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Wieland samos User Manual

Multifunctional safety switching device
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Multifunctional Safety
Switching Device
Modular Electronic
Safety System
with Coding
BA000256
12/2012 (Rev. I)

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Summary of Contents for Wieland samos

  • Page 1 Multifunctional Safety Switching Device Modular Electronic Safety System with Coding BA000256 12/2012 (Rev. I)

  • Page 2: Table Of Contents

    Logic functions, Expansion function 71 Index 74 Configuration List ___________________________________________________________________________ Validity of the manual as from module revision:  SA-BM : F-01  SA-IN : F-01  SA-OR : D-01 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 3: About This Manual

    About this manual What Does This Manual Describe? This manual provides an overview of the functionalities of the modular samos safety system as a safety processing unit for plant and machines. It describes the individual modules and the way they function together in the system as a whole with safety sensors, switches and actuators..

  • Page 4: Of Installation

    ___________________________________________________________________________ Proper Use The samos safety system described in this manual serves to protect people, the environment, the machine and the material according to the valid EU occupational health and safety directive 89/391/EEC, the machinery directive 2006/42/EC, the use of work equipment directive 89/655/EEC as well as the statutory regulations and standards applicable in other countries (e.g.

  • Page 5: Safety Function Blocks

     Two-hand applications to EN 574, type IIIA and IIIC  Jog mode  4-wire switching mat monitoring  Muting and bypass  Enabling function for cascading and grouping  Automatic or manual Reset, starting and restarting inhibit © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 6    Configuration The samos modular safety system is a programmable electronics PE) element of an electrical/ electronic/programmable electronic system (E/E/PES) as described in IEC/EN 61508/EN 62061. The system comprises base modules, input and output modules, and bus coupler modules.
  • Page 7 Safety System The coded modules of the samos system Accordingly to the applications in a samos overall system hard-coded system groups can Coding be assembled, whose codings are different and whose logical functions are independent from each other. Every system group of the overall system consists of a distinctly coded basic module, which can be amended with input modules of the same coding.
  • Page 8  Master base module (Coding 1) The master base module is the obligatory basic element of the samos system. On its own it functions as a complete safety switching device for monitoring up to 2 safety circuits. It offers 8 function blocks for inputs and logic functions (set on rotary switch on front), 8 inputs and 4 wear-free semiconductor safety outputs.

  • Page 9: Risk Assessment And Risk Minimization

    Determine residual risks  Test effectiveness of safety measures  Validate acc. to EN ISO 13849-2  If necessary introduce additional measures to reduce residual risk to an acceptable level. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 10 Selection 19 and 36. of stop category 0 and/or 1 (EN 60204-1).  Select function blocks and input circuit functions for the application on the samos base module. How many safety sensors and safety circuits...

  • Page 11: System Functions

    (on the left) via the internal safety bus (SBus). The relay output modules are not integrated directly via the SBus in the samos safety communication system. However, indirect monitoring is possible via the feedback circuits.
  • Page 12 The diagnosis function allows internal system data to be provided to external systems via a diagnosis module or bus coupler module. For detailed explanations of system functions and other hints and examples please refer to NOTE the glossary on page 45ff. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 13: Base Module Data

     When inductive loads are connected (e.g. valves, contactors) a suppressor circuit must be set up (e.g. RC combination).  Internal samos module addresses are assigned automatically when the system starts up. Manual addressing is unnecessary (and not possible).  The safety system must be installed in an enclosure with at least IP 54 protection.
  • Page 14 Base modules to supply Wire capacitance, C 500 nF external sensors, may not 100  Wire resistance, R exceed 600 mA! Type of outputs / short-circuit behavior Semiconductor / absolutely short-circuit-proof © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 15 Power circuitry – input circuit Power circuitry – output circuit Input circuit – output circuit Weight 0.16 kg General technical data See page 65. Order numbers See page 69. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 16 : Test pulse period ___________________________________________________________________________ Input circuit function diagram (equivalent activation) Input I1 : ON period Input I2 : OFF period : see page 47 (good state)  t  t © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 17: Interfaces And Operation

    H-level on corresponding input  S1..S3 flashes Feedback circuit open  Q1/2, Q3/4 on H-level on corresponding outputs, Q3/4 flashes during off delay time  FLT off No fault states © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 18: Installation And Accepting

    74. bus coupler module. There is a separate manual for the bus coupler modules (see page 70). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 19: Input Circuit Functions

    Enabling input for cascading and grouping input module Muting: OR operation Muting, OR, bypass 1AB, 2AB, for bridging safety functions for setup mode, input module Bypass: clearing, alternative safety function input module © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 20 The diagram shows three different types of evaluation and the signal flows between inputs and outputs for single function 1, combination function 6 and dual function 8. The diagram is an excerpt from the function overview (see page 30). together linked separate © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 21 Settable off delay for output Q4 Configuring of retriggering via terminal (bridge or feedback circuit) Safe semiconductor outputs Q1, Q2, Q3, For input module functions see page 32ff. See control circuit functions, page 24. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 22 The U signal can come from  supply voltage +U  the Q semiconductor outputs on the base modules,  the OSSD outputs of muting light barriers (muting function only). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 23 (EN 574 Type IIIC). ___________________________________________________________________________ Configuration Single function 3.2 Combination function 5.2 S2 and supply voltage unbridged ___________________________________________________________________________ Single function 3.1 Combination function 5.1 Bridge between S2 and supply voltage © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 24: Control Circuit Functions

    During the configuration phase (after power on) of manual Reset (with Reset button) the NOTE corresponding S output must be open or connected to a high-ohm output (e.g. a PLC). High or low potential will result in incorrect configuration. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 25 Reset button operated, the enabling paths shut down anyway.  Auto mode (restarting inhibit OFF) The delay time must expire before enabling via the Reset input is possible again. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 26 * With off delay 0 s all the associated outputs of the group do not switch back on until all NOTE feedback circuits in the group are closed. ** For special functions see page 23. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 27 Q4 the NC contacts of the respective contactors or output expansions must be connected monitoring in series with the associated control inputs (see the tables here and page 47). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 28: Function Blocks

    Dual-channel NC / NC with cross monitoring, stop category 0 and 1 Emergency stop, safety door, non-contact safety device type 4 Dual-channel NC/NC, single-channel NC, stop category 0 and 1 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 29 In combination functions 5 to 7 the signals on I1, I2 shut down all outputs Q1 to Q4, the NOTE signals on I3, I4 shut down only the outputs Q3 and Q4. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 30 Bridge or feedback circuit Q3 **For signal supply to ENABLE input EN OSSD of light barriers/light Bridge or feedback circuit Q4 see page 48. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 31 Restarting inhibit ON: Manual Reset after safety event. Retriggering OFF: Unconditional time delay period (see page 25). Restarting inhibit OFF: Automatic Reset after safety event (see page 24). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 32: Input Module Data

     The rotary switches for selecting function must only be adjusted when power is off.  Never connect or disconnect modules while the operating voltage is switched on.  Internal samos module addresses are assigned automatically when the system starts up. Manual addressing is unnecessary (and not possible).
  • Page 33 The time is independent of the number of input modules connected to the base module. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 34 : Test pulse period ___________________________________________________________________________ Input circuit function diagram (equivalent activation) Input I1 Input I2 (good state)  t  t : ON period : OFF period : see page 47 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 35: Interfaces And Operation

    Good state of AND-linked input pairs I1/I2 and I3/I4 (function group A)  QB on Good state of AND-linked input pairs I5/I6 and I7/I8 (function group B)  FLT off No fault states © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 36: Input Circuit Functions

    Both pairs are then linked by a logical AND. Dual-channel equivalent (without cross-circuit monitoring) As above, but without cross-circuit monitoring. Can also be operated as dual-channel three- wire circuit. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 37 ON signal of duration limited to 60 s. For the BYPASS function see page 46. When cross-circuit is detected the whole group (A or B) is shut down. NOTE © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 38 Synchronous time monitoring  Not used * & : AND-linked input pairs : Combination of flipflop + AND link; see "Evaluating inputs", page 36. Terminal assignment see page 41. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 39 Input expansion  Time limit 60 s * 1 : OR-linked input pairs : Combination of flipflop + AND operation; see "Evaluating inputs", page 36. Terminal assignment see page 41. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 40: ___________________________________________________________________________

    System 2: INPUT A of the input module acts together with base module function group A on output group A (blue); INPUT B acts together with function group B on output group B (pink). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 41: Terminal Assignment

    2x single-channel BYPASS X1-I1 I3 n.c. X5-I5 I7 n.c. 1x dual-channel X2-I2 I4 n.c. X6-I6 I8 n.c. Cross monitoring Input expansion Function as INPUT B Function as INPUT A © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 42: Relay Output Module Data

     In the event of single-channel control of a contact extension (e.g. SA-OR) through a base module (SA-BM/BS), category 4 according to EN ISO 13849-1 can be achieved if both devices are installed in the same enclosure and the samos system is separated from the power supply at least once a day.
  • Page 43 AC 230 V Connection diagram SA-OR-S1 KS 260-1-4 SA-OR-S2 KS 260-1-6 Weight SA-OR-S1 0.17 kg SA-OR-S2 0.10 kg General technical data See page 65 Order numbers See page 69 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 44: Interfaces And Operation

     PWR on Power supply to module electronics is on Meaning of LEDs  K1 on Relay K1 in operated condition  K2 on Relay K2 in operated condition © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 45: Glossary

    Two equivalent inputs are monitored (e.g. the signals from a light barrier). A valid input signal is only generated if ON state (H-level) is present at both inputs and both were previously in OFF state (L-level). © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 46 START function The muting function in the samos base device corresponds to an input circuit function with dual-channel equivalent activation without cross-circuit monitoring. Muting of a safety function must not be dependent on a single signal! An output controls the corresponding muting lamp.
  • Page 47 . All input and muting signals from the base START module and the associated input modules (i.e. of a system group within the samos system), and the bypass/OR signals from the input modules are logically linked (AND/OR). The terminal configuration with bridges and feedback circuits is also evaluated (see below).

  • Page 48: Diagnosis

    LEDs. The diagnosis and display functions are decoupled and are not safety functions. In other words, no data from external systems can enter the system via a diagnosis or bus coupler module. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 49: Samos And Iec/En 61508/En 62061

    ___________________________________________________________________________ Safety integrity level The safety function of the samos system is shutting down or preventing a dangerous process. All the system functions described in this manual are safety functions. A safety integrity level defines the range for failure probability of a safety function in relation to operating mode and request frequency.

  • Page 50: Characteristic Safety Values

    1. single-channel input - single-channel output Input 2. single-channel input - dual-channel output Base module expansion 3. dual-channel input - single-channel output 4. dual-channel input - dual-channel output Relay output expansion © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 51 Variant 4 PFDavg 2,5E-05 7,1E-06 2,3E-05 5,8E-06 % of SIL 3 2,5% 0,7% 2,3% 0,6% PFH (1/h) 1,4E-08 3,9E-09 1,4E-08 3,9E-09 % of SIL 3 13,5% 3,9% 13,5% 3,9% © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 52: Applications And Pictograms

    Safe position, e.g. of a robot, is detected by a sensor. Zone protection is lifted and an operator can enter the robot zone. If the robot leaves the position it is switched off safely. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 53: Logic Functions

    + Combination of flipflop + AND operation 1* MUTING the conditional OR- combination is valid only if the result of the Reset function before was =1 (see pages 46/47). SA-BM-S1 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 54: And Links

    SA-BM-S1 emergency stop function block (FUNCTION 1). The AND link is made by output Q2 on the SA-BM-S1 and the EN enabling input on the right SA-BM-S1. + Combination of flipflop + AND operation SA-BM-S1 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 55: Or Links Of Safety Inputs

    Actuation of lockswitch S1 bridges the safety door function with an OR link; i.e. all outputs Q1 to Q4 remain on. Lockswitch takes effect even with safety door opened and switches all outputs on. + Combination of flipflop + AND operation © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 56 + Combination of flipflop + AND operation 1* MUTING the conditional OR- combination is valid only if the result of the Reset function before was =1 (see pages 46/47). SA-IN-S1 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 57 SET1. If enabling button SET1 is actuated, outputs Q3 and Q4 do not shut down when door SG2 is opened. + Combination of flipflop + AND operation SA-IN-S1 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 58: Applications

    OFF delay 1,5 s Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON AUTO-RESET MANUAL RESET Comment samos modules and contactors in the same enclosure  e © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 59 (see pages 46/47). Synchronous time monitoring Stop category (EN 60204-1) OFF delay Retriggering ON AUTO-RESET after POWER ON MANUAL RESET after POWER ON AUTO-RESET MANUAL RESET Comment Crossmonitoring by safety sensors © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 60 Stop category (EN 60204-1) OFF delay Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON AUTO-RESET MANUAL RESET Comment samos modules and contactors in the same enclosure © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 61 Stop category (EN 60204-1) OFF delay Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON AUTO-RESET MANUAL RESET Comment samos modules and contactors in the same enclosure © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 62 Synchronous time monitoring – – – (see pages 46/47). Stop category (EN 60204-1) OFF delay Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON AUTO-RESET MANUAL RESET Comment © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 63: Annex

     manufacturer if required Cyclical visual check of configuration The leadable cover SA-COVER is available as an accessory for the safe samos modules. It prevents the rotary switches from changing their setting after system start-up. Error Codes of Error LED...

  • Page 64: Installing / Removing

    Push down at the back. While pressing down, remove the module from the DIN rail in the direction of the arrow. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 65 The SA-COVER accessory can be used with safe modules as of revision C-01. © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 66: Screw Terminals Pluggable, Spring

    Screw terminals pluggable Spring force terminals pluggable Marking -A Marking -C ___________________________________________________________________________ Input module, Output module SA-IN, SA-OR Screw terminals pluggable Spring force terminals pluggable Marking -A Marking -C © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 67: General Technical Data

    The system must be switched off and restarted at least once a year and the safety functions must be tested! Approvals SIL 3 (EN 61508/EN 62061) and PLe/category 4 (EN ISO 13849-1) (not for bus coupling modules) TÜV cULus © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 68 1 male (left) Rail DIN rail EN 50022-35 ___________________________________________________________________________ Module connections Max. number of parallel-connected module inputs or S that can be controlled from one module output X or Q © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 69 R1.180.0100.0 SA-DeviceNet-A DeviceNet field bus Screws R1.180.0350.0 SA-EN-MOD-A Modbus/TCP Screws R1.180.0750.0 SA-EN-PN-A Profinet Screws R1.180.0760.0 SA-EN-IP-A EtherNet/IP Screws R1.180.0770.0 Accessories SA-COVER Cover for samos modules, leadable,PU 10 p. R9.211.0430.0 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 70 Annex Manuals (downloadable PDF documents) SA-MANUAL-D BA000255 samos manual, German SA-MANUAL-GB BA000256 samos manual, English SA-MANUAL-BUS-D BA000268 samos bus coupler manual, German SA-MANUAL-BUS-GB BA000269 samos bus coupler manual, English © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 71: Index

    S2 23, 26 Input dynamization 45 S3 25, 26 Input expansion 39, 40 Control input 47 Input module 8, 32 Controlled stopping 21, 48, 52 INPUT rotary switch 36 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 72 Safety shutdown 52 Order numbers 69 Safety standards 4 OSSD 22, 52 Safety structure 49 Output dynamization 48 Safety zones 10, 48 Output function 12, 48 Safety-related information 3 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)
  • Page 73 Switch off and on again 18 Use of work equipment directive 4 Switching mats 52 V  Switching on procedures 48 Valve monitoring 52 Synchronous time monitoring 11, 36, 45 © 2010 Wieland Electric GmbH | BA000256 | 12/2012 (Rev. I)

  • Page 74: Configuration List

    Annex samos Configuration List This is a blank samos configuration list (module location list) for copying. We recommend keeping a record of the configuration with the documentation or in a clearly visible place in the enclosure. ___________________________________________________________________________ samos Notes on the...

  • Page 75: Wieland Electric Gmbh | Ba000256 | 12/2012 (Rev. I

    Date: Name: Comment: Sign: Data transfer betw een samos-module SA-PROFIBUS-DP-A and PC via Mastersimulator BW1131 (company Bihl+Wiedemann) Dow nload of samosConfigListSetupX.X.zip under w w w .w ieland-electric.com --> Infoservice --> Dow nload Center Wieland-Service: www.wieland-electric.com info@wieland-electric.com Hotline: +49 951 9324-995...

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