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Mitsubishi Electric SW1DNN-WS0ADR-B, Operating Manual

The Mitsubishi Electric SW1DNN-WS0ADR-B Operating Manual is a comprehensive guide for effectively using this product. Available for free download on our website, it provides step-by-step instructions and troubleshooting tips. Enhance your experience with this reliable Mitsubishi Electric product by accessing the manual at manualshive.com.

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Chapter 14 

283

 

Troubleshooting 

14 

Troubleshooting 

 

In case of an error please refer to the Safety Controller User’s Manual. There you 
will find a list of LED error displays, error codes, error causes and rectification 
measures. 

Error codes and error messages can also be displayed in the 

Diagnostics

 view if 

you are connected to the MELSEC-WS safety controller. For more information on 
how to perform diagnostics, see Section 5.8. 

Summary of Contents for SW1DNN-WS0ADR-B

Page 1: ...Safety Controller Setting and Monitoring Tool Operating Manual WS0 CPU0 WS0 CPU1 WS0 CPU3 SW1DNN WS0ADR B ...

Page 2: ......

Page 3: ... the product shall be for one 1 year after the date of delivery or for eighteen 18 months after manufacturing whichever is less The onerous repair term after discontinuation of production shall be for four 4 years Mitsubishi shall mainly replace the product that needs a repair It may take some time to respond to the problem or repair the product depending on the condition and timing Specifications...

Page 4: ...hen a load current exceeding the rated current or an overcurrent caused by a load short circuit flows for a long time it may cause smoke and fire To prevent this configure an external safety circuit such as a fuse For safety relays configure an external circuit using a device such as a fuse or breaker to protect a short circuit current When changing data and operating status and modifying program ...

Page 5: ...EC Provision and Use of Work Equipment Directive 89 655 EC Low Voltage Directive 2006 95 EC The work safety regulations safety rules Manufacturers and owners of the machine on which a MELSEC WS safety controller is used are responsible for obtaining and observing all applicable safety regulations and rules The notices in particular the test notices of this manual e g on use mounting installation o...

Page 6: ...etic compatibility EMC the DIN mounting rail has to be connected to functional earth FE Ensure that the earthling contact is positioned correctly The earthling spring contact of the module must contact the DIN mounting rail securely to allow electrical conductivity Shut off the external power supply for the system in all phases before mounting or removing the module Failure to do so may result in ...

Page 7: ...rew within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction Prevent foreign matter such as dust or wire chips from entering the module Such foreign matter can cause a fire failure or malfunction Mitsubishi MELSEC WS safety controllers must be installed in control c...

Page 8: ...ults in a loss of the safety functions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the safety outputs Wire the MELSEC WS safety controller so that 24 V DC signals cannot unintentionally contact safety outputs Connect the GND wires of the power supply to earth so that the devices do not switch on when the safety output line is applied to frame ...

Page 9: ...Shut off the external power supply for the MELSEC WS safety controller in all phases before mounting or removing the module Failure to do so may cause the module to fail or malfunction After the first use of the product do not mount remove the module from to the DIN mounting rail and the terminal block to from the module more than 50 times IEC 61131 2 compliant respectively Exceeding the limit of ...

Page 10: ... liable for damages that could have been prevented by compliance with any applicable safety standard regulation or law 2 MELCO prohibits the use of Products with or in any application involving and MELCO shall not be liable for a default a liability for defect warranty a quality assurance negligence or other tort and a product liability in these applications 1 power plants 2 trains railway systems...

Page 11: ... was upgraded August 2014 SH NA 080856ENG E A new module WS0 CPU3 module was added Description on Flexi Line system was added Setting and Monitoring Tool was upgraded Japanese manual version SH 080853 F This manual confers no industrial property rights or any rights of any other kind nor does it confer any patent licenses Mitsubishi Electric Corporation cannot be held responsible for any problems ...

Page 12: ... protective notes and protective measures 21 3 Version compatibility and features 22 4 Installation and removal 24 4 1 System requirements 24 4 2 Installation and Update 24 4 3 Removal 25 4 4 Troubleshooting 25 5 The graphical user interface 26 5 1 Start view 26 5 2 Setting the desired language 26 5 3 Standard views 27 5 4 Positioning windows 28 5 5 Hardware configuration view 29 5 5 1 Exercise fo...

Page 13: ...ps for establishing a connection 68 6 1 1 Connecting the PC to the MELSEC WS safety controller via RS 232 68 6 1 2 Online status and background color 69 6 2 Editing the communication settings 70 6 3 Establishing a connection with the MELSEC WS safety controller 76 6 4 User levels in the Setting and Monitoring Tool 77 6 5 Identify project 78 7 Flexi Link 79 7 1 Flexi Link overview 79 7 1 1 System r...

Page 14: ...ing started 116 8 3 1 Configuration and commissioning of a Flexi Line system 116 8 3 2 Conversion of a Flexi Line system 117 8 3 3 Configuration of the Flexi Line logic 118 9 Logic programming Function blocks 120 9 1 General description 120 9 2 Safety notes for the logic programming 120 9 3 Function block Overview 122 9 4 Function block properties 123 9 5 Input and output signal connections of fun...

Page 15: ...11 Error output combination 172 9 8 12 Ramp down detection 173 9 8 13 Frequency monitor 178 9 8 14 Start warning 182 9 9 Function blocks for dual channel evaluation 187 9 9 1 Single channel evaluation 187 9 9 2 Dual channel evaluation 1 pair and discrepancy time 188 9 9 3 Double dual channel evaluation 2 pair synchronization evaluation and synchronization time 190 9 9 4 Emergency stop 192 9 9 5 Ma...

Page 16: ...2 Customized function block 262 9 14 Simulation of the configuration 265 9 15 Force mode 267 10 I O modules 271 10 1 Dual channel evaluation and discrepancy time monitoring 271 10 2 ON OFF filter and OFF ON filter 273 10 3 Disabling the test pulses of WS0 XTIO outputs 273 11 Transferring the system configuration 274 11 1 Transferring project data to the safety controller 274 11 2 Compatibility che...

Page 17: ...on reports 284 15 1 1 Example application Newspaper palletizer 284 15 1 2 Example application Wood scanner 295 15 1 3 Example application Ramp down detection 304 15 2 List of function block status in simulation mode 312 15 3 Precautions 313 15 4 SICK contact 314 ...

Page 18: ...ation for the WS0 XTIO84202 MELSEC WS safety controller safety I O combined module WS0 XTDI The abbreviation for the WS0 XTDI80202 MELSEC WS safety controller safety input module WS0 4RO The abbreviation for the WS0 4RO4002 MELSEC WS safety controller safety relay output module WS0 GETH The abbreviation for the WS0 GETH00200 MELSEC WS safety controller Ethernet interface module WS0 GCC1 The abbrev...

Page 19: ...scribed in MELSEC WS series Safety Controller Setting and Monitoring Tool Operating Manual The operating manual also contain a description of the diagnostic functions most important for operation and detailed information on the identification and rectification of errors Use the operating manual in particular for the configuration commissioning and operation of MELSEC WS safety controllers MELSEC W...

Page 20: ...W E 13JZ93 Safety Controller Ethernet Interface Module User s Manual Hardware WS ET U HW E 13JZ95 Safety Controller CC Link Interface Module User s Manual Hardware WS CC U HW 13J209 1 2 Target group These user s manuals are addressed to the planning engineers designers and operators of systems which are to be protected by a MELSEC WS safety controller They also are addressed to people who integrat...

Page 21: ...representative see Section 15 4 http www sick com 1 3 1 Recommendations for familiarising yourself with Setting and Monitoring Tool We recommend the following procedure for users who want to familiarize themselves with Setting and Monitoring Tool for the first time Read Chapter 5 to familiarize yourself with the graphical user interface and do the exercises for the configuration of example applica...

Page 22: ...afety function may be impaired and a dangerous state may occur The names of software menus submenus options and commands selection boxes and windows are highlighted in bold Example Click Edit in the File menu The term dangerous state The dangerous state standard term of the machine is always shown in the drawings and diagrams of this document as the movement of a machine part In practical operatio...

Page 23: ... themselves with them and have access to the operating instructions for the protective devices e g C4000 connected to the safety controller and have read and familiarised themselves with them 2 2 Correct use The Setting and Monitoring Tool is used to configure a MELSEC WS safety controller consisting of modules of the safety controller The MELSEC WS safety controller may only be used by qualified ...

Page 24: ...nal rules and regulations apply to the installation and use as well as commissioning and periodic technical inspection of the MELSEC WS safety controller in particular Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Provision and Use of Work Equipment Directive 2009 104 EC and the supplementary Directive 35 63 EC Low Voltage Directive 2006 95 EC Work safety regulations and safety rules Ma...

Page 25: ... 0 Input output relation matrix V1 3 0 Invertable inputs for the AND OR RS Flip Flop and Routing N N function blocks V2 01 Revision 2 xx V1 3 0 Ramp down detection function block V1 11 Revision 1 xx V1 3 0 Adjustable on delay timer and adjustable off delay timer function blocks V2 01 Revision 2 xx V1 3 0 Fast Shut Off with Bypass function block only with WS0 XTI0 V2 01 Revision 2 xx V2 00 Revision...

Page 26: ...tting and Monitoring Tool can be found in the Extras menu under About For the acquisition of the newest version of the Setting and Monitoring Tool please contact your local Mitsubishi representative The function package Revision 1 xx or Revision 2 xx must be selected in the Setting and Monitoring Tool hardware configuration Function package Revision 2 xx is available with Setting and Monitoring To...

Page 27: ...ws operating systems To display text of Setting and Monitoring Tool in Japanese or Chinese in Windows XP English version add the language in the Regional and Language Options dialog box The dialog box can be accessed from Control Panel 4 2 Installation and Update For the acquisition of Setting and Monitoring Tool including information for installation please contact your local Mitsubishi represent...

Page 28: ...r error message is displayed DLL not found the Dynamic Link Library mscoree dll was not found in the specified path Specify the registration key HKLM Software Microsoft N ETFramework InstallRoot so that it refers to the installation location of the NET Framework Microsoft NET Framework is not installed on the PC Install a suitable version of Microsoft NET Framework Ask your system administrator if...

Page 29: ...l on the basis of a small section of the functions Experienced users of Setting and Monitoring Tool can skip this chapter 5 1 Start view After the Setting and Monitoring Tool has been started the start view is displayed The user can specify here with which of the following actions he wants to start Open existing project file Connect to physical device Create new project Create new Flexi Link proje...

Page 30: ...ere you can configure the network module and the data that are transferred to and from the network Do not save the project data while Setting and Monitoring Tool is connected to the MELSEC WS safety controller Before saving the project data disconnect the PC from the MELSEC WS safety controller Complete information on the currently loaded project and all settings including the logic programming an...

Page 31: ... move the frame or title bar of the sub window convert a sub window into a flyout window by clicking the Hide button drawing pin symbol on the right in the title bar The flyout is then positioned on the left hand margin of the Setting and Monitoring Tool window move flyout windows back to their normal position by clicking the drawing pin icon in the flyout window again Figure 3 Sub windows can be ...

Page 32: ...the current configuration are grayed out Modules that can be added to the current configuration are identified by a green symbol The number of inputs outputs and EFI connections is displayed for each module From a drop down list under the module the Revision or function package for the respective module can be selected The function package chosen defines the minimum firmware version that must be u...

Page 33: ... a dialog where you can adjust the settings for your project Here you can create your own tag name format enable or disable customized elements see Section 5 5 6 enable or disable the import of customized function blocks enable or disable RS 232 routing for the CPU enable additional XT modules see Section 5 5 1 save the current view and or activate a saved view change the path for the folders wher...

Page 34: ...he CPU module is displayed magnified there The inputs outputs and terminals are visible The CPU modules are now grayed out and the other modules network modules I O modules can be selected in the Modules selection window Move further safety I O modules in the Configuration area Green arrows indicate where the new module will be positioned Grey arrows indicate possible other positions The CPU modul...

Page 35: ...this configuration to the related system by simply deleting modules that are not required For configurations containing more than twelve I O modules the following restrictions apply You can not connect to a system and the configuration can not be transferred to the MELSEC WS safety controller Simulation is not possible A MELSEC WS safety controller can only ever contain a maximum of two network in...

Page 36: ...any module CPU module network module or safety I O module and select Edit in the context menu If the system is online the dialog window for the selected module opens with the additional Diagnostics file card where all available status bits for the selected module and their values are displayed Click on the Refresh button to update the values of the module status bits Figure 9 CPU status bits in th...

Page 37: ...log On the Export module status file card click on the Export button A file selection dialog opens Navigate to the folder where you want to save the export file enter a file name for the export and click on Save The module status bits are saved as a CSV file Figure 11 WS0 XTIO module status bits in the Hardware configuration view Figure 12 WS0 XTDI module status bits in the Hardware configuration ...

Page 38: ...tputs they light up green The Setting and Monitoring Tool automatically considers the required number of inputs or outputs Drop the device on a suitable position The device icon is now displayed in the view at this point Certain elements can not be connected to all modules Dual channel elements can only be connected to safe modules Pure safety elements can only be connected to safe modules Drag th...

Page 39: ... using the right mouse button and select Edit on the context menu The Element settings window opens Activate the Safety element checkbox Click on OK to close the Element settings window The element is now marked yellow 5 5 5 Expanding elements Some elements consist of a group of two or more sub elements such as an interlock that consists of a safety switch as input element and an interlock with lo...

Page 40: ...erize a connected element Double click on the element or right click an element in the Parking area or in the Configuration area and select Edit from the context menu The Element settings window is opened Tag name Enter a Tag name for the element if desired Otherwise the default tag name is used Nr of devices Adjust the Nr of devices if necessary E g if you have connected a cascade of several SICK...

Page 41: ...n after the error detection time back to Low again Due to the error detection a pulse may be generated Therefore single channel signals with test pulses need special attention If the stuck at high occurs on a single channel signal input with test pulses that was previously High the logic will see a delayed falling edge High to Low transition If a single channel input is used and an unexpected puls...

Page 42: ...elements option Click on OK How to create a customized element In the Hardware configuration view right click on any element in the Elements window in the Configuration area or in the Parking area It is recommended to choose an element that is as similar as possible to the customized element you want to create From the context menu select the command Save as customized element The Create custom el...

Page 43: ...our PC Use the Browse button at the bottom of the screen to assign a custom image to any element or sub element If an element contains two or more sub elements the Extractable option is available Elements based on a template that has been configured with this option active can be expanded or split into their sub elements which can then be treated as individual elements see Section 5 5 5 If the opt...

Page 44: ...ox if Elements based on this new template shall be editable within the limits that are preset on the Settings file card If only selected individual configuration options shall not be editable uncheck the Visible checkbox for these options How to transfer a customized element to another PC Save the project file and open it on the other PC Customized elements contained in the project will be importe...

Page 45: ...ectly Click Finish to confirm your selection and to connect the selected SICK EFI compatible device The EFI bits for the connected SICK EFI compatible device are now available in the logic editor as inputs and outputs for the CPU Double click an SICK EFI compatible device to open its configuration dialog The configuration of an SICK EFI compatible device must be uploaded or transferred separately ...

Page 46: ...ible device is physically present on this EFI connection but not in the configuration of the CPU module If you now upload the configuration using the Transfer project command this device will be added to the configuration of the CPU module Exception If the configuration in the CPU module is verified the sensor is not corrected In this case the configuration in the CPU module remains unchanged An E...

Page 47: ...er with a tag name is imported to another project the tag name is not reflected A tag name configured in the import target project is displayed If no tag name is configured in the import target project no name is displayed Among the outputs in the logic editor CPU output markers logic results and EFI1 EFI2 are imported only when they are not used in the import target project How to export a partia...

Page 48: ...sary logic in the logic editor The partial application to be imported contains another WS0 XTIO module with a two hand control and a motor plus one logic editor page with the logic for controlling these devices After the import has been completed the project will contain both WS0 XTIO modules with the respective devices connected and both logic programs on two separate pages How to exchange a CPU ...

Page 49: ...hange Add the desired new safety I O module to the hardware configuration Move the connected elements from the old module to the new module This way the logic connections will be preserved Delete the old module This method does not work for elements that are used in combination with a Fast shut off function block because these elements can not be moved to another module anymore This method does no...

Page 50: ...upport any safety mechanisms necessary for communication in a safety network For this reason the data exchanged via the RS 232 interface are not allowed to be used for safetyrelated functions How to activate the RS 232 routing In the hardware configuration click the Settings button in the left of the configuration area On the General tab select the Enable RS 232 routing for the CPU option Click OK...

Page 51: ...t to right The Load user configuration and Save user configuration buttons allow you to load and or save a configuration in XML format including the used tag names If you load a configuration all previously made changes that have not been saved will be lost You can not undo this action Using the Import and Export buttons you can import and export the tag names used as a CSV file comma separated va...

Page 52: ...as well as the Logic results from the logic editor All sources supported by the current configuration are displayed in black connected MELSEC WS modules connected EFI devices configured logic results 1 gateway input data and gateway output data Sources currently not configured will be displayed in grey Activating the Show only available data checkbox in the upper left corner hides the unused sourc...

Page 53: ...free you will have to clear it first by deleting or moving the byte currently assigned to it Tag names area This area shows the tag names for all bits in the byte currently selected in the Available data area or in the RS 232 data area You can edit the tag names in the tag name editor and also to some extent in the logic editor and in the hardware configuration dialog box e g for expansion modules...

Page 54: ...a configuration all previously made changes that have not been saved will be lost You can not undo this action Importing and exporting a configuration Using the Import and Export buttons you can import and export a configuration including the tag names used as a CSV file comma separated values This allows you to import and use tag names you have assigned in the MELSEC WS project in the Programmabl...

Page 55: ...dule Report Diagnostics and Data Recorder view Specific toolbar for the logic editor with the following functions Add Delete Rename page Print current page Zoom Copy Cut Paste Delete elements Undo Redo last action Open dialog to edit logic result markers Show Hide grid Show grid of lines dots Show function block I O description Search function block Start simulation mode and Start forcing mode Sel...

Page 56: ... block have been connected the function block is displayed yellow Alternatively it is possible to place and connect inputs or outputs in one step Drag an input or output while keeping the left mouse button pressed to the desired function block input or output node If the mouse pointer hovers over the node it will be highlighted Then drag the input or output to the place on the worksheet where it s...

Page 57: ...sword protection for Logic pages option Enter passwords for the logic access levels 1 and 2 Click OK How to log in for a logic access level In the hardware configuration right click on the CPU module and select the Change in access for Logic pages command from the context menu In the Current User Level area click on Log in In the Log in dialog box select the logic access level for which you want t...

Page 58: ... appears in the upper right corner of the screen Additionally a warning icon marks the erroneous page of the logic program and the function block that is not connected correctly e g one or more inputs are not connected is displayed orange As long as the configuration is invalid it is not possible to start the simulation mode or to transfer the configuration to the MELSEC WS safety controller How t...

Page 59: ...sition from the Stop state to the Run state For all following logic cycles it remains Low This input can be useful to trigger initialization functions in the logic program Simulation bit You can be set this bit to 0 Low or 1 High in simulation mode or force mode Otherwise the bit is always 0 This bit is only available with a CPU module with firmware version V 3 02 and higher and Setting and Monito...

Page 60: ...ation with different Flexi Link ID found See also Section 7 4 7 5 6 6 Module input and output status bits in the logic editor The input and output status of the connected network modules and safety I O modules is available in the Diagnostics tab of the logic editor and can be used as input for the logic programming In some applications an evaluation of this status information can be important in o...

Page 61: ...ake the delay caused by CPU markers into account CPU markers always cause a delay of one logic execution time because the input marker always uses the value of the output marker in the previous logic cycle The resulting delay must be considered for the response time calculation and for the functionality How to use a CPU marker Connect a CPU output marker e g Marker 0 0 from the Outputs tab of the ...

Page 62: ...n jump address in the following logic cycle i e with a delay of the logic execution time If a jump address causes a loop back this is indicated automatically by an additional clock symbol shown on the destination jump address icon The resulting delay is equal to the execution time and must be considered for the response time calculation and for the functionality How to use a jump address First add...

Page 63: ...uts are listed By checking or unchecking the checkboxes you can select which inputs and outputs shall be displayed in the I O matrix This can be useful in complex projects with many inputs and outputs to condense the displayed information to the most important aspects I O matrix in simulation mode In simulation mode see Section 9 14 the I O matrix displays the values of the used inputs and outputs...

Page 64: ...dules Network module at address 13 14 Input and output data set tag names network modules EFI1 EFI2 Input and output tag names for devices on EFI interface 1 and 2 RS232 HMI RS 232 I O tag names The tag names of the selected type are listed in a tree view on the right side of the screen If a device type is not available in your project e g no SICK EFI compatible device connected then the correspon...

Page 65: ...tag names and Export tag names buttons at the top left of this window you can save the tag names as a text file in the CSV format comma separated values or import tag names from a CSV file or Excel file Symbol Meaning Import tag names Export tag names Table 7 Buttons for exporting and importing tag names ...

Page 66: ...es between a hardware oriented and a function oriented report structure Detailed information on using the wiring information at the end of the report is available in the Safety Controller User s Manual You will find example application reports in the annex of this manual see Section 15 1 Exercise for the Report view Open the Report view by clicking on the Report button Use the Change report struct...

Page 67: ...nformation warning recoverable error critical error Source Module that detected the error Category Part of the module that detected the error Information Internal information about the error Occurrence counter Number of times this error has occurred If an error occurs several times in a row only the last occurrence will be recorded and the occurrence counter is increased Power on hour Total time s...

Page 68: ...the Diagnostic Settings dialog activate the Automatic Refresh checkbox and enter the desired refresh interval in seconds Using the Show history button you can display or hide older messages still stored in the MELSEC WS safety controller The Filter pull down menu enables you to display or hide different types of messages In the menu click on the different message types to activate or deactivate th...

Page 69: ...dows for the Inputs or Outputs on which the signals are to be recorded For this purpose drag the required inputs and outputs from the selection window to the data display window Data display window 1 where the signals recorded on the inputs and outputs are displayed Toolbar with icons to import export and delete the data recorded to increase or reduce the size of the view or to reset it to its ori...

Page 70: ...ion window to the data display window You can then define in the Trigger and trace configuration selection window when the data recording is to start Continuous The recording starts immediately after you click the Start recording button Trigger After you have clicked the Start recording button the recording only starts once the trigger condition you have defined is met For this purpose select one ...

Page 71: ...d on the PC Click on Com settings to ensure the correct communication interface has been selected The following dialog appears To edit the settings click on the pencil icon to the right The following dialog appears Modify the settings if required Click OK The Connection settings dialog closes Click on Connect The Setting and Monitoring Tool will search for connected MELSEC WS modules and load the ...

Page 72: ...ool by double clicking the icon or alternatively configured and verified locally at the device via the RS 232 interface For this purpose the SICK configuration and diagnostics software CDS is used The SICK configuration and diagnostics software CDS included in Setting and Monitoring Tool is the product of SICK For CDS please contact your local SICK representative see Annex Section 15 4 http www se...

Page 73: ...ting the connection profiles is opened All existing connection profiles are displayed here The currently activated profile is marked light green and with bold typeface the profile selected for editing is marked blue At the bottom of the dialog an overview of the current settings is displayed The symbols for editing the profiles have the following meaning Symbol Meaning Save profile with the curren...

Page 74: ...t for the new profile or activate the COM auto detection checkbox Select a fixed baudrate or activate the Auto scan checkbox Click OK The dialog is closed and the new profile is displayed in the list To activate the new profile select it using the left mouse button and click on the green arrow symbol on the right From now on the Setting and Monitoring Tool will use this profile Figure 42 Create ne...

Page 75: ...e for the new profile Select a CPU module to be conneted in Connected Devices Click OK The dialog is closed and the new profile is displayed in the list To activate the new profile select it using the left mouse button and click on the green arrow symbol on the right From now on the Setting and Monitoring Tool will use this profile Figure 43 Create new profile dialog USB ...

Page 76: ... an Ethernet interface module WS0 GETH which must be configured with a valid IP address for your network For detailed instructions on the Ethernet interface module configuration please see the Safety Controller Ethernet Interface Module User s Manual Click on the Add TCP IP profile button The Create new profile dialog is opened Note Figure 44 Create new profile dialog TCP IP ...

Page 77: ... list To activate the new profile select it using the left mouse button and click on the green arrow symbol at the right From now on the Setting and Monitoring Tool will use this profile How to check a profile Click on the green tick on the right side of the profile to be checked To check all profiles click on the Check all profiles button The Setting and Monitoring Tool checks the connection sett...

Page 78: ...network adapter from the dropdown list at the bottom of the dialog Click on the Scan button Your network is scanned for connected network modules and the network modules found are displayed in the list Click on the network module you want to edit Enter the new settings in the Edit IP address area Click on the Set device config button to transfer the new settings to the device Figure 46 List of net...

Page 79: ...or multiple PCs may result in inconsistencies of the configuration and the diagnostics as well as in operational errors Click on the Connect button The Setting and Monitoring Tool will try to connect to your MELSEC WS safety controller using the currently activated connection profile If a connection is established successfully the Setting and Monitoring Tool goes into online mode and you can perfo...

Page 80: ...Switch to the user group Operator If you leave the PC connected to devices without personal attendance or supervision you must log off from the user levels Maintenance or Administrator and switch to the user level Operator to make sure that no unauthorized person can transfer configurations to the devices The password protection relates to the configuration of the current devices The password is s...

Page 81: ... and Monitoring Tool In the Device menu choose the Identify project command The current project will be closed The Setting and Monitoring Tool will search for connected MELSEC WS modules and load the hardware configuration into the Hardware configuration dialog Once all modules have been identified the Setting and Monitoring Tool will ask whether the configuration shall be uploaded Click Yes if yo...

Page 82: ...stem requirements and restrictions for Flexi Link The minimum system requirements for Flexi Link are as follows System component Minimum version Hardware WS0 CPU1 or WS0 CPU3 with firmware version V2 00 or higher Software Setting and Monitoring Tool version 1 3 0 or higher The Flexi Link system can be connected using only EFI1 or using both EFI1 and EFI2 The overall number of status bits per stati...

Page 83: ...If a differing Flexi Link ID is detected in a Flexi Link system all connected stations will change into Invalid configuration mode MS LED flashing red at 1 Hz The Flexi Link IDs are numeric values that are calculated from the default values for the process image This means that a change of the default values for the process image of any station will change the Flexi Link ID of all stations Adding ...

Page 84: ... configuration you have changed Otherwise the new Flexi Link IDs will be transferred only to this station while the other stations will keep the old Flexi Link IDs The resulting Flexi Link ID mismatch between the stations will disrupt the process image communication in the system If a differing Flexi Link ID is detected no process image transfer between the stations is possible and all CPU modules...

Page 85: ...or your Flexi Link system WS0 CPU1 or WS0 CPU3 modules safety I O modules and connected devices such as sensors switches actuators etc For information on wiring please see the Safety Controller User s Manual Step 2 Establish a connection to your Flexi Link system Connect a PC or notebook to the RS 232 interface of any CPU module in the system Power on the Flexi Link system Open the Setting and Mon...

Page 86: ...Hz You will need the password for Administrator The default password is MELSECWS To stop the LED flashing click the button again it is now labeled Stop identify Check the serial number on the memory plug and compare it with the serial number shown in the Setting and Monitoring Tool Click on the Apply settings button in the upper left hand corner of the screen The Flexi Link addresses of the statio...

Page 87: ...s on this station When the hardware configuration is complete click Disconnect You can now configure your project as described in Section 7 3 3 The Disconnect command in the System overview will disconnect all Flexi Link stations simultaneously The buttons for Transfer and Upload react the same way as well If you switch to the view for an individual station these buttons will affect only that stat...

Page 88: ...ime later Now add the first station to your project Click one of the buttons for adding a new station on the left side of the screen This will open the view for this individual station Alternatively you can also switch to the view for an individual station using the Station buttons in the toolbar at the top of the screen In the view for the individual station add the desired hardware for this stat...

Page 89: ... and then an WS0 XTIO module for Station A Connect a single channel emergency stop button to input I1 and a single channel reset button to input I2 of the Station A WS0 XTIO module Connect a single channel robot to output Q1 and a lamp to output Q2 of the Station A WS0 XTIO module Now click on the button for Station B in the toolbar The Hardware configuration view for Station B opens Add a CPU1 or...

Page 90: ...PU1 or CPU3 A square with the letter A D within it denotes a bit within the Flexi Link process image Each output can be used only once Used outputs are displayed green Connect the outputs of the Routing N N function block to the two CPU1 A outputs e g Info 0 3 CPU1 A EFI1 and Info 0 4 CPU1 A EFI1 as shown in Figure 57 Note which input is being routed to which output In more complex projects config...

Page 91: ... 0 and its bits in the lower half of the window Now replace the default tag names e g Safe 0 3 and Safe 0 4 with more expressive tag names e g Global Reset and Global E stop The assigned tag names will be displayed in the logic editor from now on It does not make a difference for the routing whether you use the default tag names or change them but assigning clear tag names will help you to keep tr...

Page 92: ...s Using these inputs the output elements on the Station B WS0 XTIO module and a Restart function block create the following logic configuration With this step the example project is finished The input from the emergency stop button and from the reset button connected to Station A is routed to Station B via Flexi Link so that the robots connected to both stations can be controlled simultaneously Fi...

Page 93: ...Tool installed on the PC and load the project file with your configuration If necessary adjust the communication settings see Section 6 2 Switch to the Flexi Link system overview The configured stations in your project will be displayed with a light yellow background Click on Connect You will be prompted to select the stations you want to connect to Activate all stations then click OK If the CPU m...

Page 94: ...ion to Select all stations and click on OK The Setting and Monitoring Tool will now transfer the configuration to each station You will need the password for Administrator the default password is MELSECWS Once a valid configuration has been transferred to a station successfully the Setting and Monitoring Tool will ask you whether you want to set this station into the Run state Click either Yes or ...

Page 95: ...he configuration from the module and compare it to the configuration in the Setting and Monitoring Tool If both configurations match the result will be displayed as a report and you will be asked whether you want to set the device to Verified Read the report carefully You can print the report or save it in PDF format If you have checked the report and want to set the device to Verified click Yes T...

Page 96: ...ation that is exchanged between the connected Flexi Link stations See Section 7 4 2 In the Flexi Link Network settings view you can scan the Flexi Link network for connected stations view and assign the Flexi Link address to the connected stations and distribute the stations to their individual positions A to D in the Flexi Link network See Section 7 4 3 The EFI1 2 and EFI1 radio buttons are used ...

Page 97: ...rated in the Network modules menu 7 4 1 Flexi Link system System overview The Flexi Link System overview provides information on the configured connected stations and their status To open the system overview first click on the Flexi Link system button in the toolbar and then on the System overview button In this view each station is displayed with its current hardware configuration information on ...

Page 98: ... stop the application etc Disconnect Disconnects from this station so that you can e g edit the configuration If a function is not available the corresponding icon is displayed grey Instead of clicking the Add or Edit button you can also switch to the view for an individual station by clicking the corresponding button for Station A to D or by double clicking on that station s graphical representat...

Page 99: ...I1 and EFI2 if used are displayed with their tag names Bits that are currently High in the process image are highlighted green If a station is not in the Run state its process image will be set to Low and its I O error status bits will be set to High see Section 5 6 5 Double clicking on the hardware symbol for a station will open the routing view for this station where you can edit the tag names f...

Page 100: ... are shown with their current address assignment address A to D Additionally the memory plug serial number and the current Flexi Link IDs for EFI1 and EFI2 of each station are displayed here You can update this information using the Scan button at the top left of the window Error messages and warnings regarding the current system status are displayed as a pop up message for each station You have t...

Page 101: ...n the switching cabinet from left to right for better orientation If you change the address assignment of a Flexi Link system you may have to reconfigure the process image and the parts of the logic programming that use input bits from the Flexi Link process image because the Flexi Link address is part of the bit assignment in the process image 7 4 4 Flexi Link stations Flexi Link data in the logi...

Page 102: ...Link process image Each output bit can be used once Outputs that are already in use are displayed green You can edit the tag names of the output bits in the Flexi Link station X view see Section 7 4 5 How to send information into the Flexi Link network Drag the bit you want to define on the worksheet and connect it to the output of a function block To have the value of an input available directly ...

Page 103: ... You can edit the tag names in the Flexi Link station X view of the originating station see Section 7 4 5 7 4 5 Flexi Link stations Station X view and process image In the Flexi Link station X view you can do the following Edit the tag names for the bits and bytes that this station sends to the Flexi Link network Set the default values for this station s process image bits to Low or High see also ...

Page 104: ...e Outputs tab with their new tag names Some bits are reserved and can not be used or edited These bits are displayed grey in the upper half of the window You can also delete tag names Bits that have no tag name can not be used They will be displayed grey in the upper half of the window and they are not displayed in the Flexi Link process image see also Section 7 4 2 How to set the default values C...

Page 105: ...d in the Run state it will trigger the complete system to perform a network scan and to treat all missing stations as suspended I e the system will function as if these stations were still online and use their default process images Before you use the Teach function check whether a dangerous state can occur If the Teach function is used the safety outputs on any of the still active stations may be...

Page 106: ... dual channel key operated switch In the logic editor for these stations use a Restart function block to connect the Teach button input to this station s Teaching output as shown in Figure 79 If the Teach button is pressed the Teaching output will become High for one logic cycle The rising edge Low to High on the Teaching output triggers the Teach function Ensure that the transitions of the signal...

Page 107: ...atus bit Teach required becomes High Now press the Teach button again The system will reintegrate the suspended station and continue operation The Teach required system status bit will become Low as well as the respective EFI status bits e g Station C missing remains Low and Station C taught also becomes Low If a station is missing not because its power supply has been switched off but due to an i...

Page 108: ...A B C or D is missing In this case the process image of the corresponding Flexi Link station is set to Low and the EFI I O error bit is set to High This means that the Station missing status bit see above is High as well Station X taught The station with the Flexi Link address X A B C or D is suspended In this case the default process image of the corresponding Flexi Link station is used Using the...

Page 109: ...ID mismatch This means that at least one of the stations in the system has one or two Flexi Link IDs that differ from the other stations Flexi Link IDs Diagnostics Switch to the Flexi Link System overview If the Setting and Monitoring Tool is not connected to the system connect to all stations Check the status messages of the stations for indication of a Flexi Link ID mismatch Correction of the er...

Page 110: ...bal or local bytes can be defined The process image can contain up to 12 bytes or 96 bits The maximum cable length between 2 stations is 1000 meters The possible total length of a system with 32 stations is therefore 31 kilometers 8 1 1 System requirements and restrictions for Flexi Line For Flexi Line the following system requirements must be met as a minimum System component Version Hardware WS0...

Page 111: ...ar The view is also opened automatically if you add a Flexi Line element to an WS0 CPU3 The Flexi Line view comprises the following elements menu bar with the Project Device Extras menus toolbar with icons for quick access to frequently used menus tabs for changing to the Hardware configuration Logic editor Network modules Report Diagnostics and Data recorder views toolbar for Flexi Line configura...

Page 112: ...s well as a revision number consisting of a major revision number and a minor revision number The checksum for the process image CRC is also displayed here see section 8 2 3 On the right you can define the size of the process image and the update rate The possible values are dependent on the maximum segment length in the complete Flexi Line system see Table 18 If a cell in the table is displayed i...

Page 113: ...d for one or both immediately neighboring stations or global in the entire Flexi Line system A byte that is valid globally is communicated to the entire Flexi Line system All stations can read and change each bit of this byte If a station changes a bit this change will be effective on all other stations A byte that is valid locally is shared with either one or both immediately neighboring stations...

Page 114: ... in a Flexi Line system must have an identical checksum This ensures that only stations that belong to the same Flexi Line system can communicate with each other If a different checksum is detected in a Flexi Line system then all connected stations will change to the Error on the Flexi Line bus mode Line LED flashes Red green at 2 Hz The checksum is calculated from the following settings size of t...

Page 115: ...cess image The output process image is prepared with the aid of Routing function blocks Here the signals on the local inputs must each be routed to a Flexi Line output Then the values on these local inputs are available in the entire Flexi Line system as Flexi Line inputs via the Flexi Line process image In the context of the logic programming the Flexi Line inputs do not differ from other types o...

Page 116: ...ty measures have to be implemented if the Teach function is enabled Consider how to handle the disconnected machine modules Point out that the control parts and sensors have no effect to the previously connected machine modules e g install out of order signs at E stops The teach function must be considered as a configuration process Therefore the Teach function needs to be secured according to the...

Page 117: ...n you can also run the Teach function using a pushbutton How to configure the Teach function using a pushbutton Connect a Teach button to the inputs of the station in the Flexi Line system that shall be able to activate the Teach function The Teach button can be e g a dual channel key operated switch In the logic editor for this station use a Restart function block to connect the Teach button inpu...

Page 118: ... in the Detail overview area on the right On the left you can see the input bits that are received from the two neighboring stations as well as the status of the local inputs On the right you can see the output bits that are sent to the two neighboring stations as well as the status of the local outputs If the Flexi Line system is online active bits are shown in color and inactive bits in gray In ...

Page 119: ...the process image must be transferred to these stations Each station in a Flexi Line system must be configured in Setting and Monitoring Tool as an individual station and placed in operation Configuration of the first station in the Setting and Monitoring Tool Open the Setting and Monitoring Tool software on your PC or notebook In the startup dialog click on Create new Flexi Link project or choose...

Page 120: ... 2 Hz Once all stations are in the Teach required status change to the Flexi Line view while Setting and Monitoring Tool is connected to any station Click the Teach button on the toolbar to place Flexi Line in operation The topology of the system is then checked and confirmed and the Flexi Line system is started 8 3 2 Conversion of a Flexi Line system New stations can be added to an existing Flexi...

Page 121: ...he hardware configuration The station is connected via Flexi Line to identical or similarly configured stations on which the states of the two buttons should also be available For this purpose two bits are used in the process image Bit 1 global byte default value high name E stop This bit collects all emergency stop commands from all stations If an emergency stop pushbutton is actuated on any stat...

Page 122: ...er 8 119 Flexi Line Then these signals can be evaluated in the logic on any station in this Flexi Line system in the following manner Figure 90 Usage of signals from the Flexi Line process image in the logic ...

Page 123: ...e in accordance with your risk avoidance strategy Take additional safety measures if the safe value may lead to a dangerous condition The safe value of process data and outputs is Low which is applied if an error is detected If the safe value signal Low may lead to a dangerous condition in the application additional measures must be taken e g evaluation of the status of the process data and switch...

Page 124: ...re the input uses the output value of the previous logic cycle This must be considered for the functionality and especially for the response time calculation To connect a loop back signal a jump address or a CPU marker must be used A CPU marker generally causes a delay of one logic cycle A jump address causes a delay of one logic cycle if it constitutes a loop back If this is the case the input of...

Page 125: ...Adjustable on delay timer Adjustable off delay timer Counter and cycle Event counter up down up and down Clock generator Ramp down detection Frequency monitor Log generator EDM Output blocks EDM Valve monitoring Fast shut off with bypass Fast shut off Muting Press Sequential muting Parallel muting Cross muting Universal press contact Press single stroke Press setup Press automatic N break PSDI Pre...

Page 126: ...have further parameters that are defined on the properties page of the function block shown above On the Parameter tab and on the I O settings tab you will find the configurable parameters depending on the function block The I O comment tab allows you to replace the standard I O descriptions of the function block with your own names and to add a name or a descriptive text to the function block tha...

Page 127: ...d as inverted This means that the function block evaluates a High signal at an inverted input as Low and vice versa In order to invert an input double click on the function block icon and check the desired input on the parameter page of the function block properties dialog Inverted inputs are displayed with a small white circle Examples of function blocks with invertable inputs include the followi...

Page 128: ... physical outputs with a single function block use the Routing 1 N function block The behaviour of the outputs is explained at the description of the individual function blocks You can choose whether error and diagnostics outputs are displayed In the configuration basic setting of the function blocks only the Enable output and some further outputs are selected e g Reset required In order to displa...

Page 129: ...block The Fault present output changes to High when an error has been detected on the basis of the configured function block parameters e g discrepancy time error function test error synchronization error etc When the Fault present output is High the main output e g the Enable output changes to Low The Fault present output is set to Low if all errors are reset The conditions to reset an error are ...

Page 130: ...the logic editor in the FB preview window It has a precision of 100 ppm parts per million Effect of tested sensors During a test signal the signal bit is frozen i e the value that was present prior to the test gap is retained for the duration of the test signal and possibly also the max off on delay As a result a signal change can be delayed by this time i e a pulse can be longer or shorter 9 7 Lo...

Page 131: ...ues Number of inputs 2 to 8 Invert input x Each input of this function block can be inverted see Section 9 5 2 Truth table The following applies for the truth tables in this section 0 means logic Low 1 means logic High x means any 0 or 1 Truth table for AND evaluation with one input Input 1 Output 1 0 0 1 1 Truth table for AND evaluation with two inputs Input 1 Input 2 Output 1 0 x 0 x 0 0 1 1 1 F...

Page 132: ... are attached to the inputs of the function block the output would become High as soon as at least one of the light curtains is free Parameters of the function block Parameter Possible values Number of inputs 2 to 8 Invert input x Each input of this function block can be inverted see Section 9 5 2 Truth table The following applies for the truth tables in this section 0 means logic Low 1 means logi...

Page 133: ...x x x x x 1 1 9 7 4 XOR exclusive OR Function block diagram General description The output is High only if both inputs are complementary i e with contrary values one input High and one input Low Truth table The following applies for the truth table in this section 0 means logic Low 1 means logic High Truth table for XOR evaluation Input 1 Input 2 Output 1 0 0 0 0 1 1 1 0 1 1 1 0 Table 27 Truth tab...

Page 134: ...means logic Low 1 means logic High Truth table for XNOR evaluation Input 1 Input 2 Output 1 0 0 1 0 1 0 1 0 0 1 1 1 9 7 6 Multiple release Function block diagram General description Using the multiple release function block an AND operator can be applied to up to 7 inputs along with the Release input 7 times AND Figure 103 Function block diagram for the Exclusive NOR XNOR function block Table 30 T...

Page 135: ...lock stores the last value of the inputs Set or Reset It is used as a simple storage cell The Reset signal has a higher priority than the Set signal If Set was High last output Q is High and output Q Q inverted is Low If the Reset input was High last output Q is Low and output Q is High Parameters of the function block Parameter Possible values Invert Set Each input of this function block can be i...

Page 136: ...t the Clock input In this case If J input is High and K input is Low the Q output will be High and the Q Q inverted output will be Low If J input is Low and K input is High the Q output will be Low and the Q output will be High If both inputs are Low the last values of outputs Q and Q will be held If both inputs are High the outputs will toggle i e their last values will be inverted Parameters of ...

Page 137: ...ut Q n x x 0 1 or 0 0 1 x x 0 1 or 1 1 0 0 0 0 0 1 0 0 1 1 0 0 1 0 0 1 0 1 1 0 1 1 0 0 1 0 1 0 1 1 0 1 1 0 1 0 1 1 1 0 1 9 7 9 Multiple memory Function block diagram General description Using the multiple memory function block the state of up to 7 inputs can either be forwarded unchanged or saved depending on the Latch input If the Latch input is low the state of inputs 1 to 7 is forwarded unchang...

Page 138: ...Latch input Latch output Output Xn 0 0 Input x Input x 1 1 Output xn 1 9 7 10 Clock generator Function block diagram General description The Clock generator function block is used to generate a pulsed signal When the Enable input is High the Clock output pulses from Low to High and back to Low in accordance with the parameter settings of the function block When the Enable input is Low the Clock ou...

Page 139: ... pre defined overflow value is reached this will be indicated on the Overflow output or when zero is reached this will be indicated on the Underflow output Depending on the required counting direction there are the function blocks Event counter Up Event counter Down and Event counter Up and down Parameters of the function block Parameter Possible values Counter reset Manual Automatic Counter reloa...

Page 140: ...ired duration of the pulse at the Reload input Valid values are 100 ms and 350 ms If the pulse duration is shorter than the configured minimum pulse time or longer than 30 s the pulse is ignored Ensure that the transitions of the signals for resetting or reloading value fulfill the requirements In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can have a pulse ...

Page 141: ...Truth table for the Event counter function blocks Up Down and Up and down The following applies for the truth table in this section 0 means logic Low 1 means logic High means that a rising edge has been detected at the input means that a falling edge has been detected at the input n 1 references the preceding value n references the current value Y references the value of the internal counter X mea...

Page 142: ... shut off with bypass function block however allows to temporarily bypass the Fast shut off function using the bypass input The Fast shut off with bypass function block is only available with WS0 XTIO with firmware version V2 00 or higher Example In the following logic example the C4000 will switch off the Q2 motor Simple logic such as this can be accomplished within the Fast shut off function blo...

Page 143: ...t off with bypass 1 to 7 Select output for fast shut off All outputs of the safety I O module whose inputs are connected to the function block if the output is not already used for Fast shut off How to configure the Fast shut off function block The following example shows the function with three light curtains attached to a Fast shut off function block To configure the Fast shut off function block...

Page 144: ...s needed leave the Zone 2 AND function block inputs unchecked If additional OR logic is required in the application the inputs can be combined using the Zone 1 and Zone 2 AND function blocks and subsequently connecting to the internal OR function block Finally select the output for Fast shut off Figure 116 Parameter settings dialog for the Fast shut off function block Note Figure 117 Output select...

Page 145: ...ine is in a safe condition when using the bypass function As long as the bypass function is active any stopping condition e g the infringement of a protective field will not lead to a shut off of the machine You must ensure that other protective measures are forcibly activated during the bypass e g the safe machine setup mode so that the machine cannot endanger persons or parts of the system durin...

Page 146: ...e to implement further bypass conditions in the logic editor between the output of the Fast shut off function block and the connected WS0 XTIO Be aware that in the logic online monitor the value of the connected WS0 XTIO output may differ from the effective value at the physical output of the WS0 XTIO For example the connected output can be Low as a result of the subsequent logic while the output ...

Page 147: ...edge a negative edge or both If an edge corresponding to the parameter settings is detected the Edge Detected output changes to High for the duration of the logic execution time Parameters of the function block Parameter Possible values Edge detection Positive Negative Positive and negative Sequence timing diagram Figure 120 Function block diagram for the Edge detection function block Table 43 Par...

Page 148: ... Priority to binary Input 1 dominant Use fault present With Without One out of N In One out of N mode only one input may be High at the same time The outputs are set dependent on the index input 1 1 input 2 2 of the High input If all inputs are Low or if more than one input is High at the same time all outputs are set to Low and Fault present becomes High Priority In Priority mode more than one in...

Page 149: ...t present 0 0 0 1 0 1 0 0 1 0 1 0 1 1 0 1 Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1 Output C Output B Output A Fault present 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 1 1 0 0 0 0 1 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 1 0 1 0 0 1 0 0 0 0 0 0 1 1 0 0 1 0 0 0 0 0 0 0 1 1 1 0 More than one input 1 0 0 0 1 Table 4...

Page 150: ... 0 0 0 0 0 0 0 0 0 0 0 1 x x x x x x x 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 1 x 0 0 1 0 0 0 0 0 0 1 x x 0 0 1 1 0 0 0 0 1 x x x 0 1 0 0 0 0 0 1 x x x x 0 1 0 1 0 0 1 x x x x x 0 1 1 0 0 1 x x x x x x 0 1 1 1 0 Table 50 Truth table for the Binary encoder function block with 8 inputs in Priority mode with dominant input 1 Evaluate Fault present if the Binary encoder function block is used for...

Page 151: ...e binary codes with decimal values from 0 to 31 Parameters of the function block Parameter Possible values Encoder mode One out of N Priority Inputs Not inverted Inverted Number of inputs 1 to 5 Value range 0 7 8 15 only available if more than 4 inputs are used 16 23 only available if 5 inputs are used 24 31 only available if 5 inputs are used One out of N In One out of N mode only the output with...

Page 152: ...ary decoder with 3 inputs in One out of N mode Input A Output 2 Output 1 0 0 1 1 1 1 Input B Input A Output 4 Output 3 Output 2 Output 1 0 0 0 0 0 1 0 1 0 0 1 1 1 0 0 1 1 1 1 1 1 1 1 1 Input C Input B Input A Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 1 1 0 1 0 0 0 0 0 0 1 1 1 0 1 1 0 0 0 0 1 1 1 1 1 0 0 0 0 0 1 1 1 1 1 1 0 1 0 0...

Page 153: ...ue range is set to 16 23 the function block will behave as shown in the truth tables above depending on the values of inputs A B and C and the configured Encoder mode One out of N or Priority If Input D and Input E are set to a lower value than the Value range parameter e g Input E 0 Input D 1 and Value range 16 23 all outputs are Low independent of the configured Encoder mode One out of N or Prio...

Page 154: ...on 5 8 These messages will be deleted when the voltage supply for the MELSEC WS safety controller is interrupted Parameters of the function block Parameter Possible values Number of inputs 1 to 8 Messages Up to 64 user defined messages per project Message assignment Rising edge Falling edge Rising or falling edge How to configure the Log generator function block The following example shows the Log...

Page 155: ...er the messages that shall be output in the diagnostics The messages entered are valid globally for all Log generator function blocks used in a project In a single project you can enter up to 64 different messages with a length of up to 32767 characters each Using the Import from CSV and Export to CSV buttons at the top left of the window you can save the messages to a text file in CSV comma separ...

Page 156: ...h the lower function block index is prioritized i e the messages generated by this function block will be logged first 9 7 17 Routing 1 N Function block diagram General description The Routing 1 N function block passes an input signal from a preceding function block to up to eight output signals This function block makes it possible to connect an output of a function block or an input element with...

Page 157: ...ht outputs The input signal can originate from a preceding function block or directly from a physical input Parameters of the function block Parameter Possible values Number of inputs 1 to 8 Invert input x Each input of this function block can be inverted see Section 9 5 2 Figure 131 Function block diagram for the Routing N N function block Table 62 Parameters of the Routing N N function block ...

Page 158: ...tput The Reset required output shows by pulsing at 1 Hz that the function block expects a valid reset pulse at the Reset input so that the Enable output can become High This is the case if the Release condition fulfilled output is High i e all activated Release inputs are High but the Enable output is still Low Typically this output is used to control a signal lamp Enable output The Enable output ...

Page 159: ...ption The internal logic of the Restart function block has the same functionality as the Reset function block The Restart function block allows graphic differentiation between the function blocks with regard to the observation of application standards for acknowledging a manual restart request Parameters of the function block Parameter Possible values Min restart pulse time 100 ms 350 ms Number of...

Page 160: ...the minimum required duration of the pulse at the Restart input Valid values are 100 ms and 350 ms If the pulse duration is shorter than the configured minimum pulse time or longer than 30 s the pulse is ignored The Enable output becomes Low if one or more Release inputs become Low Ensure that the transitions of the signals for restarting fulfill the requirements In case of a short circuit to High...

Page 161: ...than the logic execution time The timer begins with the delay sequence when a falling edge High to Low on the input occurs If the timer has expired after the configured delay period the Enable output changes also to Low provided the input remains Low If the input changes to High the Enable output is set to High immediately and the delay timer is reset Sequence timing diagram Figure 136 Function bl...

Page 162: ... the selected overall delay period the Enable output changes also to Low provided the Control input remains Low If the Control input changes to High the Enable output is set to High immediately and the delay timer is reset If during a running delay sequence any Delay input changes its value the Time changed output changes to High and remains High until the Control input becomes High again The effe...

Page 163: ...han the logic execution time The timer begins with the delay sequence when a rising edge Low to High on the input occurs If the timer has expired after the configured delay period the Enable output changes also to High provided the input remains High If the input changes to Low the Enable output is set to Low immediately and the delay timer is reset Sequence timing diagram Figure 140 Function bloc...

Page 164: ...ed overall delay period the Enable output changes also to High provided the Control input remains High If the Control input changes to Low the Enable output is set to Low immediately and the delay timer is reset If during a running delay sequence any Delay input changes its value the Time changed output changes to High and remains High until the Control input becomes Low again The effective overal...

Page 165: ...rectly Output 1 and Output 2 become High if the EDM feedback is High and the Monitored input changes from Low to High subsequently Output 1 and Output 2 become Low if the Monitored input is Low or if an EDM error is present EDM error output is High EDM error and Fault present Generally it is expected that the EDM feedback input always takes the inverted value of the Monitored input before the conf...

Page 166: ...DM function block and not after it Otherwise this can result in an EDM error Sequence timing diagram 9 8 8 Valve monitoring Function block diagram General description The Valve monitoring function block allows to control valves and to check on the basis of their feedback signals whether they have switched as expected To this purpose the valves are connected with Output 1a to Output 2b The feedback...

Page 167: ... time Min reset pulse time 100 ms 350 ms Use fault present With Without Connect the feedback signals correctly The signals for Feedback 1 and Feedback 2 have to be protected against short circuits to the signals for outputs e g Output 1a 1b 2a and 2b as well as against each other e g by means of protected wiring or wiring of these signals solely within the control cabinet Output 1a to Output 2b Bo...

Page 168: ...ontrol 1 and Control 2 inputs are High at the same time The Fault present output becomes High if Feedback error and or Directional error is High The Feedback error Directional error and Fault present outputs become Low if all activated Control inputs are Low and all activated Feedback inputs are High If the Reset condition is configured as Manual reset a valid reset pulse must be applied at the Re...

Page 169: ...ion blocks Sequence timing diagrams Figure 147 Sequence timing diagram for single valve in manual reset mode Figure 148 Sequence timing diagram for double valve in manual reset mode Figure 149 Sequence timing diagram for directional valve ...

Page 170: ...h and all outputs change to the value defined in the error output combination If in the first logic cycle after the transition from the Stop state to the Run state there is no valid input combination the configured error output combination is applied to the outputs and the Fault present output changes to High immediately Parameters of the function block Parameter Possible values Discrepancy time 0...

Page 171: ...no input High for equal or longer than the set discrepancy time 1 Error output combination Sequence timing diagram If the inputs of the function block are connected to inputs of an safety I O module which are connected to test outputs and the faulty input combination is the result of a test pulse error stuck at high which leads to a Low input value the test pulse error needs to be reset first e g ...

Page 172: ...l invert the corresponding output signal as well E g if input 1A is High but configured as inverted it will be evaluated as Low and output 1A will be set to Low Hold time for outputs The Hold time for outputs defines the time delay between the first change of any input signal and the latching of the input signals i e the reaction of the outputs This can be used to compensate delays e g between the...

Page 173: ...s elapsed the values of the inputs 1A to 3B at this point of time are applied to output 1A to 3B irrespective of the result of the antivalence check The outputs keep these values until the next synchronization process occurs Antivalence check If this function is enabled an antivalence check is performed every time when the Hold time for outputs has elapsed i e every time when the outputs take the ...

Page 174: ...unction blocks Sequence timing diagrams Figure 154 Sequence timing diagram for the Switch synchronization function block without cascading Figure 155 Sequence timing diagram for the Switch synchronization function block with cascading ...

Page 175: ...s 1 error input 2 error inputs Number of inputs or Number of outputs 1 to 6 Error output combination For each output individually High Low Truth table The following applies for the truth table in this section 0 means logic Low 1 means logic High x means any 0 or 1 Error input 1 Error input 2 Output 1A Output 1B Output 2A Output 2B Output 3A Output 3B 1 x Error output combination x 1 Error output c...

Page 176: ...is High and during the stop detected state Ramp down ended output is High the Incremental inputs are not monitored for signal changes see Figure 163 The function block allows an optional plausibility check of the Incremental inputs to detect cable interruptions provided that the encoder provides appropriate signals e g complementary outputs or proximity switches and a tooth wheel with 270 tooth wi...

Page 177: ...ased input It must be ensured that if this input is Low the torque of the drive is switched off in any case Encoders must be connected locally to a WS0 XTIO or WS0 XTDI module on the same Flexi Link station not via network or Flexi Link etc Configuration steps Check the minimum duration of the encoder pulses see step 1 below Determine the time between signal changes for the speed limit see step 2 ...

Page 178: ...ety door Define the maximum time that can pass between two signal changes at this speed highest values of t1 to t4 Take all possible tolerances into account e g switching tolerances tooth wheel tolerances etc Min time between signal changes highest values of t1 to t4 10 ms In any case the Min time between signal changes must be greater than the logic execution time and must be rounded up to a mult...

Page 179: ... time between signal changes for the speed limit Signal frequency for release 0 2 Hz 8 teeth revolution 1 6 Hz Max input pattern period 1 1 6 Hz 122 360 212 ms Time between signal changes 212 ms 10 ms 222 ms Min time between signal changes 230 ms rounded up to multiples of 10 ms Example 3 Zero pulse 10 1 tooth per revolution Switching tolerances 1 teeth 9 to 11 corresponds to tlow thigh signal cha...

Page 180: ...ence timing diagrams Figure 162 Logic example for the Ramp down detection function block Figure 163 Sequence timing diagram for the Ramp down detection function block Figure 164 Sequence timing diagram for the Ramp down detection function block with plausibility check ...

Page 181: ... s in 10 ms increments The value must be greater than the min period duration the logic execution time Average value of the pulse duration thigh 0 inactive 10 ms to 2 53 s in 10 ms increments With 0 inactive the pulse duration is not evaluated The pulse duration is then always valid for the evaluation If the value is not 0 it must meet the following conditions 2 x Logic execution time and Min peri...

Page 182: ...ased by this amount If the average period duration of the signal is greater than the limit for a reliably valid signal but lower than the limit for an reliably invalid signal then it can take several periods until the deviation has accumulated adequately such that an invalid signal is then evaluated Number of periods logic execution time 10 ms real averaged period duration effective limit for reli...

Page 183: ...le x output changes to high if two periods with a valid period duration and a valid pulse duration are detected on the Frequency x input If the pulse duration monitoring is inactive the pulse duration is always valid for the evaluation The Enable x output changes to low if an invalid signal has been measured on the Freqency x input i e if 1 the period duration measured is too short or 2 the period...

Page 184: ... changes to high i e two periods with a valid period duration and a valid pulse duration have been detected on the Frequency x input After the transition from the Stop state to the Run state all outputs are low Sequence timing diagrams Figure 167 Sequence timing diagram for the frequency monitor function block period duration too long Figure 168 Sequence timing diagram for the frequency monitor fu...

Page 185: ...equence is enabled and the function block goes into Waiting for start mode 3 A rising edge on the Inch forward or on the Inch backward input will trigger the start sequence The Startup active output changes to Low the waiting time and the signal time start and the Waiting time active output as well as the Warning output change to High for the duration of the signal time After expiration of the Wai...

Page 186: ... Possible values Direction switching Locked Not locked Waiting time 1 to 60000 ms in steps of 10 ms The value has to be greater than the logic execution time Release time 1 to 600000 ms in steps of 10 ms The value has to be greater than the logic execution time Signal time 0 to 6000 ms in steps of 10 ms If the value is not 0 it has to be greater than the logic execution time but smaller than the W...

Page 187: ...e can only be initiated after the Control input has changed to Low again Lock input A start sequence can only be initiated if the Lock input is High If the Lock input changes to Low during a start sequence the start sequence is aborted and another start sequence can only be initiated after the Lock input has changed to High again This input can be used for safety stops If inch mode is active a fal...

Page 188: ... active output is Low during the start sequence waiting or release time is running or if inch mode is active the Enable output is High The Startup active output can be used to lock other parallel Start warning function block instances To this purpose connect the Startup active output via a CPU marker to the Lock input of the other function block instance see Figure 171 Waiting time active output a...

Page 189: ...nch backward input causes a restart of the waiting time during the start sequence A rising edge at the Inch backward input causes a stop of the inch mode if the Inch forward input is High Figure 172 Sequence timing diagram for the Start warning function block in Not locked mode Figure 173 Sequence timing diagram for the Start warning function block in Locked mode Note ...

Page 190: ...ual types of input signal evaluations of the MELSEC WS safety controller Truth tables The following applies for the truth tables in this section 0 means logic Low 1 means logic High x means any 0 or 1 The Fault present output is High when the logic processing of the MELSEC WS safety controller detects an error in the combination or in the sequence of the input signals 9 9 1 Single channel evaluati...

Page 191: ...ation In this case the dual channel evaluation takes place in the function block The disadvantage of this alternative is that it requires one function block more in the logic which can lead to a higher logic execution time The advantage is that a discrepancy time error is made available via the output of the function block and can be evaluated in the logic The following function blocks generate th...

Page 192: ... start i e a timeout will never occur 2 Unchanged Last status is preserved 3 If the correct sequence has been observed For the change between the different states of the dual channel evaluation the following rules apply A dual channel evaluation can only change to Active Enable output changes from Low to High if since the last Active status at least once the status was Inactive i e it is not possi...

Page 193: ...ks The double dual channel evaluation synchronization evaluation evaluates the correct sequence of the two input signals for each of the two input pairs as described in Section 9 9 2 Additionally the correct sequence of the two dual channel evaluations in relation to each other is monitored It is expected that if one of the two dual channel evaluations has caused a switching off the other dual cha...

Page 194: ...evaluations must be Inactive at the same time for the Safety gate monitoring function block this can occur at different times as well It is not possible to switch from Active to Discrepant and back to Active the synchronization time has not elapsed or the synchronization time is deactivated and after the state change of the MELSEC WS safety controller from the Stop state to the Run state the synch...

Page 195: ...lt present output is required for further processing the function block can be used To this purpose the two input signals have to be configured as single channel signals and applied to the inputs of the function block In the case of emergency stop pushbuttons a Reset and or Restart function block has to take over the processing of the reset restart conditions for the safety chain when the Enable o...

Page 196: ...block only with a limited parameter selection The function block allows graphic differentiation in accordance with the application The Magnetic switch function block is a predefined function block for reed switches or other sensors for which discrepancy time monitoring is required When the evaluation of the complementary inputs is High the Enable output is High see Section 9 9 2 Parameters of the ...

Page 197: ...he Setting and Monitoring Tool this function block is no longer required in the logic since the pre evaluation is then carried out directly on the safety I O module e g WS0 XTDI or WS0 XTIO module But if the Fault present output is required for further processing the function block can be used to this purpose To this purpose the two input signals have to be configured as single channel signals and...

Page 198: ...ual channel complementary 1 pair Dual channel equivalent 2 pairs Dual channel complementary 2 pairs Function test No function test Function test required Discrepancy time pair 1 Discrepancy time pair 2 Can be set separately for the inputs 1A 1B and 2A 2B Values 0 disabled 10 to 30 000 ms in 10 ms steps If enabled the value has to be greater than the logic execution time Synchronization time 0 disa...

Page 199: ...put This is indicated by a High signal at the Function test required output The Function test required output changes back to Low if a signal sequence occurs at the inputs that causes the Enable output to change from Low to High before the next rising edge at the Function test request input occurs The Function test error output becomes High and the Enable output becomes Low if the next machine cyc...

Page 200: ...llowed to be met on the two inputs with a delay It is not imperative for the switch off condition to be met simultaneously on both inputs at least at one point in time Optionally an AND mode can be activated to make the evaluation even more tolerant in certain circumstances In this case even switching off only one input is accepted as a correct sequence without the need for the other input to foll...

Page 201: ...n time Use outputs Status input A and Status input B Without With Use Fault present Without With Dual channel monitor The value necessary on the two signals to achieve the required state depends on the Input mode selected There are two possibilities equivalent evaluation complementary sampling Input mode Input A Input B State of the tolerant dual channel monitor Equivalent 0 0 Inactive 0 1 Discrep...

Page 202: ...el monitor the following rules apply The tolerant dual channel monitor can only transfer to active Release output changes from low to high if the following criteria are met both inputs have each switched off once since the last active state and the discrepancy time has not elapsed or the discrepancy time monitoring for switching on is deactivated This means that it is not possible to change from a...

Page 203: ...depending on the Actuator released input If the AND mode is active then it is possible to change back to the active state by switching off and switching back on only one input without the need for the other input to switch as well If one or both of the inputs switches off in all cases the Release output is also switched off The value for switching off due to Input B is also dependent on the input ...

Page 204: ... two Status input A and Status input B outputs indicate the internal value on the two inputs A and B The outputs correspond to the value on the Input A and Input B inputs with the following exceptions The status output indicates the value for Switched off even though the related input is switched on with input mode equivalent low instead of high as the other input must first switch off before it i...

Page 205: ...the discrepancy time is fixed and cannot be changed Parameters of the function block Parameter Possible values Inputs Fixed value Dual channel equivalent Discrepancy time Fixed value 500 ms equivalent to the discrepancy time according to EN 574 Number of outputs 1 Enable output 2 Enable output and Discrepancy error output Use fault present With Without 9 9 10 Two hand control type IIIC Function bl...

Page 206: ...ime is the time during which the input pairs may have different values As specified in the standards and regulations the synchronization time for a two hand switch evaluation may not exceed 500 ms the synchronization time is preset and cannot be changed For the behaviour of the double dual channel evaluation see Section 9 9 2 and Section 9 9 3 The synchronization evaluation for the Two hand contro...

Page 207: ...ed to a signal that generates a pulse with each machine cycle In this way it can be prevented that one or more of the two hand controls remain actuated permanently The Operator inputs and the Release inputs must be pre evaluated signals Connect only safe pre evaluated signals to the Operator inputs e g the Enable output of a Two hand control type IIIA or Two hand control type IIIC function block A...

Page 208: ...Run state or after a rising or a falling edge depending on the configuration has been detected at the Cycle request input and all activated Operator inputs have changed to High subsequently The Enable output changes to Low if one or more of the Release inputs is Low or one or more of the Operator inputs is Low or a rising or a falling edge depending on the configuration has been detected at the Cy...

Page 209: ...sensors two sensor pairs and an additional signal C1 Muting sensor signals can be generated by the following external sensors optical sensors inductive sensors mechanical switches signals from the control system If you use optical sensors for muting applications use sensors with a background suppression in order to ensure that only the transported material fulfills the muting condition These senso...

Page 210: ...ondition here is that the required safety distances defined in EN ISO 13855 are observed At least two muting signals that are independent of each other are required Muting may only be activated for the period in which the object that triggered the muting condition blocks access to the hazardous area The area between the ESPE and the muting sensors must be protected against standing behind For Para...

Page 211: ...times check that the muting sensors function correctly A muting and or override lamp has to be used in order to signal that the muting or override function is active It is possible to use an external muting override lamp or one that is integrated in the protective device ESPE It may be necessary to monitor the muting override lamp depending on your local regional and national regulations and stand...

Page 212: ...sible values Direction detection Disabled Only with Parallel muting and Sequential muting Forward A1 A2 first Backward B1 B2 first Sequence monitoring Not selectable Defined by selection of the muting function block Enabled With Sequential muting Disabled With Parallel muting or Cross muting Condition of other sensor pair for muting start Both inputs are clear Only with Parallel muting and Sequent...

Page 213: ...e following conditions Both inputs are clear All muting sensors have changed to Low together or individually and the OSSDs of the protective device e g safety light curtain are High i e the protective field is clear or If last muting sensor is active All muting sensors except the last muting sensor are Low and the OSSDs of the protective device e g safety light curtain are High i e the protective ...

Page 214: ...itoring time The Concurrency monitoring time is used to check whether the muting sensors are activated simultaneously This value specifies the maximum duration for which each of the two dual channel evaluated muting sensor inputs may have different values without this being evaluated as an error This means that input pair A1 and A2 or input pair B1 and B2 must have equivalent values before the Con...

Page 215: ...muting error indicated by the Muting error output The C1 input subsequently has to return to Low again before the next muting cycle is permitted Override input An Override input signal is used to remove transported objects that have remained in the protective field of the protective device e g safety light curtain after power failures triggering of an emergency stop muting errors or similar circum...

Page 216: ...n 3 s the Override input is ignored If you use Override check whether the system is in a safe state The Override function is used to activate the safety output i e the Enable output of the muting function block although the safety device e g a safety light curtain signals that a dangerous state may exist The Override input should only be used when the hazardous area has been checked visually and n...

Page 217: ...ent Override signal has become High Muting begins again and the Enable output becomes High If the muting cycle is stopped because of a faulty input signal of a muting sensor Override required changes to High for the duration of the logic execution time provided that the remaining conditions for Override required are fulfilled If the faulty input of the muting sensor returns to High and subsequentl...

Page 218: ...detected Low Override active no error High Muting lamp output The Muting lamp output is used in order to indicate an active muting cycle The value for the Muting lamp output depends directly on the value of the Muting status output as shown in the following table Status of the Muting function block Value of the Muting lamp output Muting status output is Low Low Muting status output is High High Ov...

Page 219: ...nal description A1 A2 B1 B2 C1 Conveyor ESPE Override input Enable output Muting lamp Muting status Override required A1 A B B A A A A A A A C A2 A B B A A A A A A A C B1 B B A A A A A A A A C B2 B B A A A A A A A A C C1 A A A A A A A A C C C Conveyor A A A A A C A A C C C ESPE A A A A A C C A C C C Override input A A A A A A C A A C A A The specified signals may not be installed in a common wire ...

Page 220: ...nsors are Low Muting is blocked The sensor OSSDs have to become High before muting can take place The muting condition is partially fulfilled Override is required if configured Either transition to normal behaviour in case of a cyclically correct sequence of sensor states or the total override time is exceeded The muting condition is fulfilled 9 10 5 Error states and information on resetting Diagn...

Page 221: ...rs Condition Description A1 A2 or B1 B2 Starts the muting cycle The first sensor pair is activated depending on the direction of transportation of the material A1 A2 B1 B2 Condition for transferring the muting function to the second sensor pair B1 B2 or A1 A2 Muting applies as long as this condition is fulfilled The second sensor pair is activated depending on the direction of transportation of th...

Page 222: ...meter In parallel layout the position of the muting sensors also determines the width of the permissible object The objects always have to pass the muting sensors with an identical width Optical probes and all types of non optical sensors can be used for this application Use sensors and probes with background suppression Avoid mutual interference of the sensors Increase the protection against mani...

Page 223: ... pair B1 B2 becomes clear again Input conditions for muting sensors Condition Description A1 A2 or B1 B2 Starts the muting cycle The first sensor pair is activated depending on the direction of transportation of the material A1 A2 B2 B1 Condition for transferring the muting function to the second sensor pair B1 B2 or A1 A2 Muting applies as long as this condition is fulfilled The second sensor pai...

Page 224: ...n can be defined as follows With the optional input C1 If used the C1 input always has to be activated before both muting sensors of the first sensor pair e g A1 and A2 become High By means of the Direction detection configuration parameter The sensor layout shown in this example is suitable for all types of sensors Avoid mutual interference of the sensors Increase the protection against manipulat...

Page 225: ...activated before both muting sensors of the first sensor pair e g A1 and A2 become High Input conditions for muting sensors Condition Description C1 A1 A2 Input C1 always has to be activated before both muting sensors of the first sensor pair e g A1 and A2 become High A1 A2 Muting applies as long as this condition is fulfilled and the requirement mentioned above existed Equations and prerequisites...

Page 226: ...lace the intersection directly in the light beams of the ESPE See also Section 9 10 9 The sensor layout shown in this example is suitable for both through beam photoelectric switches and photoelectric reflex switches Avoid mutual interference of the sensors Increase the protection against manipulation and the safety level by using the following configurable functions concurrency monitoring monitor...

Page 227: ...uch a manner that no one can enter the hazardous area by fulfilling the muting conditions meaning that they activate both muting sensors and thus create the required conditions for muting Input conditions for muting sensors Condition Description A1 A2 Muting applies as long as this condition is fulfilled and furthermore the requirements mentioned above existed Equations and prerequisites for calcu...

Page 228: ...In order to move material in one direction only place the intersection with regard to the direction of the transport behind the light beams of the ESPE see Section 9 10 8 The sensor layout shown in this example is suitable for both through beam photoelectric switches and photoelectric reflex switches Avoid mutual interference of the sensors Increase the protection against manipulation and the safe...

Page 229: ...e corresponding inputs of one or more press cycle control function blocks Eccentric press Universal press Typical press types Eccentric press Eccentric press Hydraulic press Press travelling directions Forward Forward and backward Cams Overrun cam Upstroke cam Dynamic cam Top dead center TDC Bottom dead center BDC Overrun cam Top position condition When Overrun cam High When TDC Low Upstroke condi...

Page 230: ...ments of the safety standards and regulations In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can have a pulse when the signal is reset due to the short circuit detection If such a pulse can result in a dangerous state in the machine the following points have to be observed Ensure protected cable laying for the signal line due to cross circuiting to other sig...

Page 231: ...f the Upstroke cam input and is set to Low with a rising edge of the Overrun cam input The Top output is set to High if the Overrun cam input is High With Dynamic cam If this function block is configured with Dynamic cam the start of the Top phase can be brought forward with a falling edge transition from High to Low of the Dynamic cam input The Upstroke output is set to High with a rising edge tr...

Page 232: ...the Upstroke cam input is already High when the monitoring of the cam inputs begins e g in the first logic cycle after resetting an error or after enabling monitoring with Disable monitoring input the Upstroke output will remain Low until the first actual transition from Low to High has been detected at the Upstroke cam input Figure 213 Press cycle for the Eccentric press contact function block wi...

Page 233: ... one of these conditions is not fulfilled during operation the Enable output becomes Low and the Contact error output becomes High A valid sequence to fulfill the conditions is as follows 0 Start condition Overrun cam input High Upstroke cam input Low 1 Overrun cam input High Low 2 Upstroke cam input Low High 3 Overrun cam input Low High 4 Upstroke cam input High Low Observe the relevant safety st...

Page 234: ...w and the Overrun error output becomes High The Drive released input must be connected to the signal that controls the physical output of the press drive so that the function block can determine whether the press is currently supposed to be running or has been stopped Typically this is the Enable output of a subsequent Press setup or Press single stroke function block Do not connect any physical i...

Page 235: ... again 9 11 3 Universal press contact Function block diagram General description The Universal press contact function block can be used for different press types e g hydraulic presses and eccentric presses i e mechanical presses The minimum configuration requires only TDC Top dead center Optionally the BDC Bottom dead center and Overrun cam inputs can be connected The Upstroke output is available ...

Page 236: ...nimum pulse duration of 100 ms or 350 ms and maximum 30 s Shorter and longer pulses are ignored Ensure that the transitions of the signals for resetting fulfill the requirements of the safety standards and regulations In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can have a pulse when the signal is reset due to the short circuit detection If such a pulse ca...

Page 237: ...ngle stroke or Press Setup Additionally it can be used to initiate upstroke muting This function block sets the Upstroke output and the Top output based on value changes of the cam inputs If the function block detects an error both outputs are set to Low The Top output is set to High if the TDC input is Low The Upstroke output is set to High with a rising edge transition from Low to High of the BD...

Page 238: ...If the BDC input is already High when the monitoring of the contact inputs begins e g in the first logic cycle after resetting an error or after enabling monitoring with Disable monitoring input the Upstroke output will remain Low during the first cycle The next BDC transition from Low to High is only accepted after a transition from High to Low has occurred at the Top output Figure 219 Press cycl...

Page 239: ...ng edge of the Overrun cam input High Low transition must occur after the rising edge of the TDC input This means that at any time at least one of both inputs must be High BDC monitoring If BDC is enabled and Overrun cam is disabled the BDC input signals must accord with Figure 222 and the following rules 1 The beginning of the BDC Low High transition must be close to 180 and has to occur while th...

Page 240: ...nce that fulfills the conditions for BDC and Overrun cam is 1 Start condition TDC Low BDC Low Overrun cam High 2 TDC Low High 3 Drive released High this is to fulfill the condition for overrun monitoring 4 Overrun cam High Low 5 BDC Low High 6 Overrun cam Low High 7 TDC High Low and BDC High Low sequence does not matter Depending on the type of press e g hydraulic press it may occur that the begin...

Page 241: ...dards such as EN 692 and EN 693 and regulations Only safety relevant signals may be used in safety relevant logic Ensure that the application fulfills all applicable standards and regulations This needs to be considered especially for the BDC if the Upstroke output is used for upstroke muting e g in combination with a press cycle control function block If the Number of BDC signals per cycle is con...

Page 242: ...that this signal is a loop back This is indicated by a clock icon on the destination tag of the jump address To this purpose connect the outputs of this function block to the following function blocks before you connect the jump address to the Drive released input This applies especially if all connections to the following function blocks are also realized using jump addresses If a CPU marker is u...

Page 243: ...lease is Low When Release 1 is Low or Top changes to High Always Release 2 start input With Without Single stroke protection With Without Min restart pulse time 100 ms 350 ms Ensure that the transitions of the signals for restarting fulfill the requirements of the safety standards and regulations In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can have a puls...

Page 244: ...e 2 start is optional If Release 2 start is configured the Enable output can only change to High e g during switching on if Release 2 start is High If the Enable output is High Release 2 start is no longer monitored Do not use the Release 2 start input for safety purposes Do not use the Release 2 start input for initiating safety stops because this input is evaluated temporarily during the start s...

Page 245: ...ut Output signals of the function block Restart required The Restart required output is High when a valid restart sequence is expected at the Restart input Enable The Enable output is High when Restart required is Low i e a restart is not required and the following conditions are fulfilled When Single stroke protection is set to Without Release 1 static is High Release 2 start if configured is Hig...

Page 246: ...put is always set to Low The requirements for a restart depend of the configuration of the parameter for Restart interlock Parameters of the function block Parameter Possible values Restart interlock Without When Release 1 or Release 3 or Start Release is Low When Release 1 or Release 3 is Low or Top changes to High Always When Release 1 or Release 3 is Low Release 2 start input With Without Relea...

Page 247: ...y you must use additional safety measures e g hazardous point protection with a light curtain Otherwise the operator of the press will be in danger If the Mode for Start Release input parameter is set to Stepping and Restart interlock is set to When Release 1 or Release 3 or Start Release is Low or Always a valid restart sequence is required after a stop that was caused by a Low Start Release inpu...

Page 248: ...e connected Connect the Upstroke input only with the Upstroke output of an Eccentric press contact or a Universal press contact function block In this case the Release 3 safety and Start Release input signals are muted muting of the Start Release input depends on the parameter settings when the Enable output is High and the Upstroke input is High This function block does not carry out a plausibili...

Page 249: ... for EN3 on Top The Disable Restart Interlock for EN3 on Top parameter prevents the restart interlock being activated if the Release 3 safety input changes to Low during a regular stop of the press This means that if the Disable Restart Interlock for EN3 on Top parameter is configured as Yes and the Enable output changes to Low as a result of the Top input changing to High then the Restart require...

Page 250: ...n With Without Stop request When Start Release input is Low When Stop input is High Upstroke input With Without Release 2 start input With Without Min restart pulse time 100 ms 350 ms Ensure that the transitions of the signals for restarting fulfill the requirements of the safety standards and regulations In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can ha...

Page 251: ...ition Connect the Upstroke input only to the Upstroke output of an Eccentric press contact or a Universal press contact function block Start Release The Start Release input signal is used to provide signals for the beginning and end of the press movement If a rising edge Low to High is detected at the Start Release input the Enable output becomes High provided that the Stop request input is Low an...

Page 252: ...the top dead center This signal is available at the function blocks Eccentric press contact or Universal press contact Do not use the Top input for safety purposes Connect the Top input only with the Top output of an Eccentric press contact or Universal press contact function block or to an equivalent signal source Do not use the Top input for initiating safety stops Otherwise the operator of the ...

Page 253: ...dards Prevent access to hazardous movements Press systems with a configuration that would allow a person to enter to cross through and to leave the protective field of an ESPE are not permitted for PSDI mode This function block defines a specific sequence of events that trigger a press cycle Breaks are defined as the transition from High to Low to High of the PSDI input signal In PSDI mode of a pr...

Page 254: ...he transitions of the signals for restarting fulfill the requirements In case of a short circuit to High to 24 V DC at a physical input the evaluated signal can have a pulse when the signal is reset due to the short circuit detection If such a pulse can result in a dangerous state in the machine the following points have to be observed Ensure protected cable laying for the signal line due to cross...

Page 255: ...ored If the Condition for Release 2 start input is configured as Necessary for first start or as Necessary for every start the Release 2 start input also must be High if a complete start sequence is required After the initial complete start sequence has been executed and the press has completed a press cycle the Top input must indicate that the press has currently reached the top dead center This ...

Page 256: ...the break i e falling edge High to Low at the PSDI input occurs after the rising edge at the Top input In both cases the end of the break i e rising edge Low to High at the PSDI input must occur after the rising edge at the Top input no matter whether the Top input is still High or has changed back to Low already If the Start of first PSDI pulse PSDI input Low High parameter is set to After the st...

Page 257: ...to monitor whether the press is currently running or has been stopped This must be the signal which directly controls the press Typically the Control of drive input will be connected via a jump address or a CPU marker to the logic editor signal which is connected to the physical output for the press Do not connect any physical input signals to the Control of drive input Connect the signal that con...

Page 258: ...p input only with the Top output of an Eccentric press contact or Universal press contact function block or to an equivalent signal source Do not use the Top input for initiating safety stops Otherwise the operator of the press will be in danger Upstroke input If upstroke muting is enabled i e if the Max Up Stroke muting time is greater than 0 the PSDI input of the function block is bypassed if th...

Page 259: ...x Up Stroke muting time has elapsed from High to Low and back to High the Enable output also changes from High to Low and back to High The setting for this parameter does not have any effect when the Restart and Upstroke input signals remain unconnected Output signals of the function block Restart required output The Restart required output is High when a valid restart sequence is expected at the ...

Page 260: ...ck is set to Deactivation on upstroke only for PSDI Error states and information on resetting Diagnostics outputs Resetting the error state Remarks Unexpected PSDI If an interruption of the protective field occurs the PSDI input generally has to return to High followed by a valid restart sequence in order to reset the error If the Unexpected PSDI output is High and the Enable output is Low and the...

Page 261: ...function block is chosen from a fixed library within the Setting and Monitoring Tool It is created within the logic editor but is not listed in the function block list It is saved with the project file Upon re opening the project file on another PC the grouped function block will be displayed It can be saved as a customized function block When determining the total number of function blocks within...

Page 262: ... Select to open the Select Icon dialog You can choose the icon from a fixed library Select the desired icon and click OK Back in the Edit Function Block Details dialog click OK to confirm your changes and to leave the dialog The selected function blocks will be reduced to a single grouped function block on the worksheet for the main program Figure 243 Edit Function Block Details dialog for the Gro...

Page 263: ...view By clicking on the associated tab here Machine 1 you can edit the grouped function block How to add inputs and outputs to a grouped function block Click on the tab for the grouped function block Switch to the FB Group Info view on the left side of the screen Drag and drop inputs or outputs onto the function block worksheet and attach them within the logic as needed Automatic wiring is not sup...

Page 264: ...e toolbar The internal view shows the grouped function block s tag names for its inputs and outputs The external view shows what is connected to the grouped function block How to transfer a grouped function block to another PC Save the project file and open it on the other PC Grouped function blocks contained in the project will be imported automatically The import of function blocks must be enabl...

Page 265: ...ks on another PC you have the following options You can import the customized function blocks into the function block listing on the new PC for further use in new projects Or you can import the customized function blocks for this project only In this case they will not be listed in the function block list When determining the total number of function blocks within a project the customized function...

Page 266: ...rojects on the same PC Once a customized function block has been placed on the worksheet its content is displayed on a new page In the example the name of the customized function block is Machine 1 The worksheet for the customized function block is displayed orange The customized function block can not be edited A grouped function block contains a small pencil icon in the upper right corner indica...

Page 267: ...ction block list Click on No to import the Customized Function Blocks as grouped function blocks only In this case they will not be listed in the function block list and will be available for the current project only If a customized function block to be imported has the same name as another customized function block saved in the PC the imported customized function block will be added under the sam...

Page 268: ...to see at normal speed there are two possibilities Use the sliding bar 4 to slow the simulated passage of time It is possible to execute a simulation in time increments To do so stop the simulation by clicking on the red Stop button and click on one of the time increment buttons to the right of the sliding bar 6 The following time periods are available by default 4 ms 20 ms 40 ms 200 ms and 400 ms...

Page 269: ...re elements at the same time and see their direct effect on the logic After activation of the desired inputs the simulation must be continued either by pressing the green Start button or by using one of the time increment buttons in order for the logic and outputs to switch accordingly If the EDM or the Valve monitoring function block is being used it is recommended to remove them from the logic b...

Page 270: ...pment can be impaired and a dangerous state may occur Ensure that no person is present in the dangerous area of your machine or system before activating force mode Ensure that no person can intrude into the dangerous area of the machine or system while force mode is active Additional safety measures may be required if forcing is used Do not use force mode from several PCs simultaneously When using...

Page 271: ...eft if no actions are taken Choose the desired time span from the drop box list and click OK Force mode will be activated and the background colour of the logic editor changes to orange While force mode is active it is not possible to logout to upload and compare a configuration or to stop the safety controller Figure 258 Dialog window when starting force mode Figure 259 Logic editor with force mo...

Page 272: ...s for logic programs using more than one page in the logic editor that a forced input will be set to the same value on each page of the logic editor where it is used not only on the currently displayed page If forcing an input in a logic program causes more than 16 outputs to switch at the same time then some of these outputs will be switched with a delay of one or more logic cycles due to the lim...

Page 273: ... or system Click on the Stop force mode button A safety message will appear Click on Yes to confirm and terminate the force mode or click on No to keep the force mode active If no force action e g forcing of an input has occurred for the time defined when the force mode was started the force mode will be automatically terminated During force mode a timer in the top right corner shows the time rema...

Page 274: ...el elements can be evaluated with or without a Discrepancy time The discrepancy time defines for how long the two inputs may have discrepant values after one of the both input signals has changed without this being considered as an error To activate or to deactivate the Discrepancy time either click on the checkbox or on the 3D buttons on the right side of the element settings dialog For elements ...

Page 275: ...pply A dual channel evaluation can only change to Active the input of the safety I O module in the logic editor changes from Low to High if since the last Active status at least once the status was Inactive i e it is not possible to switch from Active to Discrepant and back to Active and the discrepancy time has not elapsed or the discrepancy time is deactivated If the correct sequence to reach th...

Page 276: ... reaction time by at least 8 ms If the signal is alternating within these initial 8 ms the signal change can be delayed for much longer i e until a constant signal of at least 8 ms has been detected For dual channel elements with complementary evaluation the respective filter ON OFF or OFF ON is always related to the leading channel Filtering of the complementary channel is active automatically 10...

Page 277: ... PC disconnect the PC from the MELSEC WS safety controller Before removing the RS 232 USB converter WS0 UC 232A disconnect the PC from the MELSEC WS safety controller 11 1 Transferring project data to the safety controller After the transfer the configuration data are read back from the memory plug if the verification has been activated in the Setting and Monitoring Tool see Section 11 3 The readi...

Page 278: ... data are displayed in a report If the user confirms that they are correct the safety controller is considered to be verified If the configuration is verified the MELSEC WS safety controller will change into the Run state automatically after the voltage supply has been switched on If the configuration is not verified the system must be set into the Run state manually using the Setting and Monitori...

Page 279: ...cess Their verification is carried out in the same way as the configuration and verification via the serial interfaces of the devices If differences between the project data and the read back configuration data are detected a corresponding message including information about possible actions is displayed Verification of the configuration is not possible then Observe the information in the error me...

Page 280: ...nfiguration data are duplicated The safety controller is also ready to use when the configuration is only validated and not verified or does not have a write protection However the automatic transition of the MELSEC WS safety controller into the Run state after the voltage supply has been switched on is not possible then The dialog box for verification is only displayed after a request by the user...

Page 281: ...sums Configuration checksums are displayed in Setting and Monitoring Tool in the report and on the information page for the hardware configuration The checksums have the following meaning Total checksum Same value as the WSFlexi Soft checksum WS checksum This checksum covers the configuration of the WS system i e for all Modules The configuration of EFI devices connected is not included in the WS ...

Page 282: ... the Setting and Monitoring Tool For detailed diagnostics information refer to the Setting and Monitoring Tool Red 2 Hz Critical error in the system possibly in this module Application is stopped All outputs are switched off Switch the supply voltage off and on again If the error is not eliminated after multiple repetition replace this module For detailed diagnostics information refer to the Setti...

Page 283: ...nt in the logic editor All timers and states including the error states of the function blocks are reset 12 3 Software reset of the CPU module It is possible to reset the CPU module via software i e without interrupting the voltage supply if the Setting and Monitoring Tool is connected with the CPU module How to perform a software reset In the Hardware configuration view right click on the CPU mod...

Page 284: ...vel Eliminate any faults e g incorrect wiring or crossed signals at each safety input test signal output or safety output before you continue with the next step Switch on the voltage supply As soon as the supply voltage is applied to the connections A1 and A2 of the CPU modules or the WS0 XTIO modules the MELSEC WS safety controller automatically carries out the following steps internal self test ...

Page 285: ...t connected back to the wrong connection Verify the configuration of the MELSEC WS safety controller Check the signal paths and the correct inclusion in higher level controllers Check the correct data transfer from and to the MELSEC WS safety controller Check the logic program of the safety controller Completely document the configuration of the entire system of the individual devices and the resu...

Page 286: ...er s Manual There you will find a list of LED error displays error codes error causes and rectification measures Error codes and error messages can also be displayed in the Diagnostics view if you are connected to the MELSEC WS safety controller For more information on how to perform diagnostics see Section 5 8 ...

Page 287: ...Chapter 15 284 Annex 15 Annex 15 1 Example application reports 15 1 1 Example application Newspaper palletizer ...

Page 288: ...Chapter 15 285 Annex ...

Page 289: ...Chapter 15 286 Annex ...

Page 290: ...Chapter 15 287 Annex ...

Page 291: ...Chapter 15 288 Annex ...

Page 292: ...Chapter 15 289 Annex ...

Page 293: ...Chapter 15 290 Annex ...

Page 294: ...Chapter 15 291 Annex ...

Page 295: ...Chapter 15 292 Annex ...

Page 296: ...Chapter 15 293 Annex ...

Page 297: ...Chapter 15 294 Annex ...

Page 298: ...Chapter 15 295 Annex 15 1 2 Example application Wood scanner ...

Page 299: ...Chapter 15 296 Annex ...

Page 300: ...Chapter 15 297 Annex ...

Page 301: ...Chapter 15 298 Annex ...

Page 302: ...Chapter 15 299 Annex ...

Page 303: ...Chapter 15 300 Annex ...

Page 304: ...Chapter 15 301 Annex ...

Page 305: ...Chapter 15 302 Annex ...

Page 306: ...Chapter 15 303 Annex ...

Page 307: ...Chapter 15 304 Annex 15 1 3 Example application Ramp down detection ...

Page 308: ...Chapter 15 305 Annex ...

Page 309: ...Chapter 15 306 Annex ...

Page 310: ...Chapter 15 307 Annex ...

Page 311: ...Chapter 15 308 Annex ...

Page 312: ...Chapter 15 309 Annex ...

Page 313: ...Chapter 15 310 Annex ...

Page 314: ...Chapter 15 311 Annex ...

Page 315: ...it for function test Inactive Monitoring disabled Muting active No edge detected Off delay On delay OK Upper counter limit reached Overrun Cam left Overrun Cam reached Override Required Wait for reset restart pulse Output Enable is active Wait for all monitored inputs becoming active Drive is enabled Run up Cam reached Drive stopped Top dead center TDC left Top dead center TDC reached User mode is...

Page 316: ...Chapter 15 313 Annex 15 3 Precautions 1 Edit a CSV file exported from Setting and Monitoring tool in a text editor ...

Page 317: ...39 02 27 43 41 E Mail info sick it Japan Phone 81 0 3 3358 1341 E Mail support sick jp Nederlands Phone 31 0 30 229 25 44 E Mail info sick nl Norge Phone 47 67 81 50 00 E Mail austefjord sick no Österreich Phone 43 0 22 36 62 28 8 0 E Mail office sick at Polska Phone 48 22 837 40 50 E Mail info sick pl Republic of Korea Phone 82 2 786 6321 4 E Mail kang sickkorea net Republika Slovenija Phone 386 ...

Page 318: ...h MELCO s Technical Bulletins Products discontinued and repair parts for them may not be available after their production is discontinued 2 Limits of Warranties a MELCO does not warrant or guarantee the design specify manufacture construction or installation of the materials construction criteria functionality use properties or other characteristics of the equipment systems or production lines int...

Page 319: ...d in these terms shall apply to all three types of damages to the fullest extent permitted by law If however the personal injury wrongful death and or physical property damages cannot be disclaimed or limited by law or public policy to the extent provided by these terms then in any such event the disclaimer of and limitations on pecuniary or economic consequential and incidental damages shall neve...

Page 320: ...ted States and other countries Pentium is a trademark of Intel Corporation in the United States and other countries Ethernet is a trademark of Xerox Corporation All other company names and product names used in this manual are trademarks or registered trademarks of their respective companies SH NA 080856ENG E ...

Page 321: ......

Page 322: ...ations subject to change without notice When exported from Japan this manual does not require application to the Ministry of Economy Trade and Industry for service transaction permission HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN NAGOYA WORKS 1 14 YADA MINAMI 5 CHOME HIGASHI KU NAGOYA JAPAN ...

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