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GE VersaSafe VersaPoint IC220SDL840 User Manual Download Page 85

8

GFK-2734

Chapter 8 Startup and validation

8-1

8

Startup and validation

8.1

Initial startup

To start up, proceed as described in Table 8-1.

Table 8-1

Steps for startup

Step

Relevant section and literature

Set the transmission speed and the mode.

Section "Setting the DIP switches" on page 4-2

Set the protocol/address.

Section "Setting the DIP switches" on page 4-2

Install the safety module within the VersaPoint station.

Section "Assembly, removal, and electrical installation" on 
page 4-1

Connect the bus system and supply voltage cables to the 
VersaPoint station.

GFK-2736 or documentation for the bus coupler

Wire the relay outputs according to your application.

Section "Assembly, removal, and electrical installation" on 
page 4-1

Section "VersaPoint potential and data routing" on page 3-1

User manuals for the function blocks used

Before applying the operating voltage:

–

Ensure that there are no wiring errors (e.g., cross 
circuit or short circuit) or grounding errors by testing 
with a multimeter.

–

Check whether the ground connection is safe.

Connect the required voltages to the VersaPoint station.

GFK-2736 or documentation for the bus coupler

Connect the required voltages (U

M

) to the safety module.

Section "Supply voltage U

M

" on page 3-2

Once the operating voltage has been applied:

–

If possible, measure the wave form of the voltages to 
ensure that there are no deviations.

–

Measure the output voltages on the module, as well as 
the supply voltages, which supply the connected loads 
(e.g., motor) to ensure that they are in the permissible 
range.

–

Use the LEDs on the devices to check that the module 
starts up without any errors (there must be no red LEDs 
permanently on; the FS LED flashes because the 
device is not parameterized).

Check  the assembly  and  installation.

Checklist "Assembly, removal, and electrical installation" on 
page 4-1

Carry out the necessary parameterization.

Section "Parameterization of the safety module" on 
page 5-1

Documentation for SafetyProg software

Documentation for the configurable logic module used 
(VersaSafe)

Documentation for the controller used (PROFIsafe)

Summary of Contents for VersaSafe VersaPoint IC220SDL840

Page 1: ...GE Intelligent Platforms VersaSafe VersaPoint Module IC220SDL840 SAFE OUTPUT RELAY 4 PT User s Manual GFK 2734 Programmable Control Products May 2018 ...

Page 2: ...T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y ...

Page 3: ...le with safe digital relay outputs GFK 2734 Catalog No Revision IC220SDL840 HW FW FW 00 200 100 HW FW FW 00 201 100 User s Manual Catalog No Revision This user manual is valid for 04 2018 05 15 HW FW FW BA 01 201 100 ...

Page 4: ...sible property damage and general information concerning proper operation and ease of use This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER This indicates a hazardous situation which if not avoided will result in death or serious injury WARNING This indicates a hazar...

Page 5: ...s of the information contained herein No warranties of merchantabil ity or fitness for purpose shall apply How to contact us Internet Up to date information on GE Intelligent Platforms products and our Terms and Conditions can be found on the Internet at www ge ip com Make sure you always use the latest documentation It can be downloaded at http support ge ip com Subsidiaries If there are any prob...

Page 6: ...T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y User manual IC220SDL840 May 2018 GFK 2734 ...

Page 7: ... Connection options for actuators depending on the parameterization 2 9 2 9 Local diagnostic and status indicators 2 10 2 10 Safe state 2 12 2 10 1 Operating state 2 12 2 10 2 Error detection in I O devices 2 12 2 10 3 Device errors 2 13 2 10 4 Parameterization errors 2 14 2 11 Enabling safe outputs for PROFIsafe 2 14 2 12 Process data words 2 15 2 12 1 PROFIsafe PROFIBUS PROFINET 2 17 2 13 Progra...

Page 8: ...otes on the protective circuit for external relays contactors free running circuit 6 2 6 3 Measures required to achieve a specific safety integrity level 6 3 6 4 Single channel assignment of safe relay outputs 6 5 6 5 Two channel assignment of floating contacts 6 9 6 5 1 Monitoring via common readback 6 9 6 5 2 Monitoring via separate readback 6 13 6 5 3 External monitoring 6 16 6 6 Safety related...

Page 9: ...owledging an error for VersaSafe 9 6 9 5 2 Acknowledging an error for PROFIsafe 9 6 10 Maintenance repair decommissioning and disposal 10 1 10 1 Maintenance 10 1 10 2 Repair 10 1 10 3 Decommissioning and disposal 10 1 11 Technical data and ordering data 11 1 11 1 System data 11 1 11 1 1 VersaPoint 11 1 11 1 2 VersaSafe 11 1 11 1 3 PROFIsafe 11 1 11 2 IC220SDL840 11 1 11 3 Conformance with EMC Dire...

Page 10: ... 1 Diagnostic messages for F Parameters and iParameters for PROFIsafe B 3 B 3 2 Diagnostic messages for parameter errors for VersaSafe B 4 C Appendix Checklists C 1 C 1 Planning C 2 C 2 Assembly and electrical installation C 4 C 3 Startup and parameterization C 5 C 4 Validation C 6 D Index D 1 iv User manual IC220SDL840 May 2018 GFK 2734 ...

Page 11: ...OFIsafe system the following operations may only be carried out by qualified personnel Planning Configuration parameterization programming Installation startup servicing Maintenance decommissioning This user manual is therefore aimed at Qualified personnel who plan and design safety equipment for machines and systems and are familiar with regulations governing safety in the workplace and accident ...

Page 12: ...s 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 Measures to prevent incorrect connection and polarity reversal Take measures to prevent the incorrect connection polarity reversal and manipulation of connections 1 2 Electrical safety WARNING Hazardous body currents and the los...

Page 13: ...32 V even in the event of an error Insulation rating When selecting the operating equipment please take into consideration the contamination and surge voltages which may occur during operation The IC220SDL840 module is designed for surge voltage category II according 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 ...

Page 14: ...Within a VersaSafe or PROFIsafe system the IC220SDL840 safety module can be used to achieve safety functions with the following requirements Up to SIL 3 according to standard EN 61508 Up to SIL CL 3 according to standard EN 62061 Up to Cat 4 PL e according to standard EN ISO 13849 1 Check hardware and parameterization Carry out a validation every time you make a safety related modification to your...

Page 15: ...ing to standard EN 61508 Up to SIL CL 3 according to standard EN 62061 Up to Cat 4 PL e according to standard EN ISO 13849 1 It is designed for connecting single channel or two channel actuators which can be used in association with safety technology For example the module can be used in the following applications Safety circuits according to EN 60204 Part 1 Safe shutdown of contactors motors 24 V...

Page 16: ...sed Table 1 1 Abbreviations used Abbreviation Meaning Standard Example SIL Safety integrity level EN 61508 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 Performance level EN ISO 13849 1 PL e PL d Table 1 2 Abbreviations used Abbreviation Meaning PELV Protective extra low voltage A circuit in which the voltage does not exceed 30 V AC 42 4 V peak val...

Page 17: ...station in a VersaSafe or PROFIsafe system The module has a 10 pos DIP switch which is used to set the VersaSafe or PROFIsafe address The module has four safety relays which can be operated via one or two channels depending on the parameterization The relay outputs can be parameterized according to the application and enable the integration of actuators in the VersaSafe system or in the PROFIsafe ...

Page 18: ...Point connector for assignment see Section Terminal point assignment on page 3 4 7 Terminal points 8 COMBICON connector 9 Diagnostic and status indicators for assignment and meaning see Section Local diagnostic and status indicators on page 2 10 10 Labeling field For more detailed information about setting the switches please refer to Setting the DIP switches on page 4 2 77221007 0 PS DO R D 1 IN1...

Page 19: ...2 GFK 2734 Chapter 2 Product description 2 3 2 3 Housing dimensions Figure 2 2 Housing dimensions in mm 77222001 71 5 73 2 119 8 9 8 7 6 5 4 3 2 1 0 ...

Page 20: ...mum short circuit current IK of 250 A must not be exceeded Make sure that the miniature circuit breaker trips in the event of a short circuit for your DC application This depends on the power supply unit used Two two channel relay outputs Four single channel relay outputs OUT0_Ch1 Relay output 0 channel 1 OUT0_Ch2 Relay output 0 channel 2 OUT1_Ch1 Relay output 1 channel 1 OUT1_Ch2 Relay output 1 c...

Page 21: ... actuators The error detection of the module varies depending on the parameterization This results in specific requirements for the actuators Only use appropriately qualified actuators Use reliable components These include for example Use relays or contactors with forcibly guided N C contacts to safely monitor the state pick up drop out Please observe any special environmental requirements in your...

Page 22: ...e last terminal before another power supply unit or at the end of the station Only VersaPoint terminals that are specifically designed for this safety related segment circuit may be used The safety module can be used to safely connect or disconnect the supply voltage segment supply to the subsequent VersaPoint terminals in the safety related segment circuit A maximum of 4 A can be switched in this...

Page 23: ...e parameterized Technical data For the technical data for the clock outputs please refer to page 11 7 Error detection Error detection is via the assigned alarm input Diagnostics The diagnostics of clock outputs and the associated alarm inputs are based on the expected behavior for the corresponding signals depending on the switching state of the monitored load NOTE Incorrect use of the clock outpu...

Page 24: ...of deviations the affected outputs are switched off and a diagnostic error message is sent to the safe controller Through the dynamization of signals and the corresponding expected behavior in the device firmware all errors which can occur internally in the circuit or externally in the wiring are detected Diagnostics Diagnostics of the alarm inputs are provided via both the local diagnostic indica...

Page 25: ...er to achieve this Observe the information in the connection examples see Section 6 Connection examples for the safe relay outputs and the safety related segment circuit 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 6 3 Relay output S...

Page 26: ...interface between previous and flashing terminal the terminals after the flashing terminal cannot be addressed E g loose contact at the bus interface terminal before the flashing terminal has failed another terminal was snapped on during operation not permitted ON Communications power present local bus active FS Red LED Failure state Flashing at 1 Hz Device not parameterized or parameterization wa...

Page 27: ...reset IN1 IN2 Green LED Status of each alarm input see Terminal point assignment on page 3 4 Green Input at logic 1 OFF Input at logic 0 no error P Green LED Status indicator for safe communication OFF No safe communication Flashing at 0 5 Hz Safe communication running the controller requests operator acknowledgment ON Safe communication running without errors Table 2 1 Local diagnostic and status...

Page 28: ...if the alarm inputs are used An external load does not drop out if the alarm inputs are used The relevant diagnostic message is transmitted to the safe controller see Section Safe digital relay output errors on page 9 3 For information about which errors are detected and when please refer to Section Connection examples for the safe relay outputs and the safety related segment circuit on page 6 1 P...

Page 29: ...ng errors result in the safe state Serious hardware faults in the internal circuit User errors Module overload Module overheating Incorrect supply The relevant diagnostic message is transmitted to the safe controller see Section Errors Messages and removal on page 9 1 WARNING Loss of safety function On a device error in Cat 2 applications single channel it is not always possible to enter the safe ...

Page 30: ... is only forwarded by the PST PROFIsafe driver for F Slaves to the SAL safety application layer for a safe output if the consecutive number has changed in the corresponding PROFIsafe container A 0 is always forwarded This prevents the toggling of an output by telegrams with the same consecutive number e g by changing the order of PROFIsafe containers with the same consecutive number Exception If a...

Page 31: ...bit by bit for each safe output channel The enable function can be parameterized enabled disabled for each specific channel see Section Parameterization of the safe relay outputs on page 5 2 The structure and function of the register are as follows When the enable function is enabled the relevant safe output is ANDed bit by bit with the corresponding output bit of the standard control system Data ...

Page 32: ...stem Standard function block for ANDing SPSDO Safe control signal from the configurable logic module Data PSDO x Standard data of the standard control system which is to enable the IC220SDL840 bit x OUTx_Chy Safe output x channel y Internal sequences Table 2 3 Parameterization of output channels for the example in Figure 2 5 Output channel Output Enable OUT0_Ch1 Single channel Enabled OUT0_Ch2 Not...

Page 33: ...operation 2 13 Programming data configuration data 2 13 1 Local bus 2 13 2 Other bus systems PROFIBUS PROFINET VersaSafe PROFIsafe Mode switch Mode 2 Mode 1 ID code A7hex 167dec CBhex 203dec Length code 04hex 04dec 04hex 04dec Input address area Controller specific Controller specific Output address area Controller specific Controller specific Parameter channel PCP 0 words 1 word Register length 4...

Page 34: ...2 T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y 2 18 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 35: ... supply the communications power and the relays For the technical data for the supply voltage UL please refer to Section Supply voltage UL logic relay on page 11 4 The maximum current carrying capacity for the supply voltage UL is 2 A This current carrying capacity can be reduced if certain terminals are used Please refer to the information in the terminal specific data sheets For more detailed in...

Page 36: ...E Module damage due to polarity reversal Polarity reversal places a burden on the electronics and despite protection against polarity reversal can damage the module Therefore polarity reversal must be prevented 24 V DC PELV 230 V 24 V External fuse 8 A maximum U für Einspeisung am Buskoppler oder einer Einspeiseklemme M GND der Einspeisung am Buskoppler oder einer Einspeiseklemme 77220003 U für Ei...

Page 37: ...tion Internal basic circuit diagram on page 3 6 There are two options for inserting additional VersaPoint terminals after the safety module 1 Use of the safety related segment circuit For general information please refer to Section Safety related segment circuit on page 2 6 for connection examples please refer to Section Safety related segment circuit on page 6 17 2 Use of the segment circuit In o...

Page 38: ... 1 2 3 4 D 1 2 0 IN1 1 2 1 2 3 4 1 2 3 4 FS 1 2 1 IN2 1 2 1 1 1 2 1 3 1 4 2 1 2 2 2 3 2 4 1 2 3 4 1 2 3 4 1 2 3 4 3 1 3 2 3 3 3 4 4 1 4 3 4 4 4 2 X2 5 1 5 2 5 3 5 4 X3 6 1 6 2 6 3 6 4 X4 Only use the connectors supplied with the module or connectors that are approved as replacement items see Ordering data Accessories on page 11 9 WARNING Loss of electrical and functional safety if potential areas ...

Page 39: ...channel 2 contact 14 24 V 3 4 UT2 Clock output channel 2 Feedback circuit 2 external contact monitoring 4 4 IN2 Alarm input channel 2 Table 3 3 Terminal point assignment for COMBICON connector X3 Terminal point Signal Channel assignment Remark 5 1 OUT0_Ch1_23 Relay output 0 channel 1 contact 23 24 V or 250 V 5 2 OUT0_Ch1_24 Relay output 0 channel 1 contact 24 24 V or 250 V 5 3 OUT0_Ch2_23 Relay ou...

Page 40: ... V U S UL Local bus Key Protocol chip bus logic including voltage conditioning Terminal point Logic circuit Potential or data jumpers with jumper contacts on the side Optocoupler Cable s x indicates the number of cables Forcibly guided N O contact COMBICON connection OPC L o g i c x 3 6 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 41: ...rsons Mount all VersaPoint terminals on 35 mm DIN rails Only connect the cables using the supplied VersaPoint and COMBICON connectors or VersaPoint and COMBICON connectors listed in the ordering data NOTE Electrostatic discharge The safety module contains components that can be damaged or destroyed by electrostatic discharge When handling the safety module observe the necessary safety precautions ...

Page 42: ...the PROFIsafe address for the PROFIsafe device PROFIsafe addresses 1 to 1022 are permitted The terminal is detected as a PROFIsafe device by means of the set PROFIsafe address The DIP switch is set to 3FFhex by default This address is not valid for a VersaSafe or PROFIsafe system therefore a valid address must be set A Switch for setting the transmission speed and the mode B Switch for setting the...

Page 43: ...n for VersaSafe VersaSafe Mode switch Address switch Island number Satellite number 9 8 7 6 5 4 3 2 1 0 Mode 2 off off 1dec to 31dec 1dec to 5dec Table 4 2 Switch position for PROFIsafe PROFIsafe Mode switch Address switch 9 8 7 6 5 4 3 2 1 0 Mode 1 1hex to 3FEhex Set the DIP switches before assembling the module in the VersaPoint station The switches cannot be accessed when the safety terminal is...

Page 44: ...o the station Before snapping on the safety module remove the connectors from the safety module and the adjacent connector from the neighboring VersaPoint terminal on the left Removing the VersaPoint connectors Remove the connectors by pressing the back shaft latching A and levering off the connector B Figure 4 4 Removing the connector 1 A 1 B Only use the connectors supplied with the module or co...

Page 45: ...des the following Connecting PROFIBUS or PROFINET to the VersaPoint station Connecting the supply voltages for the VersaPoint station Carry out electrical installation for the VersaPoint station according to the GFK 2736 user manual or the VersaPoint system manual for your bus system Please also observe the specifications in the documentation for the bus coupler used The module can be removed with...

Page 46: ...ssible current carrying capacity of the VersaPoint connectors of 4 A Protect the connectors from overload using a 4 A fuse Observe the current carrying capacity when selecting the cables To wire the VersaPoint connectors proceed as follows Strip 8 mm off the cable For multi strand cables fit the stripped cable ends with suitable ferrules and ensure that they are properly crimped Push a screwdriver...

Page 47: ...ed cable ends with suitable ferrules and ensure that they are properly crimped Insert the cable in the corresponding terminal point of the connector Insert the assembled connectors in the corresponding module slot see Section Terminal point assignment on page 3 4 WARNING A short circuit between adjacent terminal points can lead to the loss of the safety function Ensure that the wires are connected...

Page 48: ...4 T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y 4 8 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 49: ...is automatically written to the module on every power up or reset The module cannot be operated if it is not parameterized In this case the FS LED flashes The module is ready to operate if the parameters for all outputs are valid and transmitted without errors Valid output data is only written in this state In any other state every output is set to the safe state If errors are detected during para...

Page 50: ...fer to Section Errors Messages and removal on page 9 1 F Parameters and iParameters Assign the parameterizable F Parameters and iParameters For an overview of the module parameters and possible settings please refer to Section Appendix F Parameters and iParameters on page B 1 5 3 Parameterization of the safe relay outputs The individual outputs of a safety module can be parameterized differently a...

Page 51: ...l alarm contacts of the safety relay and the status of input IN2 are detected If the status does not correspond to the desired status the output is disabled and a diagnostic message is transmitted to the safe controller Remark Input IN2 must only be assigned once to one output Parallel connection of the alarm contacts is not permitted Dual assignment is only permitted if the output is parameterize...

Page 52: ...r the parameterization of the Switch off delay for stop category 1 parameter Please observe the notes below this table Enable VersaSafe only 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 standard output data of the standard control system ...

Page 53: ...uts and alarm inputs The assignment of clock outputs to alarm inputs is fixed and cannot be parameterized For the assignment of an alarm output to a relay output please refer to the parameterization of the relay output see page 5 2 WARNING Delayed shutdown when using stop category 1 For stop category 1 please take into consideration the following In the event of an error excluding bus errors the a...

Page 54: ...5 T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y 5 6 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 55: ...ample is specified in the table Device diagnostics and behavior of the module in the event of an error Diagnostic capability depends on the parameterization If a message is transmitted to the safe controller in the event of an error the message is specified in the tables For information about the relevant error code possible remedies and information about whether acknowledgment is required please ...

Page 56: ...e circuit for external relays contactors free running circuit Figure 6 1 Example of the free running circuit for an external relay A protective circuit via the relay contacts is not permitted For all examples please also observe the measures specified in the individual tables which must be taken to achieve the specified SIL SIL CL Cat PL and all measures according to standards EN 61508 EN 62061 an...

Page 57: ...n Requirements for controlled devices actuators on page 2 5 Please note that mechanical failure of the switching device can result in the loss of the safety function Prevent the welding of contacts with appropriate protection against overcurrent and surge voltage Please note that a single error can result in the loss of the safety function between tests Ensure that the external wiring is tested by...

Page 58: ...ators at regular intervals Cat 4 Use proven safety principles Use appropriately qualified actuators see Section Requirements for controlled devices actuators on page 2 5 Please note that mechanical failure of the switching device can result in the loss of the safety function Prevent the welding of contacts with appropriate protection against overcurrent and surge voltage An accumulation of errors ...

Page 59: ... a clock output UT1 or UT2 with the associated alarm input Activate this function in the parameterization IN1 or IN2 see Section Parameterization of the safe relay outputs on page 5 2 Figure 6 2 Single channel assignment of floating contacts with readback A and without readback B Key OUT0_Ch1_13 OUT0_Ch1_14 24 V M UT1 UT2 IN1 IN2 400 V IC220SDL840 A B 77220005 OUT0_Ch1_13 OUT0_Ch1_14 24 V M 400 V ...

Page 60: ...l Alarm input assigned Error type Detection Diagnostics Loss of SF Remark Error in the actuator Despite being disabled the actuator does not switch to the safe state e g a contact will not open Yes Yes Yes Please take into consideration all the possible errors for the actuator used Test the shutdown capability of the actuator at regular intervals Actuator cannot be enabled e g interrupt at coil Ye...

Page 61: ...larm input to 24 V Yes Yes No The error is detected by clocking or by the plausibility check Clock output alarm input to ground Yes Yes No The error is detected by clocking or by the plausibility check Table 6 3 Single channel Alarm input assigned Error type Detection Diagnostics Loss of SF Remark Table 6 4 Single channel Alarm input assigned typical parameterization Parameterization Parameterized...

Page 62: ...tor Please take into consideration all possible errors that can occur in the actuator Error in the wiring Interrupt Cable interrupt between output and actuator or between actuator and ground No None No Detect errors using external monitoring Please take into consideration all the possible errors for the actuator used Ensure that this error does not result in delayed system startup Cross circuit Ou...

Page 63: ... parameterization IN1 or IN2 see Section Parameterization of the safe relay outputs on page 5 2 6 5 1 Monitoring via common readback Monitoring is common for both channels of an output In this case the second alarm input is available for other outputs Figure 6 3 Two channel assignment of floating contacts with common readback If you are using monitoring via one or both alarm inputs with two channe...

Page 64: ...tage is not provided by the VersaPoint station A Alternative A B Alternative B OUT0_Ch1_13 Output 0 channel 1 contact 13 OUT0_Ch1_14 Output 0 channel 1 contact 14 OUT0_Ch2_13 Output 0 channel 2 contact 13 OUT0_Ch2_14 Output 0 channel 2 contact 14 UT1 UT2 Clock output UT1 or UT2 IN1 IN2 Alarm input IN1 or IN2 WARNING Loss of the safety function due to external supply Make sure that no cross circuit...

Page 65: ...spite being disabled an actuator does not switch to the safe state e g a contact will not open Yes Yes No The error is detected by the forced guidance of the N C contacts Please take into consideration all the possible errors for the actuator used Test the shutdown capability of the actuator at regular intervals Actuator cannot be enabled e g interrupt at coil No None No Ensure that this error doe...

Page 66: ...ity check Clock output alarm input to ground Yes Yes No The error is detected by clocking or by the plausibility check Table 6 7 Two channel with monitoring by the alarm input Error type Detection Diagnostics Loss of SF Remark Table 6 8 Two channel with monitoring by the alarm input typical parameterization Parameterization Parameterized as Remark Channel 1 Channel 2 Assignment Used Used Output Tw...

Page 67: ...t of floating contacts with separate readback Key IC220SDL840 K2 R K1 R M OUT0_Ch1_13 OUT0_Ch1_14 24 V OUT0_Ch2_13 OUT0_Ch2_14 24 V UT1 UT2 IN1 IN2 400 V UT2 UT1 IN2 IN1 77220011 IC220SDL840 K2 R K1 R M OUT0_Ch1_13 OUT0_Ch1_14 24 V OUT0_Ch2_13 OUT0_Ch2_14 400 V A B UT1 UT2 IN1 IN2 UT2 UT1 IN2 IN1 K1 K2 K1 K2 WARNING Failure of the safety relay contacts due to overload Protect all safety relay cont...

Page 68: ...ications OUT0_Ch2_13 Output 0 channel 2 contact 13 OUT0_Ch2_14 Output 0 channel 2 contact 14 UT1 UT2 Clock output UT1 or UT2 IN1 IN2 Alarm input IN1 or IN2 UT2 UT Clock output UT2 or UT1 IN2 IN1 Alarm input IN2 or IN1 WARNING Loss of the safety function due to external supply Make sure that no cross circuits can occur Actuator Two channel Achievable SIL SIL CL Cat PL SIL 3 SIL CL 3 Cat 4 PL e Exte...

Page 69: ...Loss of SF Remark Error in the actuator Despite being disabled an actuator does not switch to the safe state e g a contact will not open Yes Yes No The error is detected by the forced guidance of the N C contacts Please take into consideration all the possible errors for the actuator used Test the shutdown capability of the actuator at regular intervals Actuator cannot be enabled e g interrupt at ...

Page 70: ... Output to ground Yes Yes No Protect the output against damage using a preconnected fuse Clock output alarm input to 24 V Yes Yes No The error is detected by clocking or by the plausibility check Clock output alarm input to ground Yes Yes No The error is detected by clocking or by the plausibility check Table 6 9 Two channel with monitoring by two alarm inputs Error type Detection Diagnostics Loss...

Page 71: ...rnal and external wiring of the IC220SDL840 for the use of the safety related segment circuit Observe the notes in the document for the safety related segment circuit in the VersaPoint system see Section Ordering data Documentation on page 11 9 77220012 1 2 1 2 3 4 1 2 3 4 1 2 1 2 3 4 1 2 3 4 D 1 2 0 IN1 1 2 1 2 3 4 1 2 3 4 FS 1 2 1 IN2 1 2 1 2 3 4 1 2 3 4 1 2 1 2 3 4 1 2 3 4 OUT1_Ch2 OUT1_Ch1 3 2...

Page 72: ...his version is shown in Figure 6 5 Replace the fuse that is supplied as standard with a fuse with an l2 t value of less than 100 A2 s and maximum 4 A If a power terminal with fuse is not used protect the supply UM using an external fuse IL Standard VersaPoint IL SAFE Safety related segment circuit PWR Power terminal with fuse or power terminal with fuse and diagnostics see Ordering data Documentat...

Page 73: ...l switching state of the standard outputs Figure 6 6 Single channel actuators in the safety related segment circuit Key IL SAFE Safety related segment circuit K11 R represents the forcibly guided N C contact of the relay Connect this contact via a safe digital input Evaluate the readback and thus the state of the switching element in your safe application WARNING Loss of safety function Connect th...

Page 74: ...interrupt between output and actuator or between actuator and ground No None No Detect errors using external monitoring Please take into consideration all the possible errors for the actuator used Ensure that this error does not result in delayed system startup Cross circuit Output to output only safety related segment circuit outputs No None No A cross circuit between the outputs cannot be detect...

Page 75: ...h off delay is 30 x 1 s 30 s Table 6 12 Safety related segment circuit Assignment with single channel actuators typical parameterization Parameterization Parameterized as Remark Channel 1 Channel 2 Assignment Used Used Output Two channel Two channel Alarm input IN1 Do not evaluate Do not evaluate Alarm input IN2 Do not evaluate Do not evaluate Switch off delay for stop category 1 Enabled Enabled O...

Page 76: ...lated segment circuit K11 R and K12 R represent the forcibly guided N C contacts of the relay Connect these contacts via safe digital inputs Evaluate the readback and thus the state of the switching elements in your safe application WARNING Loss of safety function Connect the actuator ground directly to terminal point GND of the DO terminal An external ground may not be used The loads can also be ...

Page 77: ...ernal monitoring Please take into consideration all the possible errors for the actuator used Ensure that this error does not result in delayed system startup Other errors depending on the actuator Please take into consideration all possible errors that can occur in the actuator Error in the wiring Interrupt Cable interrupt between output and actuator or between actuator and ground No None No Dete...

Page 78: ... 6 13 Safety related segment circuit Assignment with two channel actuators Error type Detection Diagnostics Loss of SF Remark Table 6 14 Safety related segment circuit Assignment with two channel actuators typical parameterization Parameterization Parameterized as Remark Channel 1 Channel 2 Assignment Used Used Output Two channel Two channel Alarm input IN1 Do not evaluate Do not evaluate Alarm in...

Page 79: ...e values are given for single channel assignment and these values only refer to one internal safety relay This means that if several safety relays are used for a safety function the values must be added together If the contacts of a safety relay have different loads use the least favorable load for the calculation see assignment of outputs to the safety relay in Section Terminal point assignment o...

Page 80: ...orable load for the calculation see assignment of outputs to the safety relay in Section Terminal point assignment on page 3 4 If the calculated PFH value is 1 a value of 1 should be used Table 7 2 MTTFd depending on the load for the contacts and the switching fre quency Load for the contacts according to DIN EN 60947 4 1 DIN EN 60947 5 1 Channel 1 or channel 2 MTTFd 10 years MTTFd 30 years MTTFd ...

Page 81: ... if several safety relays are used for a safety function the values must be added together If the contacts of a safety relay have different loads use the least favorable load for the calculation see assignment of outputs to the safety relay in Section Terminal point assignment on page 3 4 The value for PFH is determined using the following formula Where c Switching frequency of the relay per hour ...

Page 82: ... 1 a value of 1 should be used 0 10 20 30 40 50 60 70 0 5 10 15 20 25 SIL3 c 1 h 75562014 80 AC 15 3 A AC 15 3 A AC 15 3 A zero current DC 13 5 A DC 13 5 A AC 15 3 A DC 13 5 A DC 15 3 A AC 15 3 A DC 13 5 A zero current 250 µF DC 4 A zero current 7 4 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 83: ... the second channel are enabled and disabled with a time delay so that zero current switching can be assumed for the first channel if the contacts of the first and second channel are connected in series see alternative B in Figure 6 3 and Figure 6 4 3 The minimum switching frequency is 1 cycle in 6 months 4 The values are only valid if an appropriate external fuse is provided to protect the contac...

Page 84: ...7 T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y 7 6 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 85: ...circuit or grounding errors by testing with a multimeter Check whether the ground connection is safe Connect the required voltages to the VersaPoint station GFK 2736 or documentation for the bus coupler Connect the required voltages UM to the safety module Section Supply voltage UM on page 3 2 Once the operating voltage has been applied If possible measure the wave form of the voltages to ensure t...

Page 86: ...n blocks used Documentation for the configurable logic module used VersaSafe Documentation for the controller used PROFIsafe For PROFIsafe When verifying the safety function check whether the F_iPar_CRC parameter is greater than 0 for all devices If not modify the settings Checklist Validation on page C 6 Quick start guide for configuring VersaPoint modules with safe inputs or outputs under PROFIs...

Page 87: ...nment of the sensor and actuator connections Determine whether The correct safe actuators are connected to the safety module The relay contacts are protected The voltage areas are observed If the safety related segment circuit is used only VersaPoint terminals that are specifically designed for this safety related segment circuit are used The safety module has been parameterized correctly The vari...

Page 88: ...8 T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y 8 4 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 89: ... below Error removal To remove the cause of an error please proceed as described in the Remedy column in the tables below Error acknowledgment Instructions on how to acknowledge an error can be found in Section Acknowledging an error on page 9 6 Module replacement following an error If in the event of failure the safety module is replaced please proceed as described in Section 4 Assembly removal a...

Page 90: ...l is specified as the error location e g OUT0_Ch1 Some errors only occur for outputs parameterized for two channel operation Here the channel pair is specified as the error location e g OUT0_Ch1 2 Example Channels in the diagnostic code Safe output errors Table 9 3 Table 9 2 Relationship between the diagnostic code indicated and the diagnostic code specified in the documentation 15 14 13 12 11 10 ...

Page 91: ...nel parameterization this also applies to the other potentially error free output Table 9 3 Safe relay output errors Error cause Error code hex LED Remark Effect Remedy Acknow ledgment Hardware fault X091 All OUT Red ON Detected by internal tests It is possible that a relay output could not be disabled Please replace module remove module from system immediately Signal error at alarm input X0Bn OUT...

Page 92: ... frequency Yes 1 Error due to receipt of an unexpected message X1F3 Error due to receipt of an unexpected message while acknowledging a diagnostic message The device firmware handles this diagnostic message with the highest priority Only when this message has been acknowledged correctly are other errors indicated if present The acknowledgment process during which an unexpected message was received...

Page 93: ...f two related outputs does not correspond to the two channel setting Correct value and resend parameter data to the module X28n X280 OUT0_Ch1 X281 OUT1_Ch1 X287 OUT0_Ch2 X281 OUT1_Ch2 640 OUT0_Ch1 641 OUT1_Ch1 647 OUT0_Ch2 648 OUT1_Ch2 The parameterized switch off delay time for the output is outside the permissible value range Correct value and resend parameter data to the module X29n X290 OUT0_C...

Page 94: ...ructions on error acknowledgment please refer to the documentation for the configurable logic module used For instructions on error acknowledgment please refer to the documentation for the system used WARNING Acknowledgment may result in a hazardous system state With the exception of a few special cases the acknowledgment of an error immediately returns the safe output to the operating state Befor...

Page 95: ...ital relay outputs on page 11 4 Carry out maintenance of connected I O devices e g light grid according to the relevant manufacturer specifications 10 2 Repair Repair work may not be carried out on the safety module In the event of an error send the module to GE Intelligent Platforms It is strictly prohibited to open the safety module In order to prevent the manipulation of the module and to detec...

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Page 97: ...sponding documentation 11 2 IC220SDL840 VersaPoint Automation terminals of the VersaPoint product range GFK 2736 VersaSafe Processing time of the module Single channel 7 ms Two channel 17 ms PROFIsafe PROFIsafe profile 2 4 Processing time of the module Single channel 7 ms Two channel 17 ms General data Housing dimensions width x height x depth 73 2 mm x 119 8 mm x 71 5 mm Weight with connectors 31...

Page 98: ...istance of housing material to fungal decay Resistant Ambient compatibility Not resistant to chloroform Connection data for VersaPoint connectors Connection method Spring cage terminals Conductor cross section 0 2 mm2 to 1 5 mm2 solid or stranded 24 16 AWG Permissible current 4 A maximum Fuse protection 4 A maximum Connection data for COMBICON connectors Connection method Spring cage terminals Con...

Page 99: ...wo channel Depends on the parameterization and wiring see Section Connection options for actuators depending on the parameterization on page 2 9 and Section Connection examples for the safe relay outputs and the safety related segment circuit on page 6 1 Safe failure fraction SFF 99 Probability of a dangerous failure per hour for the entire module PFH SIL CL 2 1 of 10 6 maximum corresponds to 1 x ...

Page 100: ...in the bus coupler power terminal Additional internal surge protection suppressor diode between UM and GND Protection against polarity reversal Yes in the bus coupler power terminal Undervoltage detection No Diagnostic indicators None External fuse protection 8 A slow blow maximum The safety terminal is supplied with main voltage UM via the bus coupler or a power terminal in the station Potential ...

Page 101: ...rnal fuse protection Nominal current 6 A l2 t value 100 A2 s see also Section Fuse protection on page 2 4 Simultaneity 100 observe maximum current load Derating See Derating on page 11 6 Shutdown time tOUT Can be parameterized Single channel 25 ms to 6 3 s two channel 35 ms to 6 3 s see Section Parameterization of the safe relay outputs on page 5 2 Accuracy Single channel 10 ms 6 of parameterized ...

Page 102: ...10 20 30 40 50 60 TA I 23 24 13 14 C A 75560018 0 1 2 3 4 5 6 10 20 30 40 50 60 TA I 23 24 13 14 C A 75560019 0 1 2 3 4 5 6 10 20 30 40 50 60 TA I 23 24 13 14 C A 75560020 Contact data for the safety relay used Contact material AgCUNi 0 2 0 4 µm Au Type of contact Single contact Nominal switching power 250 V AC 6 A AC1 1500 VA Electrical service life 100 000 AC1 360 switching operations h approxim...

Page 103: ...250 V DC 63 W 250 V AC 1500 VA Maximum interrupting rating for inductive load 40 ms 24 V DC 35 W 48 V DC 35 W 110 V DC 35 W 250 V DC 35 W Contact data for the safety relay used Clock outputs Number 2 Supply From UM Maximum switching current 15 mA short circuit and overload protection approximately Simultaneity 100 Derating No Status indicators None Diagnostic indicators None Alarm inputs Number 2 ...

Page 104: ...C 50 Hz 1 min 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 user manual Approvals For the latest approvals please visit http support ge ip com Conformance with EMC Directive 2004 108 EC Nois...

Page 105: ...C220SCO840 1 set Description Order designation Pcs Pkt VersaPoint User manual Automation terminals of the VersaPoint product range GFK 2736 1 VersaSafe User manual VersaPoint module with inte grated safety logic and safe digital outputs GFK 2731 1 PROFIsafe Specification PROFIsafe Profile for Safety Technology on PROFIBUS DP and PROFI NET IO Version 2 4 February 2007 See www profisafe net Make sur...

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Page 107: ...customer specifications and for checking the parameterization by means of a separate method diverse The main F Parameters are F I O device Failsafe I O device safe input and or output modules Modules with integrated safety functions which are approved for safety related operation F Slave Failsafe slave F_Source_Address F Parameter PROFIsafe source address address of the safe controller see also F ...

Page 108: ...he safety program For a safe output module when the F System is passivated instead of the output values provided by the safety program substitute values 0 are transferred to the safe outputs PROFIsafe Safety related bus profile based on PROFIBUS DP or PROFINET It defines the communication between a safety program and the safe I O device F I O device in a safe system F System PROFIsafe address Each...

Page 109: ...nitoring time in the safety module A valid current safety telegram must arrive from the safe controller within the monitoring time Otherwise the safety module enters the safe state The selected monitoring time must be sufficiently high for telegram delays to be tolerated by the communication but still ensure a sufficiently fast error response in the event of an error e g interruption in communicat...

Page 110: ..._ID 1 Parameter block type identification 1 The parameter block of the F Parameters contains the F_iPar_CRC parameter F_Par_Version 1 Version number of the F Parameter block 1 Valid for V2 mode F_iPar_CRC 0 CRC checksum via the iParameters The value must be greater than 0 When verifying the safety function check whether the F_iPar_CRC parameter is greater than 0 for all devices If not check the iP...

Page 111: ... Correct value 68 44 Invalid parameterization of F_SIL The safety module F Module cannot support the required SIL Use a device with the required SIL The safety module achieves SIL 3 maximum 69 45 Invalid parameterization of F_CRC_Length The CRC length generated by the safety module F Module does not match the required length Check device description 70 46 Invalid F Parameter record version The saf...

Page 112: ...ters is incorrect Correct value Make sure that the value set under F_Destination_Address and the value that you have set via the 10 pos DIP switch are the same X3FD Incorrect order of iParameter blocks Check infrastructure components Table B 4 F Parameter parameter errors Error code Error cause Remedy dec hex 1088 440 The parameterized VersaSafe address does not match the address set on the safety...

Page 113: ...rsion HW FW FW 00 100 100 Date January 3 2008 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 firmware version of ...

Page 114: ...imple manipulation 8 Are measures planned to prevent connectors being mixed up 9 Are requirements for the actuators and cable installation observed according to the SIL SIL CL Cat PL to be achieved and is the corresponding implementation planned 10 Are the specifications for the parameterization for each channel specified 11 Are test intervals specified for testing the shutdown capability of the a...

Page 115: ...ommunicated to the relevant personnel 19 Have the separate voltage areas been taken into account 20 Have specifications for the safety related segment circuit been taken into account jumpers approved terminals fuse protection 21 Have specifications for startup been defined and communicated to the relevant personnel Date Signature author Date Signature test engineer ...

Page 116: ...nning 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 No Requirement optional Yes No Remark 4 Is the transmission speed set correctly according to the specifications 5 Is the data width set correctly according to the specifications 6 Is the profile PROFIsafe address set correctly acco...

Page 117: ...it ensured that any person starting hazardous movements intentionally can only do so with a direct view of the danger zone 3 Are all parameters parameterized for the outputs 4 For outputs that are parameterized for two channel operation are both channels parameterized correctly for each other 5 Has the switch off delay for stop category 1 been observed in the calculation of the total response time...

Page 118: ...ifications 9 Does the voltage supply correspond to the specifications for the protective extra low voltage in accordance with PELV 10 Has the power supply of UM and US in the VersaPoint system from a power supply unit been implemented 11 Is external fuse protection of the module implemented according to the specifications in this user manual for supply voltage UM 12 Is external fuse protection of ...

Page 119: ...e F_iPar_CRC parameter greater than 0 for all devices 21 Has it been ensured that any person intentionally starting hazardous movements has a direct view of the danger zone Date Signature author Date Signature test engineer No Requirement mandatory Yes Remark ...

Page 120: ...C T h i s p a g e l e f t b l a n k i n t e n t i o n a l l y C 8 User manual IC220SDL840 May 2018 GFK 2734 ...

Page 121: ...cts 2 4 F Parameters A 1 Free running circuit 6 2 F System A 2 H Housing dimensions 2 3 I ID code 2 17 Indicators diagnostic and status 2 10 Input address area 2 17 Installation Instructions 4 1 Insulation rating 1 3 iParameters A 2 L Length code 2 17 Location ID 5 2 M Maintenance 10 1 Mounting 4 3 Location 4 1 MTTFd 7 1 7 2 7 5 11 3 O Output address area 2 17 Outputs 2 4 Device errors 2 13 Errors...

Page 122: ...module 8 2 Restart 8 2 S Safe state 2 12 Operating state 2 12 Outputs 2 12 2 13 Safety notes 1 1 Safety relays 2 4 Safety related segment circuit 2 6 Security seal 1 2 Standards 1 4 Startup 7 1 8 1 Status indicators 2 10 Supply voltage UM 3 1 3 2 T Transmission speed 1 2 Setting 4 2 U Usage correct 1 5 V Validation 8 3 VersaSafe Address 5 1 Parameterization 5 1 Process data 2 15 Programming data 2...

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