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Safety components

© Siemens AG 2003 All Rights Reserved

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SIMOTION Safety Unit (AP) - Edition 06.2003

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Summary of Contents for Simotion TM 121C

Page 1: ...Application manual 06 2003 Edition simotion SIMOTION Safety Integrated Safety Unit TM 121C ...

Page 2: ......

Page 3: ... 3 Operating elements 4 Procedural functions of mechanical presses 5 Procedural functions of hydraulic presses 6 Procedural functions of press brakes 7 General functions 8 Operating and fault messages 9 Documentation 10 6AU1900 0DM20 0XA0 SIMOTION Safety Unit TM 121C Application manual for presses 06 2003 Edition ...

Page 4: ...ease observe the following information Warning The device may only be used in applications as provided for in the catalog and in the technical description and only in connection with power supply units that have either been recommended or approved by Siemens Successful and safe operation of this equipment is dependent on proper transport storage erection and installation as well as careful operati...

Page 5: ...ole warranty of Siemens Any statements contained herein do not create new warranties nor modify the existing warranty Purpose of this manual This handbook is a supplement to the equipment manual of the SIMOTION Safety Unit TM 121C with the order number 6AU1900 0CM20 0XA0 This handbook provides explanatory functional descriptions of mechanical presses hydraulic presses and press brakes assistance i...

Page 6: ... Siemens AG 2003 All Rights Reserved vi SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 7: ... 4 27 4 1 Two hand control 4 27 4 1 1 Determining the safety distance 4 29 4 2 Foot switch 4 30 4 3 Acknowledge button for group acknowledgement 4 31 4 4 Electro sensitive protective equipment ESPE 4 32 4 4 1 Determining the safety distance with ESPE 4 33 4 5 Control function with light curtain 4 34 4 5 1 Mode selector 4 34 4 5 2 Modes for clock operation 4 34 4 5 3 Starting the press in clock mod...

Page 8: ...nality 7 59 7 6 1 Conditions for fast downward movements 7 59 7 6 2 Tilt monitor 7 59 7 6 3 Moving and distance access protection 7 60 7 7 Application examples and procedural functions 7 61 7 7 1 Single operator control with foot switch 7 61 7 7 2 Multiple operator control with foot switch 7 62 8 General functions 8 63 8 1 Single operator multi operator control 8 63 8 2 Single operator control via...

Page 9: ...ary safety level For one channel signals the left side of the mask contains a terminal block field in which block X3 or X4 can be selected The required pin assignment can also be entered For two channel signals terminals X3 X4 are automatically preassigned The only data that can be entered is the pin assignment The pin assignment is identical for blocks X3 and X4 The entered value is saved by pres...

Page 10: ...General information on parameterization software Siemens AG 2003 All Rights Reserved 1 10 SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 11: ... 1 of 6 selection indicates the presence of a short circuit and a faulty multiple selection of operating modes The use of test voltages i e the selection of clocking via the internal sensor supply is therefore not required for the mode selector Parameterization The assignment of the connection terminals to the operating mode is shown in Figure 2 1 left section Figure 2 1 Operating modes 2 ...

Page 12: ...top conditions an external start and additional safety devices The entries that are adjustable for a particular operating mode are indicated by a white field They have been assigned default parameters and are indicated by a black dot If conditions are being pre assigned at additional terminals start enables external start etc an additional window for selecting the terminals automatically appears i...

Page 13: ...The operating elements must be deactivated before a new start can be initiated A triple action stop during a single stroke is not required with this control unit since the Setup operating mode reaches the same level of safety as for example the single stroke mode Parameterization Figure 2 3 Enabling of operating mode 1 Note on Safe motion parameterization When parameterizing Selected safety device...

Page 14: ...o the TDC and comes to a standstill The press can also be activated using a foot switch In this case however suitable safety measures safety gate light curtain must be implemented that either make it impossible to reach into the hazardous area with the hands during a closing movement or that cause the machine to come to a standstill in the event of such an action The same applies if the Transfer t...

Page 15: ...ires the implementation of suitable safety measures and an automated feed and removal of parts After a start pulse the press continues running until it is brought to a standstill by a stop signal Depending on the selections made in the enable mask the press either stops in the TDC or comes to an immediate standstill Parameterization Figure 2 5 Enabling of operating mode 3 ...

Page 16: ... out an automatic changeover e g to a new production part a standard control unit can be used to access the clutch and brake e g to adjust the stroke height Note In this operating mode the machine manufacturer must ensure that it is not possible to initiate a hazardous stroke when the press is controlled by a standard control unit Safety measures may have to implemented to safeguard the machine Pa...

Page 17: ...om the continuous mode in that two steps are required to enable the machine for the first time First the automatic continuous stroke mode is enabled using the two hand control Then the machine can be started by an external enable signal via the terminal Note If at the time of the two hand activation there is an external enable signal the machine starts immediately In this mode the two hand control...

Page 18: ...hen the external enable signal ceases It can be restarted with this signal alone within the next 30 s Two switching steps see Definition are always required when a restart does not take place within the next 30 s or when a safety device or a continuous stroke stop BDC or immediate stop was activated Parameterization Figure 2 9 Enabling of operating mode 5 ...

Page 19: ...s Reserved SIMOTION Safety Unit AP Edition 06 2003 2 19 2 2 6 Single stroke ESPE operating mode 6 Using a light curtain to control the press is described in the Control Elements chapter Parameterization Figure 2 10 Enabling of operating mode 6 ...

Page 20: ...Operating modes Siemens AG 2003 All Rights Reserved 2 20 SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 21: ...guard without acknowledge 4x Safety gate with manual acknowledge 3x Safety gate without manual acknowledge 3x Light curtains that are only used in the safety mode can be connected to the existing safety guard components For a description of their mode of operation see the Operating Elements chapter The parameterization of light curtains that are switched in safety and clock mode is presented in th...

Page 22: ...onents Siemens AG 2003 All Rights Reserved 3 22 SIMOTION Safety Unit AP Edition 06 2003 3 1 Parameterization of safety components Figure 3 1 EMERGENCY OFF safety functions Figure 3 2 Safety guard safety functions ...

Page 23: ...one contact is activated and reclosed an alarm is output with a continuous light In this case both contacts will then have to be opened and reclosed The continuous light goes out after both contacts have been properly opened When the contacts are closed a flashing signal indicates that the safety gate is ready for acknowledgement After the acknowledge button has been activated the machine is again...

Page 24: ...omponents Siemens AG 2003 All Rights Reserved 3 24 SIMOTION Safety Unit AP Edition 06 2003 3 2 Example of safety component wiring L L Clock voltage X2 5 X2 1 X3 5 X4 5 Figure 3 5 Example of EMERGENCY OFF wiring ...

Page 25: ...Safety components Siemens AG 2003 All Rights Reserved SIMOTION Safety Unit AP Edition 06 2003 3 25 L L Clock voltage X2 6 X2 2 X3 6 X4 6 Figure 3 6 Example of safety guard wiring ...

Page 26: ...Safety components Siemens AG 2003 All Rights Reserved 3 26 SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 27: ... hand activation has been simultaneous and if both engagement buttons are activated Operating instructions A maximum of 3 two hand consoles can be connected Each console has its own two hand function It is possible to use consoles that can be plugged in Plug in monitoring takes place via the NC and NO contacts of the two hand buttons This eliminates the need for an additional contact for plug in m...

Page 28: ... AG 2003 All Rights Reserved 4 28 SIMOTION Safety Unit AP Edition 06 2003 Parameterization Figure 4 1 Two hand control Example of wiring Clock voltage X3 1 X3 2 X4 1 X4 2 L L L L X2 5 X2 6 X2 1 X2 2 Figure 4 2 Two hand control ...

Page 29: ... The reaction time and the resulting safety distance can be calculated using the following equation S T2 T3 vg S Safety distance T2 Reaction time of control unit T3 Reaction time of machine vg Activation time 1 6 m s according to EN 999 Example T2 according to Safety Unit data sheet connection of the lag meter for determining the reaction time of the machine empirical T3 measurement use the poores...

Page 30: ...ON Safety Unit AP Edition 06 2003 4 2 Foot switch This has the same function as the two hand control with the exception that it has only one NC and one NO contact A maximum of 3 foot switches can be connected Parameterization Figure 4 3 Operation of the foot switch ...

Page 31: ...ng L Clock voltage X2 5 X2 1 L X3 7 X4 7 Figure 4 4 Foot switch 4 3 Acknowledge button for group acknowledgement Definition This button is used to reset signals requiring acknowledgement such as error messages and safety guard acknowledgement messages Parameterization Figure 4 5 Operation of the acknowledge button ...

Page 32: ...s safety control unit to correctly interpret the output signal of the light curtain and to generate from it the subsequent operation and control of the press safety valve Light curtains can be operated in safety mode as a substitute for a permanently closed safety gate see the Safety Components chapter control mode In this mode the operator can reach into the protective zone when the press is at a...

Page 33: ...ng the following equation S T1 T2 T3 vg k S Safety distance T1 Reaction time of the ESPE T2 Reaction time of control unit T3 Reaction time of machine vg Activation time 1 6 m s or 2 0 m s according to EN 999 k Addition for resolving power of the ESPE k 8 p 14 p Resolving power of the ESPE Example T1 according to manufacturer data sheet T2 according to Safety Unit data sheet connection of lag meter...

Page 34: ...mode The only difference between the two modes is in the manner in which they start after a restart inhibit Standard mode In the standard mode an interruption of the light field is initially required before starting the machine or before starting it after a restart inhibit After that the first start of the press must be initiated by the command device The two hand switch is provided for this purpo...

Page 35: ...r a power off or stop keyswitch position In the event that the operating mode is changed on the selection switch of the light curtain In the clock mode if there is an interruption during a hazardous movement In the clock mode in the event that there is no intervention for more than 30 s The restart inhibit is acknowledged by the command device Either a separate button or a two hand control can be ...

Page 36: ...cking may not be connected to the control unit side 1 2 7 1 2 7 3 4 4 3 OSSD1 OSSD2 Output of Safety Unit X2 x L Figure 4 7 Light curtain 4 5 5 Restart inhibit of light curtain in safety mode The restart inhibit is activated in the event of an intervention during a hazardous movement This is indicated by the flashing of the fault lamp It is reset by means of the acknowledge button for group acknow...

Page 37: ...utputs and the signaling of the feedback input depends on the response times of the contactors in use Typical values lie between 50 ms and 200 ms Therefore this maximum value should not be exceed in the parameterization The Safety Unit ensures there will be an output signal in Category 4 Systems connected downstream must be designed in the category they require After the Safety Unit restarts the o...

Page 38: ... Edition 06 2003 Example of wiring L P K10A 61 62 K10B 61 62 M K10A 13 14 K10B 13 14 23 24 23 24 33 34 33 34 EMERGENCY OFF contacts e g for load voltage S X6 7 X6 8 Contactor relay feedback EMERGENCY OFF acknowledge X3 11 K10A A2 A1 K10B A1 A2 Figure 4 9 EMERGENCY OFF output signal ...

Page 39: ...mp up cam as late as possible in the TDC The ramp up cam activates the end of the hazardous closing movement and the press switch off In addition the over run cam which also plays a part in monitoring the TDC switch off and monitors the overtravel distance of the clutch brake combination must be mechanical in design Since presses capable of higher speed ranges are becoming more common an additiona...

Page 40: ... off occurs on the leading edge of the over run cam For the TDC stop at variable stroke speeds a separate electronic cam switchgear is provided that calculates the brake engagement point from the stroke speed This dynamic cam switches in the range of 320 to 340 for example and takes over the TDC switch off on a falling edge Parameterization Figure 5 2 Mechanical operation Cam monitoring system ...

Page 41: ...Siemens AG 2003 All Rights Reserved SIMOTION Safety Unit AP Edition 06 2003 5 41 Example of wiring L L Clock voltage Run up cam X3 9 Dynamic TDC switch off Electronic cam switchgear PLC or initiator Overtravel cam X3 10 Figure 5 3 Cam evaluation ...

Page 42: ... time interval If the monitor does not detect at least one pulse during this interval the press is brought to a standstill Functional description of the monitor An encoder that outputs 30 pulses per rotation is integrated in each cam switchgear These pulses are used to check whether the shaft or the cam switchgear is defective The encoder must be connected to the hardware counter of the Safety Uni...

Page 43: ...2003 5 43 Example of wiring L M B 1 X9 2 X9 7 Figure 5 5 Speed monitor 5 3 Control of press safety valves This function is used to control two press safety valves clutch and brake Both valves are controlled simultaneously each via two channels P M switching with 24 V 2 A Figure 5 6 Extras Output pin assignment mech ...

Page 44: ...s AG 2003 All Rights Reserved 5 44 SIMOTION Safety Unit AP Edition 06 2003 Example of wiring Y01 1 2 PSV1 Y02 1 2 PSV2 L M BY01 1 BY02 1 Position feedback of press safety valve if present X6 1 X6 2 X6 3 X6 4 X4 10 X4 11 Figure 5 7 Press safety valves ...

Page 45: ...ith limit switches that display the switching position of the valves these are read in via the feedback inputs in the control unit and compared to the activation of the outputs watchdog timer Note If an electrical valve monitor is not in use monitoring must be accomplished by means of other measures with a comparable degree of safety hydraulic or electric Parameterization Figure 5 8 Mechanical ope...

Page 46: ...Procedural functions of mechanical presses Siemens AG 2003 All Rights Reserved 5 46 SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 47: ...Single channel inputs are the reversing point in the TDC and BDC In the case of an automatic takeover the Safety point and Pressure value signals must be queried on the input side In Setup mode activation of the two hand switch or the foot switch causes the press to move to BDC inching An upward movement is brought about by activating the UP button Note on the wiring of the Takeover point The Safe...

Page 48: ...on 06 2003 Figure 6 2 Hydraulic operation End of stroke signals 6 2 Valve monitoring Parameterization Figure 6 3 Hydraulic operation Watchdog timer Note If an electrical valve monitor is not in use monitoring must be accomplished by means of other measures with a comparable degree of safety hydraulic or electric ...

Page 49: ...hts Reserved SIMOTION Safety Unit AP Edition 06 2003 6 49 Example of wiring Y01 1 2 PSV1 L M BY01 1 Position feedback of press safety valve if present X6 1 X4 10 X6 2 Y02 1 2 PSV2 X6 3 X6 4 Y02 1 2 PSV3 X6 5 X6 6 BY02 1 X4 11 BY03 1 X4 12 Figure 6 4 Valve monitoring ...

Page 50: ...Procedural functions of hydraulic presses Siemens AG 2003 All Rights Reserved 6 50 SIMOTION Safety Unit AP Edition 06 2003 Notes ...

Page 51: ...cial functions The only exception is operating mode 1 which is intended for fault acknowledgement 7 2 Protective features The protective features EMERGENCY OFF EMERGENCY OFF output signal safety guard safety gate engaging lock do not require special handling for the folding functionality 7 3 Control elements The control elements two hand control foot switch acknowledge button for group acknowledge...

Page 52: ...operating modes are handled identically Parameterization Figure 7 1 Enabling for operating modes 7 4 1 Information on control signals Start condition The Start condition signal is an enable signal for the downward movement It must be available prior to every start of a downward movement HIGH level but can change its state during the movement This function can be disabled when no additional start c...

Page 53: ...rds speed request signal is the command from the higher lever control to the Safety Unit for activation of the fast downward movement The signal must be active for the duration of the fast downward movement In the case of a LOW level the downward movement is always slow If the enable for the fast downward movement is to be generated internally this function can be disabled default Note Information...

Page 54: ...put signal Valve control 7 5 1 Access protection Figure 7 2 Access protection Two safety devices can be parameterized for access protection light curtain or laser safety device Each access protection can be activated as required for the mode If the access protection is deactivated in a specific operating mode it must be switched off Preferably this will be implemented via the ESPE supply 0 5 A out...

Page 55: ...erved SIMOTION Safety Unit AP Edition 06 2003 7 55 7 5 2 Watchdog timer Figure 7 3 Watchdog timer The run time of three valves can be monitored The valve run time can be variably parameterized from 20 to 2000 ms The feedback input can be defined as an NO or NC contact ...

Page 56: ... valve the read back input must be at LOW level before the valve is activated During switching at least one leading edge must be received at the read back input for NO contact Note The valve can be activated on short start pulses from the command devices but it does not switch through due to valve run times Since in this case there would also be no feedback at the read back input this would result...

Page 57: ... variants can be selected Variant 1 Here the press safety valve and valve 1 or valve pair 1 are controlled for the slow downward movement All 3 valves or valve pairs are controlled for the fast downward movement Variant 2 Here the press safety valve and valve 1 or valve pair 1 are controlled for the slow downward movement The press safety valve and valve 2 or valve pair 2 are controlled for the fa...

Page 58: ...dge of the DOWN signal request a shutdown delay 0 5000 ms can be parameterized The stop command immediately switches off the Enable DOWN output Using this signal the flow e g through the control valve can be reduced by the higher level control and the machine speed can be slowed A parameterized delay time is available for the implementation of this process The corresponding valve valve 1 valve 2 c...

Page 59: ...ording to the EN 12622 standard two hand control is only permissible in the Setup mode If the fast downward movement is to be initiated by two hand control up to the MUTE point during operation access protection is not required A MUTE point must be parameterized for this function Switching of the valve is initiated at the MUTE point slow speed A stop can now be initiated via the DOWN request signa...

Page 60: ...e safety devices parameterized in the respective operating mode must provide a HIGH level signal Application example Activation of distance protection zone protection from the MUTE point onward Figure 7 10 Distance protection In this example the downward movement was started in mode 2 e g foot The DOWN request signal of the higher level control is reset at the MUTE point or any point This brings a...

Page 61: ... switch Inputs UPPER POINT MUTE POINT END STROKE EMERGENCY OFF switch Access protection E1 Access protection E2 Operating mode 2 Foot NO 1 Foot NC 1 DOWN request Fast downwards movement request Outputs DOWN enable Valve 1 slow Press safety valve Valve 2 fast Emergency off output signal Figure 7 11 Example for foot switch For this example it is assumed that a foot switch and an access protection du...

Page 62: ...1 Access protection E2 Operating mode 4 Foot NO 1 Foot NC 1 Foot NO 2 Foot NC 2 DOWN request Fast downwards movement request Outputs DOWN enable Valve 1 slow Press safety valve Valve 2 fast Emergency off output signal Figure 7 12 Example for multiple operators with foot switch For this example it is assumed that two foot switches and an access protection dual channel E1 E2 have been parameterized ...

Page 63: ...l Figure 8 1 Implementation of single operator multi operator control In the above configuration operating mode 2 is set for single operator multi operator control Foot switch 2 can be selected using an NO contact it can be deactivated The deactivation input should be switched by the selector switch for single operator multi operator control 8 ...

Page 64: ...l elements deactivated control elements have been removed For multi operator control all activated control elements must be connected contact monitor If the monitoring function responds messages are output to notify the user 8 2 Single operator control via 2 foot switches and operating error monitor To implement single operator control via 2 separate foot switches each foot switch must be paramete...

Page 65: ...ledge signal protective door The acknowledge request for the safety gates can also be signalized on a separate output Enable DOWN for edging presses This function signalizes to a higher level control that all conditions for the downward movement have been met The DOWN enable is set when no active safety devices have been violated and the active control elements have been actuated Even if a shutdow...

Page 66: ... movement of the hydraulic press is being performed This means that the press safety valves and the valves for the downward movement are being controlled Moving upwards for hydraulic operation This function signalizes that the upward movement of the hydraulic press is being performed This means that the press safety valves and the valves for the upward movement are being controlled ...

Page 67: ...ID error See 1 F013 Error from plug in monitor for memory card See 1 F014 Keyswitch error See 1 F015 CPU error See 1 F016 System data error See 1 F017 Program execution error See 1 F018 Application error See 1 F019 Serial interface error See 1 F020 Error input X4 1 See 2 F021 Error input X4 2 See 2 F022 Error input X4 3 See 2 F023 Error input X4 4 See 2 F024 Error input X4 5 See 2 F025 Error input...

Page 68: ...Error output X2 1 See 3 F065 Error output X2 2 See 3 F066 Error output X2 3 See 3 F067 Error output X2 4 See 3 F068 F069 Not assigned F070 Error output X6 2 See 3 F071 Error output X6 4 See 3 F072 Error output X6 6 See 3 F073 Error output X6 8 See 3 F074 Error output X2 5 See 3 F075 Error output X2 6 See 3 F076 Error output X2 7 See 3 F077 Error output X2 8 See 3 Corrective measures for system err...

Page 69: ...channel 4 EMERGENCY OFF output signal F113 Light curtain mode selection 1 cycle 2 cycle F114 Short circuit or 0 at light curtain mode selector switch F115 Setting dynamic cam F122 Discrepancy error transfer point F123 Error in dynamic valve control channel 1 F124 Error in dynamic valve control channel 2 F125 Error in dynamic valve control channel 3 F316 Restart inhibit EMERGENCY OFF is set F317 Re...

Page 70: ...uard 8 F217 Contact error two hand 1 F218 Contact error two hand 2 F219 Contact error two hand 3 F220 F222 Not assigned F223 Discrepancy error restart inhibit 1 F224 Discrepancy error restart inhibit 2 F225 Discrepancy error light curtain F226 Contact error foot switch 1 F227 Contact error foot switch 2 F228 Contact error foot switch 3 F229 Discrepancy error access protection 1 F230 Discrepancy er...

Page 71: ...hts Reserved SIMOTION Safety Unit AP Edition 06 2003 10 71 10 Documentation 10 1 Documentation of inputs notes X3 Pin Description Cable Notes 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 10 ...

Page 72: ...1 Output P Cycle 1 2 Output P Cycle 2 3 4 5 Output P Cycle 3 6 Output P Cycle 4 7 8 Error message 10 3 Documentation of system data The CRC checksum should be entered on the label on the back of the memory card and on the label located on the housing next to the memory card A complete function text must be performed after changes are made to the parameterization whether after the equipment is exch...

Page 73: ... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Street _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ City _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Telephone _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Please put a cross next to your industry sector Automotive industry Pharmaceutical industry Chemi...

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Page 76: ...ives Motion Control Systems P O Box 3180 D 91050 Erlangen Federal Republic of Germany www ad siemens de Siemens AG 2003 Subject to change without prior notice Order no 6AU1900 0DM20 0XA0 Printed in the Federal Republic of Germany ...

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