parameterization and configuration data from the standard control system to the safety modules Downloading the configuration and parameter data record on page 85 ...

Page 54: ...sure that the new safety module is mounted at the correct position in the local bus The new module must meet the following requirements Same device type Same or later version Note Versions that are not compatible for replacement The IC220SDL963 device type is not the same as the IC220SDL953 and is therefore not compatible for replacement Carry out a validation and perform a function test after rep...

Page 55: ...tion 49 The safety module has been parameterized correctly The signals used in your safety logic have been linked to the safe actuators correctly Perform a function test and error simulation Please observe the checklist Validation on page 102 during validation ...

Page 56: ... errors Chapter 8 4 on page 53 X3FC X7C4 Connection errors to satellites Chapter 8 5 on page 55 As the first digit is never relevant the code always starts with an X For every error that occurs the cause of the error must first be removed If necessary the error is then acknowledged Errors that must be acknowledged are indicated in the Acknowledgment column in the tables below Important If diagnost...

Page 57: ... output cannot be disabled All other module outputs are in the safe state Power up with error free selftest Replacement Yes 1 OUT X011 OUT1_Ch1 X012 OUT2_Ch1 X013 OUT3_Ch1 X018 OUT1_Ch2 X019 OUT2_Ch2 X01A OUT3_Ch2 red ON Short circuit or overload X03n OUTy Affected output is in the safe state Check actuator Check plug and Cabling Check free wheeling circuit at the contactor Yes 2 red X030 OUT0_Ch1...

Page 58: ...abled Acknowledgment yes 1 Acknowledging the diagnostic message deletes the message The module can only be re started or reparameterized following power up or soft reset and error free selftest Acknowledgment yes 2 Acknowledging the diagnostic message deletes the message and enables a restart Following successful acknowledgment the module also expects a positive edge from the application for the o...

Page 59: ... yes 4 Acknowledging the diagnostic message deletes the message 8 4 Parameterization errors Table 22 Parameterization errors Error cause Diagnosti c code hex LED Remark Effect Solution Ackno wledg ment Incorrect parameterization See Table 23 FS flashing Each output is parameterized individually Module is in the safe state Check and correct parameterization In order to determine what type of parame...

Page 60: ...3_Ch1 2 X28n The parameterized switch off delay time for the output is outside the permissible value range Correct value and resend parameter data to the module X280 OUT0_Ch1 640 OUT0_Ch1 X281 OUT1_Ch1 641 OUT1_Ch1 X282 OUT2_Ch1 642 OUT2_Ch1 X283 OUT3_Ch1 643 OUT3_Ch1 X287 OUT0_Ch2 647 OUT0_Ch2 X288 OUT1_Ch2 648 OUT1_Ch2 X289 OUT2_Ch2 649 OUT2_Ch2 X28A OUT3_Ch2 650 OUT3_Ch2 X29n For outputs parame...

Page 61: ... The F_Source_Address set on the device is not within the permissible value range Check and correct switch position Communication Connection faulty XD00 See X500 the OAR bit is set in the diagnostic register of the IC220SDL963 8 6 Acknowledging an error In the VersaSafe system the errors of the IC220SDL963 as well as those of the corresponding island satellites must be acknowledged via the IC220SD...

Page 62: ...20 Errors messages and removal 56 If in the event of failure the safety module is replaced please proceed as described in Chapter 4 Assembly removal and electrical installation and Section Restart after replacing a safety module on page 48 ...

Page 63: ...rror send the module to Emerson It is strictly prohibited to open the safety module In order to prevent the manipulation of the module and to detect the unauthorized opening of the module a security seal is applied to the module This security seal is damaged in the event of unauthorized opening In this case the correct operation of the safety module can no longer be ensured 9 3 Decommissioning and...

Page 64: ...IC220SDL963 16 satellites IC220SDLxx freely mixed Memory capacity 30 kB for safety logic 10 2 IC220SDL963 General data Housing dimensions width x height x depth 48 8 x 119 8 x 71 5 mm Weight with connectors 200 g Operating mode IC220SDL963 Process data mode with 24 words Transmission speed local bus 500 kbaud or 2 Mbaud Ambient temperature Operation 25 C to 55 C Storage transport 25 C to 70 C Humi...

Page 65: ...ent conditions Temperature 25 C 2 K Humidity 75 5 Test duration 10 days Hydrogen sulfide H2S Concentration 1 0 3 ppm Ambient conditions Temperature 25 C 2 K Humidity 75 5 Test duration 4 days Resistance of the housing material to termites Resistant Resistance of the housing material to fungal decay Resistant Ambient compatibility Not resistant to chloroform Connection data for VersaPoint connector...

Page 66: ... characteristic data according to EN 62061 Achievable SIL claim limit SIL CL SIL 2 single channel SIL CL SIL 3 two channel Depends on the parameterization and wiring see Connection options for actuators depending on the parameterization on page 12 and Connection examples for safe outputs on page 35 Safe failure fraction SFF 99 Probability of a dangerous failure per hour for the entire module PFH S...

Page 67: ...tage UM via the bus coupler an VersaPoint controller or a power terminal in the station Potential routing is used for the main voltage in the VersaPoint station For technical data please refer to the data sheet for the bus coupler VersaPoint controller or power terminal used WARNING Loss of the safety function when using unsuitable power supplies Only use power supplies according to EN 50178 VDE 0...

Page 68: ... unit must be able to supply four times 400 the nominal current of the external fuse Safe digital outputs OUT0 to OUT3 Number 4 two channel or 8 single channel positive switching Supply From supply voltage UM Maximum output current per output 2 A Maximum output current for all outputs total current 6 A observe derating and maximum output current for each group Maximum output current for each group...

Page 69: ...Shaded area permissible range Minimum load 1 5 kΩ 16 mA at 24 V Limitation of the voltage induced on circuit interruption 15 V Output voltage UM 1 V approximately Simultaneity 100 up to 45 C observe maximum current load Derating Up to 50 C total current of all outputs 6 A maximum Up to 55 C total current of all outputs 4 A maximum Maximum switching frequency 1 Hz 0 2 Hz at 1 A Filter time None Swi...

Page 70: ...lses Electrical isolation isolation of the voltage areas Important To provide electrical isolation between the logic level and the I O area it is necessary to supply the bus coupler and this safety module from separate power supply units Interconnection of the power supply units in the 24 V area is not permitted See also GFK 2736 user manual Separate potentials in the system consisting of bus coup...

Page 71: ...V symmetrical asymmetrical Conducted interference EN 61000 4 6 IEC 61000 4 6 Criterion A test voltage 10 V Noise emission test according to DIN EN 61000 6 4 Noise emission EN 55011 Class A industrial applications 10 4 Ordering data 10 4 1 Ordering data safety module Description Type Pcs Pkt VersaPoint module with integrated safety logic and safe digital outputs IC220SDL963 1 10 4 2 Ordering data a...

Page 72: ...mentation Description Type Pcs Pkt VersaPoint User manual Automation terminals of the VersaPoint product range GFK 2736 1 VersaSafe Integration Guide GFK 2735 1 Important Make sure you always use the latest documentation It can be downloaded athttps www emerson com Industrial Automation Controls support ...

Page 73: ...36 System Installation Manual no special installation guidelines have to be observed when installing the corresponding modules They can be distributed in the network and operated at any point in the I O station Due to the technology used a special bus coupler is not required as the safety operations are processed directly in the IC220SDL963 intelligent safe output module Thanks to the comprehensiv...

Page 74: ...nces in VersaSafe systems depending upon which module with integrated safety logic is used Table 25 VersaSafe system specifications Functionality IC220SDL953 IC220SDL963 Supported networks PROFIBUS PROFIBUS PROFINET PROFINET Modbus TCP Modbus TCP DeviceNet DeviceNet Number of safe communications 5 IN OUT mixed 16 IN OUT mixed Size of memory for the safety logic 20 kB 30 kB Retentive storage Yes Ye...

Page 75: ...ledgment 2 bytes 4 bytes Block diagnostics No Yes App Diag LPSDO application diagnostics The bits in this register can be freely programmed in VersaConf Safety Implement diagnostics using these bits App Ack LPSDO application acknowledgment for IC220SDL963 The bits in this register can be freely programmed in VersaConf Safety and can be used for the safety logic Implement application acknowledgment...

Page 76: ... network Control level A standard control system is used as the controller see also Section Network and controller requirements on page 71 I O level Safe devices are integrated into the VersaPoint station at I O level Safe and standard devices can be operated simultaneously in the overall system Communication Communication takes place via the standard control system and the standard bus system usi...

Page 77: ... Important Application code for integration of VersaSafe in PACSystems RX3i RXi are available in PAC Machine Edition Refer GFK 2735 VersaSafe Integration Guide for support on integration A 2 3 Safe input and output devices Safe input and output devices form the interface to the connected I O devices The devices control contactors or valves for example and or read the input status of connected safe...

Page 78: ...etween the islands This is achieved exclusively by connecting the logic modules The IC220SDL963 can be used as a VersaSafe satellite with 16 safe inputs and outputs for a different IC220SDL963 The IC220SDL963 SL SL slave can be found in the hardware toolbox in VersaConf Safety Figure 17 VersaConf Safety hardware toolbox Once you have inserted the IC220SDL963 SL in the hardware editor the module ap...

Page 79: ...ety project for the IC220SDL963 master module In the parameterization dialog box for the IC220SDL963 SL set the number of the island that is now connected This island number must match the switch position of the IC220SDL963 for the connected island Figure 19 Parameterization dialog box ...

Page 80: ...module Figure 20 VersaConf Safety project for the IC220SDL963 slave module Cross communication output Q1 of the IC220SDL963 SL in the master project corresponds to cross communication input 0_II1 of the IC220SDL963 SL project Up to 16 safe signals can therefore be exchanged bidirectionally between two IC220SDL963 modules A master project can communicate with a maximum of 16 IC220SDL963 modules Not...

Page 81: ...hat are used as the basis for creating master projects Hierarchical topology Flat topology Both variants can be combined Example 1 hierarchical topology This example consists of 4 islands Table 27 Hierarchical topology Island Master Slave Island 1 LPSDO LPSDO SL 1 LPSDO SL 2 LPSDO SL 3 Island 2 LPSDO SL 1 PSDI 1 PSDI 2 PSDO 1 PSDO 2 Island 3 LPSDO SL 2 PSDI 1 PSDI 2 PSDO 1 PSDO 2 Island 4 LPSDO SL...

Page 82: ...verall system consisting of the VersaSafe system and a PROFIsafe system the addresses are unique Duplicate address assignment is not permitted Note Malfunction during mixed operation During simultaneous use of IC220SDL953 and IC220SDL963 on a controller make sure that the island number of the IC220SDL963 system is 8 This should be checked during overall validation of the system The VersaSafe addre...

Page 83: ...ress F Address 9 8 7 6 5 4 3 2 1 0 IC220SDL963 1dec 0dec 32dec 20hex 0 0 0 0 1 0 0 0 0 0 IC220SDL543 Position 1 1dec 1hex 1dec 1hex 33dec 21hex 0 0 0 0 1 0 0 0 0 1 IC220SDL753 Position 2 1dec 1hex 2dec 2hex 34dec 22hex 0 0 0 0 1 0 0 0 1 0 Table 32 Example 2 VersaSafe addresses Island number Satellite number VersaSafe address 9 8 7 6 5 4 3 2 1 0 IC220SDL963 4dec 4hex 0dec 0hex 128dec 80hex 0 0 1 0 ...

Page 84: ...sses actually used in the example in Figure 23 are in bold Table 33 Example addresses for VersaSafe islands Addresses for island number 1 red in Figure 23 Addresses for island number 2 green in Figure 23 Device 00001 00000 00010 00000 IC220SDL963 island node 20hex 40hex 00001 00001 00010 00001 Assigned IC220SDL543 IC220SDL543 21hex 41hex 00001 00010 00010 00010 Assigned IC220SDL543 IC220SDL543 22h...

Page 85: ...aphics below show the red and green project in the hardware editor in VersaConf Safety The DIP switch position can be displayed here Important The switch position can be displayed in VersaConf Safety by right clicking in the hardware editor and selecting Display address switch Figure 24 DIP switch position of island number 1 red in Figure 23 in VersaConf Safety Figure 25 DIP switch position of isl...

Page 86: ... parameterized enabled disabled for each specific channel When the enable function is enabled the relevant safe local output is ANDed bit by bit with the corresponding standard output of the standard control system This output is then only set if the result of the safety function calculation permits this and the standard control system has set the corresponding output The enable function is perfor...

Page 87: ...Data LPSDO x Standard data of the standard control system which is to enable the IC220SDL963 bit x OUTx_Chy Output x channel y Internal sequences Table 34 Parameterization of output channels for the example in Figure 26 Output channel Output Enable OUT0_Ch1 Single channel Enabled OUT0_Ch2 Single channel Enabled OUT1_Ch1 Two channel Enabled OUT1_Ch2 Two channel Enabled OUT2_Ch1 Two channel Enabled ...

Page 88: ...rd control system Important For more detailed information on error detection at the safe inputs please refer to the user manual for the IC220SDL543 IC220SDL544 Safe outputs Depending on the device type and parameterization the following errors can be detected at safe outputs Short circuit Cross circuit Overload When an error is detected at an output the affected output is disabled 0 OFF safe state...

Page 89: ...gment is forwarded to the satellites Important An example for the acknowledgment of error messages can be found in the quick start guides for the IC220SDL963 see Section Ordering data documentation on page 66 A 7 Configuration parameterization and download Important An example for configuration parameterization and download can be found in the quick start guides for the IC220SDL963 see Section Ord...

Page 90: ...ower up make this data record available to the IC220SDL963 island node see Section Downloading the configuration and parameter data record on page 85 The IC220SDL963 module is parameterized in this way The satellites are parameterized automatically by the IC220SDL963 module VersaConf Safety can be used as a stand alone tool However depending on the control system calling VersaConf Safety can also ...

Page 91: ...IC220SDL963 If a data record is sent to an IC220SDL963 for which it was not intended an error message is displayed in the diagnostic output of the handling block A 8 Safe state The safe state For safe output devices the safe state is the power off state at the affected output terminals For safe input devices the safe state is the transmission of the safe state value 0 in the image of the affected ...

Page 92: ...em is not relevant and not suitable for dimensioning safety distances Figure 27 Typical response time and required shutdown time for the safety function Table 35 Key for formula and Figure 26 Abbreviation Meaning Note tSF Required shutdown time for the safety function Determined from the application e g from the required times according to the distance of a light grid Important The typical respons...

Page 93: ...erial chains of IC220SDL963 modules may be implemented within a safety function Table 36 Key for formula and Figure 26 Abbreviatio n Meaning Note A Demand of the safety function B Safe state of the system tSF Required shutdown time for the safety function Determined from the application e g from the re quired times according to the distance of a light grid tS Response time of the sensor Sensor dat...

Page 94: ...FWD The F Watchdog time tFWD is specified for each communication relationship in VersaConf Safety The minimum achievable tFWD depends on the network and the controller see documentation for the controller used Important When specifying the F Watchdog time please remember that it can be affected by future system expansions Within tFWD the standard network and the standard control system must be abl...

Page 95: ...el of safety that can be achieved A 11 Behavior in the event of an error Error messages Errors that occur on the safe devices can be detected using process data functional blocks device LEDs These error messages can be evaluated in the standard application program or can be displayed by means of a visualization Important For instructions on how to proceed in the event of an error please refer to S...

Page 96: ...this class are usually errors within the system the hardware or the firmware which were not caused by the user and cannot be removed device specific exceptions are possible It is not possible to acknowledge the error or continue operating The affected devices can only be restarted via a voltage reset If the power on self tests are successful following a restart the system can continue to operate A...

Page 97: ...A 11 4 I O errors All errors that can occur and are detected within the I O devices connected to the safe I O devices are assigned to this class They include for example Short cross circuits at the inputs or outputs Other application specific errors These errors are usually indicated in the operating phase of the system When an error is detected the affected input or output is disabled and a diagn...

Page 98: ...NING Unexpected machine startup If you do not want the machine to restart automatically configure the safety logic accordingly A 13 Memory sizes for the safety logic The maximum size of the safety logic is 30 kB The following guide values can be used as a basis for creating your safety logic Functional block instances 96 If the safety logic limit has been exceeded a corresponding error message is ...

Page 99: ...aSafe system 93 Functional blocks Functional block instances 3 1 0 Safety functions CTUD F_TRIG PULSE_GEN R_TRIG RS SR TOF TON TP X Standard functions CTUD F_TRIG PULSE_GEN R_TRIG RS SR TOF TON TP X Logic functions AND EN_OUT EQ NOT_EQ NOT OR XOR X ...

Page 100: ...n IC220SDL963 Node1 Version HW FW FW AA 00 100 100 Date 2011 03 01 Author John Smith Test engineer Jane Brown Remark System XXX has been checked for engine hood production No Requirement mandatory Yes Remark X No Requirement optional Yes No Remark Y Key Equipment identification Enter the device type and or the equipment identification for the relevant device Version HW FW FW Enter the hardware and...

Page 101: ...ns e g by using functional blocks 9 Does the planned use correspond to the intended use of the system 10 Has the technical data of the VersaSafe system been observed 11 Has it been ensured that in an overall system consisting of the VersaSafe system and any higher level PROFIsafe system the addresses address within the VersaSafe system and F Address of the PROFIsafe system are unique 12 Within a V...

Page 102: ...22 Are the specifications for parameterization assembly electrical installation startup and validation of the satellites described 23 Is the assignment of responsibility specified e g for assembly installation configuration parameterization startup validation etc Name company 24 Are measures planned which prevent hazardous states in each phase e g specification of individual steps in the procedure...

Page 103: ...as the correct terminal point been assigned to the correct signal 7 Is the island address set correctly 8 For IC220SDL963 outputs that are parameterized for two channel operation are both channels parameterized correctly for each other 9 For satellite inputs that are parameterized for two channel operation are both channels parameterized correctly for each other 10 For satellite outputs that are p...

Page 104: ...lly can only do so with a direct view of the danger zone No Requirement optional Yes No Remark 2 Are startup specificationsapplicable 3 If applicable have startup specificationsbeen met Date Signature author Date Signature test engineer B 1 4 Safety functions Enter all the safety functions for your application in this checklist Checklist for checking safety functions Equipment identification Date ...

Page 105: ...ave different island addresses 7 Has it been ensured that in the overall system consisting of VersaSafe and any higher level PROFIsafe system the addresses address within the VersaSafe system and F Address of the PROFIsafe system are unique 8 Has the VersaConf Safety project been printed with the project information name CRC time stamp etc 9 Has the CRC of the VersaConf Safety project printout bee...

Page 106: ...ce with PELV 6 Has the power supply of UM and US from a power supply unit been planned 7 Is external protection of the module planned according to the specifications in this user manual for supply voltage UM 8 Is use in a control cabinet IP54 planned 9 Are measures planned to prevent simple manipulation 10 Are measures planned to prevent plugs being mixed up 11 Are requirements for the actuators a...

Page 107: ...or Test engineer Remark No Requirement mandatory Yes Remark 1 Was assembly and installation completed according to the specifications specifications from the planning phase or according to the user manual 2 Was the safety module installed in the control cabinet IP54 3 Do the cable cross sections correspond to the specifications 4 Are requirements for the actuators and cable installation observed a...

Page 108: ...nature author Date Signature test engineer B 2 4 Validation Checklist for validating the safety module Device type equipment identification Version HW FW FW Date Author Test engineer Remark No Requirement mandatory Yes Remark 1 Have all the mandatory requirementsfor the Planning checklistbeen met 2 Have all the mandatory requirementsfor the Assembly and electrical installation checklist been met 3...

Page 109: ...tage UM 12 Have measures been taken to prevent simple manipulation 13 Have measures been taken to prevent plugs being mixed up 14 Are the requirementsfor the actuators and cable installationobserved according to the SIL SIL CL Cat PL to be achieved 15 Are the specificationsfor the parameterizationfor each channel implemented 16 Are testintervalsspecifiedfortestingthe shutdowncapabilityofthe actuat...

Page 110: ...vision Date Contents 00 03 Apr 2003 First publication A 09 Jan 2020 Following Emerson s acquisition of this product changes have been made to apply appropriate branding and registration of the product with required certification agencies No changes to material process form fit or functionality ...

Page 111: ...ht to modify or improve the designs or specifications of the products mentioned in this manual at any time without notice Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any Emerson product remains solely with the purchaser 2019 Emerson All rights reserved Emerson Terms and Conditions of Sale are ...

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