SICK FX3-MOC1 Operating Instructions Manual Download

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O P E R A T I N G I N S T R U C T I O N S

Safe Linear Positioning

Safety system

Summary of Contents for FX3-MOC1

Page 1: ...O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning Safety system ...

Page 2: ...ible within the limits of the legal determination of Copyright Law Any modifica tion abridgment or translation of this document is prohibited without the express writ ten permission of SICK AG The trademarks stated in this document are the property of their respective owner SICK AG All rights reserved Original document This document is an original document of SICK AG 2 O P E R A T I N G I N S T R ...

Page 3: ... function 13 3 6 Limits of the safety system 14 3 7 Product characteristics 15 3 7 1 Safety functions 15 3 7 2 Safe state 16 4 Project planning 17 4 1 Manufacturer of the machine 17 4 1 1 Calculating the performance level 17 4 2 Operating entity of the machine 18 4 3 Design 18 4 4 Integrating the equipment into the electrical control 18 4 4 1 Circuit diagram 18 4 5 Testing plan 18 4 6 Extension an...

Page 4: ...figuring safe cam SCA 42 7 3 7 Configuring stop ramps 45 7 4 Expanding and modifying the safety system 49 7 4 1 Configuring additional safety functions 49 7 4 2 External and internal signal for activating the safely limited speed 51 7 4 3 Configuring the override function 52 7 4 4 Controlling the safety outputs directly via PLC 53 7 4 5 Use of internal status information 53 7 5 Contents of the CPU...

Page 5: ... Annex 86 17 1 Checklist for initial commissioning and commissioning 86 17 1 1 Thorough check of the requirements specified in the oper ating instructions for the safety system 86 17 1 2 Thorough check of the hardware requirements 87 17 1 3 Thorough check of the Flexi Soft configuration 88 17 1 4 Thorough check of the Flexi Soft documentation 89 17 1 5 Thorough check on the process channel standst...

Page 6: ...e of the safety system within the target application 95 17 1 12 Thorough check of the check intervals 95 CONTENTS 6 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941 12O9 2019 08 05 SICK Subject to change without notice ...

Page 7: ...documents contain information regarding the Safe Linear Positioning safety system Table 1 Documents available for Safe Linear Positioning Document type Title Part number Operating instructions OLM100 Hi linear measure ment sensor 8014310 Operating instructions Flexi Soft in the Flexi Soft Designer software 8012998 Operating instructions Flexi Soft modular safety con troller hardware 8012999 This d...

Page 8: ...e sequence of instructions for action is numbered 2 Follow the order in which the numbered instructions are given The check mark denotes the result of an instruction 1 5 Further information www sick com The following information is available via the Internet This document in other languages Operating instructions and installation instructions of SICK components suitable for the safety system The F...

Page 9: ...ctive Safe Linear Positioning is a safety component that guarantees a safety function 2 3 Reasonably foreseeable misuse It may not be possible for the system to detect a potential mounting error that involves the distance between a sensor and bar code tape falling outside of the permissible range For mounting instructions see Mounting the sensor unit page 21 WARNING There is a risk of death or ser...

Page 10: ... experience in the relevant field and is sufficiently familiar with the application of the protective device on the machine that he she can assess its work safety aspects Operation and maintenance For operation and maintenance a person is considered competent when he she has the expertise and experience in the relevant field and is sufficiently familiar with the application of the protective devic...

Page 11: ...ramp or speed reduction at certain positions the safety system provides the corresponding safe position data alongside the underlying safety functions for the machine Additional safety functions can be added to the safety system OLM100 Hi absolute displacement sensors optical linear measurement sensors from SICK are used to monitor linear movements These are opto electronic sensors that can measur...

Page 12: ...e under www sick com 3 4 1 Requirements for additional components required All safety related components must be checked to ensure that they are suitable for use with this safety system This also applies to components that are not specified by this safety system The safety values for the SLS request signal the drive the safe torque off STO function and the optional brake must be selected such that...

Page 13: ... Input XTIO Assessment Output XTIO Assessment MOC 1 Assessment CPU Safe Control Logistics CPU Safe Control Logistics OLM 1 Voltage supply Communication Control Splitter SSI SSI SSI Voltage supply Voltage supply SensorIDs Test request Control Safe outputs Test signal from the process Figure 1 System concept The rail system of the linear drive has a bar code tape e g on the mounting rail Bar codes a...

Page 14: ...ment sensors are numbered when the X junction is connected The connector plug for the OLM 2 has a colored mark and must be connected to the linear measurement sensor for which the bar code tape displays a higher position value The two linear measurement sensors OLM 1 and 2 output a code via the sensor ID signals that can be used by the Flexi Soft safety controller to identify them 3 6 Limits of th...

Page 15: ...safety controller program The Safe Lin ear Positioning safety system determines these position ranges automatically and monitors the speed If the maximum permitted speed is exceeded the Flexi Soft safety controller initiates a safe stop 2 The safely limited speed can also be activated by an internal signal in the controller or an external signal This makes it possible for external processes to act...

Page 16: ...g outputs are in the off state The machine is and remains switched off The safe state is initiated in the following cases If one of the safety functions provided by the FX3 MOC1 motion control module is triggered If one of the safety functions programed in the Flexi Soft CPU is triggered If there are connection problems with the signal cables between at least one OLM100 Hi and the FX3 MOC1 If the ...

Page 17: ...ty functions that are not part of this safety system b Validating all safety functions b Integrating the individual components in accordance with the appropriate stan dards b Please note that C standards have priority compared to statements about this safety system 4 1 1 Calculating the performance level The file provided for SISTEMA can be used to calculate the performance level achieved It is ne...

Page 18: ...e 4 4 Integrating the equipment into the electrical control NOTE Several safety functions are generally necessary in order to ensure a safe design for the entire application This requires additional components that are not part of the safety system such as switches fuses and contactors The circuit diagrams contain informa tion on wiring the safety system with additional components within an applic...

Page 19: ...on of the safely limited speed function by an external or internal signal see External and internal signal for activating the safely limited speed page 51 NOTE Internal and external trigger signals for activating the SLS function or for integrat ing additional safety functions may only be introduced at the points in the soft ware provided for the respective purpose Trigger signals and additional s...

Page 20: ...no snapshot has been generated for that point the system will not detect this fault This is not critical to safety if correct bar codes can be read again in good time If read faults are present across a longer dis tance the system will switch to the safe state Compliance with the response times see Response times page 80 is ensured 4 7 1 Illegible bar codes If bar codes are incorrect or if some ba...

Page 21: ...SOPAS ET software Only the approved sensors may be used The sensor system must be mounted such that the horizontal axis of the mounting plate runs parallel to the bar code tape The gap required between the sensor front screen and the bar code tape must be between 80 mm and 120 mm A distance of between 100 mm and 110 mm is recommended WARNING There is a risk of death or serious injury in the event ...

Page 22: ...ting requirements set out in the operating instructions for the OLM100 Hi must also be followed 5 2 Mounting the bar code tape WARNING There is a risk of death or serious injury as diagnostics for the protective device are not reliable Value range monitoring is implemented in the safety system so that diagnostics can be performed 0 is therefore not permitted as a minimum value and start value 5 MO...

Page 23: ...commended that self adhesive cut to length blank white labels should be stuck over the gap in order to allow it to be traversed without problems A sequence of bar code tapes with discontinuous measuring ranges is not allowed oth erwise a continuous position cannot be indicated position jumps The safety system will switch to the safe state in the event of discontinuity SmartPOS repair tape can be s...

Page 24: ...ng the consequences of voltage failure voltage fluctuations overcurrent and undercurrent in the voltage supply of the higher level control 6 2 Connection and wiring All of the electrical installation work must be performed in accordance with EN 60204 1 IEC 60204 1 Pre assembled wiring X junction has been developed for the safety system If longer cables are required for an application the sensor ca...

Page 25: ...ector plug on the FX3 MOC1 to the SSI signal splitter the X junction must be contained within an electrical installation area OLM 1 and OLM 2 are numbered when the X junction is connected The connector plug for the OLM 2 has a colored mark and must be connected to the linear measurement sensor for which the bar code tape displays a higher position value The connector plug for OLM 1 does not have a...

Page 26: ... a risk of death or serious injury as diagnostics and shock resistance for the protective device are not reliable b Position inputs and outputs on different modules in such a way that they have the same properties in terms of safety technology as the inputs and outputs of the original module b Adjust the current flow diagram accordingly see Safety controller pin assign ment page 26 6 ELECTRICAL IN...

Page 27: ...p pushbutton Module 1 outputs Table 7 Function of the connections Connection Function Q1 QA110 1 safety output STO Q2 QA110 2 safety output STO Q3 BG100 2 2 sensor 2 test request Q4 KF130 stop request Module 2 inputs Table 8 Function of the connections Connection Function Enc1 BG100 1 OLM sensor 1 Enc2 BG100 2 OLM sensor 2 Module 3 inputs Table 9 Function of the connections Connection Function l1 ...

Page 28: ... direction from the process in the form of the corresponding status of the test signals immediately before the change is made The test signals must be generated independently of the position data of this safety system OLM sensor 1 The test signals must be transmitted to the Flexi Soft safety controller via two separate signal cables Definition of test signals Test signal 1 active and test signal 2...

Page 29: ...ss controller is an SSI master the MOC module must function as an SSI lis tener If the process controller is an SSI listener the MOC module must function as an SSI master Requirements for the process controller SSI interface The requirements for the SSI interface vary depending on the sensor unit in use Table 12 Requirements for the sensor unit with part number 1087575 Parameter Requirement Protoc...

Page 30: ...s for category 4 PL e as per EN ISO 13849 1 NOTE The dual channel outputs switch simultaneously If the STO input of the drive system requires a complementary signal an additional safety relay with normally open and normally closed contacts must be put in place This case will not be considered with this safety system If the STO input of the drive system only has a single channel additional measures...

Page 31: ...y six months to test that it is working properly The device used for shutting down in an emergency must meet the requirements of IEC 60947 5 5 6 4 7 Signal for restart interlock Manual reset When a protective device requests a stop command the stop status must apply until a manual reset has been performed A separate reset device e g a pushbutton must be relied upon to perform this manual reset and...

Page 32: ...rsion Flexi Soft Designer 1 9 0 Firmware FX3 CPUx V4 0 Firmware FX3 XTIO V3 0 Firmware FX3 MOC1 V2 0 7 3 Configuration procedure NOTE The configuration of the software is described on the basis of the English language Flexi Soft Designer Information about configuration with Flexi Soft Designer can be found in the Flexi Soft operating instructions in the Flexi Soft Designer configuration software T...

Page 33: ...88608 Table 15 Checksum with possible pin assignment on FX3 MOC1 module MOC input E1 Not assigned MOC input E2 BG100 2 OLM sensor 2 as SSI master 24 1 bit Checksum 0xA126F159 Table 16 Checksum with possible pin assignment on FX3 MOC1 module MOC input E1 BG100 1 OLM sensor 1 as SSI listener 24 1 bit MOC input E2 BG100 2 OLM sensor 2 as SSI master 24 1 bit Checksum 0xD904FC86 Table 17 Checksum with ...

Page 34: ... 1 bit MOC input E2 BG100 2 OLM sensor 2 as SSI master 24 1 bit Checksum 0xA6050CEB 7 3 1 2 Project and export file for SSI protocol 31 1 bit FX3 CPU0 with Flexi Soft project file ID no 9290043 Table 24 Checksum with possible pin assignment on FX3 MOC1 module MOC input E1 Not assigned MOC input E2 BG100 2 OLM sensor 2 as SSI master 31 1 bit Checksum 0xDEF61431 Table 25 Checksum with possible pin a...

Page 35: ...pin assignment on FX3 MOC1 module MOC input E1 BG100 1 OLM sensor 1 as SSI master 31 1 bit MOC input E2 BG100 2 OLM sensor 2 as SSI master 31 1 bit Checksum 0x4D7CAE01 FX3 CPU3 with Flexi Soft export file SSI listener ID no 9290539 Table 32 Checksum with possible pin assignment on FX3 MOC1 module MOC input E1 BG100 1 OLM sensor 1 as SSI listener 31 1 bit MOC input E2 BG100 2 OLM sensor 2 as SSI ma...

Page 36: ...rates must be set for OLM sensor 1 and OLM sensor 2 for diagnostic purposes The transmission rate for OLM sensor 2 is 167 kBaud It is recom mended that the lowest possible data transmission rate is selected for OLM sensor 1 100 kBaud b Select the lowest possible data transmission rate for OLM sensor 1 100 kBaud The ENC2 input is already set as SSI master and is used for internal plausibility check...

Page 37: ...is page The two sensors provide sepa rate status signals This page is protected with a password Configurations must be set in the Position Moni tor function block 1 Move the mouse cursor to the Position Monitor function block 2 Double click on the function block The view opens The window containing the settings for the function block will appear Figure 7 Settings window for Position Monitor functi...

Page 38: ...igured as the maximum speed limit 7 3 3 2 Speed limits Within the application there may be requirements for safely limited speeds SLS owing to the risk assessment e g in areas where there are people or ahead of the end posi tions of the rail system The following speed ranges can be configured for the safely limited speed SLS safety function Standstill speed default values set at the factory Speed ...

Page 39: ...peed acquisition resolution The minimum speed that is to be monitored within the application should be at least three times higher than the speed acquisition resolution If this requirement is ignored the result will be an availability issue rather than a safety problem OLM linear measurement sensor order no 1087575 Speed acquisition resolution 25 mm s Lowest speed that can be acquired 25 mm s Lowe...

Page 40: ...afety system so that diagnostics can be performed For this reason the minimum and maximum values of the bar code tape in use should be configured at the configuration stage 0 is not permitted as a minimum value 1 In the settings for the Position Monitor function block move the mouse cursor to the Position Ranges button 2 Click on the Position Ranges button The view opens The Position Ranges window...

Page 41: ...1 677 m 8 589 m 7 3 5 Assigning maximum speeds to the position ranges 1 In the settings for the Position Monitor function block move the mouse cursor to the Speed position profile button 2 Click on the Speed position profile button The view opens The Speed position profile window appears A maximum permitted speed speed ID can be set for each position range in order to implement a safely limited sp...

Page 42: ...ctivated position cams are displayed in green Permitted position ranges must be configured as position cams The position CAM out put of the Position Monitor function block is set to logic High as long as the current posi tion is within the permitted position range If a position falls outside of this range the position CAM output is set to logic Low WARNING There is a risk of death or serious injur...

Page 43: ...pe of safe cam can be found in the Flexi Soft Designer operating instructions Storage and retrieval system application example Speed reduction is always safely monitored in two stages before the end positions The position ID 2 and 8 position ranges function as a buffer in case it is not possible to slow down enough owing to a fault As the speed cannot be very high in this instance owing to the fac...

Page 44: ...ple be enclosed or somewhere it is generally not possible for people to be present In the middle position range position ID 3 only a safely limited speed SLS is permit ted This may be an assembly area where people work for example Figure 14 Safe cam setting range for a range with a safely limited speed SLS 7 CONFIGURATION 44 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941...

Page 45: ...e appears Figure 15 Safe Stop page view Table 35 Inputs of the function block Input name Function Motion IN This input receives the Motion signal from the Position Cross Check function block A fault is detected as soon as the position data from the sensor is no longer reliable This signal will trigger a safe stop 2 SS2 at the Safe Stop function block Safe Stop 1a The SS1 request LowActive signal f...

Page 46: ...ly for the optional brake The signal is transmitted to the CPU logic and has an impact on the safe outputs dual channel output signal switching device Stop request This signal triggers the stop ramp of the drive The signal is trans mitted to the CPU logic and is forwarded either to the process con troller or to the drive directly 7 3 7 1 Safe Stop Stop Ramps function block 1 Move the mouse cursor ...

Page 47: ...g This Standstill Monitoring function block is only used for the Safe Stop function It is used to determine when a ramp ends or to monitor the standstill position in the case of a Safe Stop 2 function Figure 17 Standstill Monitoring function block CONFIGURATION 7 8020941 12O9 2019 08 05 SICK O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 47 Subject to change without notice ...

Page 48: ...f inputs that can initiate a safe stop 2 SS2 Stop Reset This setting allows for an additional Reset input at the Safe Stop function block NOTE The stop ramp configuration must be checked thoroughly to ensure that it is correct The machine manufacturer is responsible for checking whether the application is in line with the risk analysis and risk reduction strategy and whether it conforms to all app...

Page 49: ...anisms are implemented correctly and that the safety func tion is guaranteed Approach 1 Move the mouse cursor to the Logic editor button 2 Click on Logic editor 3 Click on the Interface logic page The view opens The page appears Figure 19 Request Safe Stop function block 4 Assign additional safety functions to the External_SS1 or External_SS2 jump addresses 5 Delete the link between static 1 and i...

Page 50: ...Safe Stop 2 requirement Figure 21 Additional Safe Stop 2 requirement Further topics Extension and modification page 19 7 CONFIGURATION 50 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941 12O9 2019 08 05 SICK Subject to change without notice ...

Page 51: ...rce is used for a safely limited speed SLS request B130 SLS request must be removed from input 1 and linked to static 1 instead Input 2 static 0 at input 2 prepares for a request from an internal source from the CPU logic High active If an internal source is used for a safely limited speed SLS request static 0 must be removed and a High active signal used instead Table 39 Function of the output Ou...

Page 52: ... project file for Flexi Soft Designer is prepared for an override func tion but does not feature the logic for activating the override function The user must develop this for the specific application in question NOTE The override function is not part of the safety system The user is responsible for ensur ing safe implementation The requirements for the override function result from the risk assess...

Page 53: ... Click on Logic editor 3 Click on the Interface logic page The view opens The page appears 4 Replace Static 1 with signals intended to control the individual outputs This involves the following assignment between the jump address and safety output Table 40 Assignment of jump address and safety output Jump address Safety output Stop_request_PLC_ctl K100 1 Q4 stop request STO_PLC_ctl K100 1 Q1 Q2 ST...

Page 54: ...est safely limited speed SLS request and override function request Safe Position and Diagnostics Diagnostics measures used to determine the safe posi tion Stop reset restart Configuration of reset and restart Safe Outputs Configuration of safe stop The logic editor uses the following safety application function blocks SAPP FBs Plausibility test SAPP FB Sensor2 test SAPP FB Sensor ID SAPP FB Safe P...

Page 55: ...est 7 5 3 Safe Outputs page Figure 26 Safe Outputs page view The following function blocks are available on this page Safe Stop outputs SAPP FB Safe Stop reset SAPP FB NOTE This page is protected with a password and cannot be configured CONFIGURATION 7 8020941 12O9 2019 08 05 SICK O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 55 Subject to change without notice ...

Page 56: ...l that triggers the stop ramp of the drive QA110 Safety output Dual channel output XTIO module Safety signal that deactivates the drive system s torque QA120 Brake optional Dual channel output XTIO module Safety signal that switches off the energy supply for the mechani cal brakes optional Override active Jump address Prepares the optional Override function The logic required to acti vate the Over...

Page 57: ...posi tion The following safety application function blocks SAPP FBs are required here Plausibility test SAPP FB Sensor2 test SAPP FB Sensor ID SAPP FB Safe Position SAPP FB This page is protected with a password and cannot be configured A message generator function block is also used on this page to generate notifications relating to diagnostics for the specific application in question 7 5 4 1 Pla...

Page 58: ...he MOC1 logic Table 48 Function of the output Output name Function Plausibility test error Result of the plausibility check 7 5 4 2 Sensor2 test SAPP FB function block The application specific Sensor2 test SAPP FB function block detects systematic faults that occur on both sensors at the same time In the case of this kind of fault the posi tion data can freeze the two sensors and output a static p...

Page 59: ...h the correct signal behavior can be used together The sensors generate further process information automatically This information is transmitted to Flexi Soft and then evaluated Figure 32 Function block view Sensor ID SAPP FB Table 51 Function of the inputs Input name Function Sensor ID 1 BG100 1 1 Sensor ID 1 input Sensor ID 2 BG100 2 1 Sensor ID 2 input These input signals are pulse width modul...

Page 60: ...w Inhibit Error Message Linked to Inhibit Error Message jump address This signal is logic High when a permissible error occurs with the position data The position date is invalid when sensor2 test is active In this case the Inhibit_Error_Message signal stops a false entry being made in the fault diagnostics history 7 5 4 5 Message Generator function block The Message Generator function block evalu...

Page 61: ...36 Stop start reset page view This page is protected with a password and cannot be configured The inputs of the reset restart function for SS1 and SS2 are linked to the Interface page via jump addresses i e the physical inputs are assigned on the Interface page The outputs are also linked to other parts of the safety application software via jump addresses and internal signals CONFIGURATION 7 8020...

Page 62: ...ows for a graphical distinction to be made between the function blocks As soon as the Release 1 input is no longer set to High it initiates the Safe Stop 1 func tion A valid reset sequence at the Reset function block is required in order for a restart to be performed If the Release input is set to High the release condition has been met The Enable output is set to High when a restart signal Restar...

Page 63: ...e Reset function block is required in order for a restart to be triggered If the Restart input is set to High the release condition has been met The Enable output is set to High when a restart signal Restart_SS2 lasts for a pulse duration of at least 100 ms The Enable output is linked to the MOC1 logic via an AND function block in order to initi ate the Safe Stop 2 function with the Safe Stop func...

Page 64: ... be random if OR were used Figure 39 View of function block for optional light 7 6 Contents of the motion control logic 1 Move the mouse cursor to the Logic editor button 2 Click on K110 1 MOC0 1 Logic editor The view opens The page appears 7 6 1 Position_Cross_Check page Figure 40 Position_Cross_Check page view This page is protected with a password and cannot be configured The purpose of this fu...

Page 65: ...f the outputs Output name Function Motion data cross checked Motion data type The Motion data type adds additional diagnostics information to all information provided by the motion sensors If the diagnostics information relates to both motion sensors the motion data becomes invalid as soon as there is a fault with one of the two sensors Status This output indicates whether or not the position cros...

Page 66: ...itor SAPP FB function block is protected with a password Configurations must only be set in the Position Monitor function block 7 6 2 1 Function block for external safely limited speed requests speed ID 2 Figure 44 Function block for external safely limited speed requests speed ID 2 This function block converts a Boolean value at input 1 4 to an integer UINT8 Table 58 Function of the inputs Input ...

Page 67: ...or function block which must be configured by the user Table 61 Function of the inputs Input name Function Sensor 1 BG100 1 OLM sensor 1 at MOC1 input ENC1 Sensor 2 BG100 2 OLM sensor 2 at MOC1 input ENC2 Static 1 Signal High for the function block Table 62 Function of the outputs Output name Function Motion out Motion data type The Motion data type adds additional diagnostics information to all i...

Page 68: ... value can be 2 lowest speed or 10 highest speed see Position_Monitor page page 66 It is guaranteed that the lowest speed ID either from Speed Position Profile or Speed Enable ID always has priority Table 64 Function of the outputs Output name Function Monitor Status The Monitor Status output is set to High during fault free operation It switches to Low if an active monitoring function detects a f...

Page 69: ... made accordingly in the fault history through the Message Generator function block This logic is not safety relevant The Monitor Status signal takes care of the safe switch off process The Speed Monitor Status diagnostics output feeds the signal from MOC1 to the CPU logic This output should not be used for safety signals owing to the short transmission time 7 6 3 Safe Stop page The Safe Stop func...

Page 70: ...etects a ramp fault This must be reset following an over ride function or Sensor2 test Inhibit Motion bits reaction The signal comes from component SAPP FB Safe Position The signal prevents unintended switching off during the self test of the safety system Table 66 Outputs of the function block Output name Function Enable torque This safety signal deactivates the drive s torque The signal is trans...

Page 71: ...k can only be created between the anchor point on the right side of an element and the anchor point on the left side of another element Creating link 1 Click and hold the blue anchor point on the right side of an element 2 Move and release the mouse cursor on the blue anchor point on the left side of an element A link is created between 2 elements Deleting link 1 Click on the link between 2 elemen...

Page 72: ... page The desired page is displayed All elements of the jump address are highlighted in color 7 7 2 2 Adding a new source jump address 1 Drag the Add source jump address symbol from the toolbar on the left of the logic cre ation page into the working range 2 Enter a unique name in the Create jump mark dialog box 3 Click on OK 7 7 2 3 Adding a new destination jump address 1 Drag the Add destination...

Page 73: ...ng or the electrical connection After exceptional events such as after a manipulation has been detected after modification of the machine or after replacing components The thorough check ensures the following All relevant regulations are complied with and the safety system is effective in all of the machine s operating modes The documentation corresponds to the state of the machine including the p...

Page 74: ...E Information is included in the operating instructions for the components 9 OPERATING THE COMPONENTS 74 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941 12O9 2019 08 05 SICK Subject to change without notice ...

Page 75: ...E Information is included in the operating instructions for the components MAINTENANCE OF THE COMPONENTS 10 8020941 12O9 2019 08 05 SICK O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 75 Subject to change without notice ...

Page 76: ...ated problems arise the user must take suitable mea sures 11 2 Exchange and repairs The sensor unit which consists of two OLM sensors and a mounting bracket may only be exchanged as a complete unit Individual sensors may not be exchanged The sensor unit may only ever be repaired by the SICK Service team 11 TROUBLESHOOTING 76 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941...

Page 77: ...s must always be followed Efforts should be made during the disposal process to recycle the constituent materials particularly pre cious metals DECOMMISSIONING 12 8020941 12O9 2019 08 05 SICK O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 77 Subject to change without notice ...

Page 78: ... kBaud Length of the SSI connection cable between the splitter coupling point and the FX3 MOC1 input Max 2 m transmission rate 400 kBaud Supply voltage UV 24 V DC 16 8 V DC 28 8 V DC SELV 2 Ambient operating temperature Flexi Soft 20 55 C OLM100 Hi 30 55 C Storage temperature 25 70 C Air humidity 10 95 non condensing Permissible operating height Max 2 000 m above sea level 80 kPa Enclosure rating ...

Page 79: ...ound connection Hardware version V1 10 0 Max 20 mA 1 5 kΩ effective reverse resistance to voltage supply Hardware version V1 10 0 Max 2 mA Input pulse filter pulses within these limits do not have any effect Pulse width Max 0 9 ms Pulse period Min 4 ms Further technical data can be found in the Flexi Soft Modular Safety Controller Hard ware operating instructions TECHNICAL DATA 13 8020941 12O9 201...

Page 80: ...ire system t1 Maximum amount of time between the protective device being activated and the OFF state of the output being reached t2 The maximum amount of stopping time required to end the dangerous sta tus of the machine once the output signal from the protective device has been switched to the OFF state The response time of the machine s control system must be taken into consideration when calcul...

Page 81: ...lt the torque will be deactivated safe torque off STO stop If the optional safe brake control SBC QA120 is linked to Flexi Soft this will be activated too NOTE If the stopping time with safe torque off STO and safe brake control SBC is greater than in the case of the standard stop ramp the higher value must be used for TPDS SR 13 4 1 Stopping time in the event of a drive fault If the drive is faul...

Page 82: ...calculate the stopping time 13 4 3 Maximum data reception interval The maximum data reception interval is an adjustable timeout period within which valid position data must be received This timeout period can be configured using the Flexi Soft Designer For this safety sys tem the value for the maximum data reception interval is set at 8 ms If this time is increased the response time will be increa...

Page 83: ...1057833 1 x FX3 MPL000001 system plug for FX3 CPU0 part number 1043700 1 x sensor unit 0 01 mm resolution 32 bit SSI part number 1090629 1 x X junction part number 2097764 SAPPD3E 14AP009 part number 1096692 Retrofitting set but with all cables 0 1 mm resolution 25 bit SSI 1 x FX3 MOC100000 drive monitor part number 1057833 1 x sensor unit 0 1 mm resolution 25 bit SSI part number 1087575 1 x X jun...

Page 84: ...or 1057833 FX3 MPL000001 System plug for FX3 CPU0 1043700 Table 72 Spare parts Name Part number Sensor unit resolution 0 1 mm SSI 25 bit 1087575 Sensor unit resolution 0 01 mm SSI 32 bit 1090629 X junction 2097764 15 SPARE PARTS 84 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning 8020941 12O9 2019 08 05 SICK Subject to change without notice ...

Page 85: ...0UA6M2A28 2096106 Connection cable 10 meters YF2A28 100UA6M2A28 2096109 Table 74 Ordering data for connection cables for OLM sensors straight male connector angled female connector Part Type code Part number Connection cable 0 6 meters DSL 1208 B0M6ASCO 6048801 Connection cable 5 meters DSL 1208 B05MASCO 6049328 Connection cable 10 meters DSL 1208 B05MASCO 6049329 ACCESSORIES 16 8020941 12O9 2019 ...

Page 86: ...ounting conditions of the Flexi Soft safety controller Compliance with the requirements specified in the operating instructions for the safety system is confirmed Yes No Electrical installation Table 77 Requirements for the electrical wiring Check sequence Expected result Result OK 1 Check the electrical wiring including the length of the cables 2 Check that the requirements for electrical protect...

Page 87: ... STO function and electrical control comply with the require ments of category 4 PL e EN ISO 13849 1 Compliance with the requirements for category 4 PL e EN ISO 13849 1 is confirmed Yes No Brake Table 82 Brake Check sequence Expected result Result OK 1 Check that the brake and electri cal control comply with the requirements of category 4 PL e EN ISO 13849 1 Compliance with the requirements for ca...

Page 88: ... limited speeds SLS have been configured and the corresponding posi tion ranges assigned speed position matrix Yes No Stop ramp Table 87 Stop ramp Check sequence Expected result Result OK 1 Check that the stop ramp has been input in line with the spe cific application and has been taken into account when calculat ing the stopping distance The stop ramp has been configured in line with the specific...

Page 89: ...le 91 Thorough check of the response time Check sequence Expected result Result OK 1 Check the Flexi Soft CPU cycle time with the Flexi Soft Designer software If the cycle time is 8 ms the over all response time for the Safe Lin ear Positioning application must be recalculated If the cycle time is 8 ms the overall response time provided in this doc ument applies Yes No CPU cycle time value Verific...

Page 90: ...forward to inactive XTIO input I1 3 Set test signal 2 backward to active XTIO input I2 The safety system switches to the safe state XTIO output Q4 KF130 stop request is deactivated Yes No 1 Apply the test signal during standstill 2 Set test signal 1 forward to active XTIO input I1 3 Set test signal 2 backward to inactive XTIO input I2 The safety system switches to the safe state XTIO output Q4 KF1...

Page 91: ...st signal 2 backward to inactive XTIO input I2 The safety system switches to the safe state XTIO outputs Q1 QA110 1 safety output STO and Q2 QA110 2 safety output STO are deactivated Yes No 17 1 7 Thorough check on the process channel backward movement Evaluation of the test signals during backward movement NOTE You must undo the manipulation on the safety system again after each individual test s...

Page 92: ...Table 98 External signal for requesting the safely limited speed SLS Check sequence Expected result Result OK 1 Check that the external signal source activates the SLS safety function outputs of the signal source 0 V A safe stop 2 SS2 is initiated at a speed speed ID 2 An automated restart is not performed Yes No Emergency stop Table 99 Emergency stop Check sequence Expected result Result OK 1 Act...

Page 93: ...nce Expected result Result OK 1 Remove the plug connection from the Flexi Soft input Switches to status XTIO output Q4 KF130 stop request is deactivated Yes No Interruption of connection for the Sensor ID 2 signal Table 104 Interruption of connection for the Sensor ID 2 signal Check sequence Expected result Result OK 1 Remove the plug connection from the Flexi Soft input Switches to status XTIO ou...

Page 94: ...ensors are mechanically secured with tightened M12 threaded rings The connector plug for the FX3 MOC1 is mechanically secured with two screws in the plug Yes No Product description Table 108 Components Check sequence Expected result Result OK 1 Check that only approved OLM sensors with the safety controller have been used Only the approved full OLM sensor system has been used Individual sensors ha...

Page 95: ...target application is appro priate Yes No Comment 17 1 12 Thorough check of the check intervals Thorough check of the check intervals Table 111 Thorough check of the check intervals Check sequence Expected result Result OK 1 Set a check interval for regular thorough checks and validation of the safety system on the basis of the risk assessment for the application 2 Specify a responsible party The ...

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SICK FX3-MOC1, Operating Instructions Manual

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