DOLD Safemaster Pro User Manual
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DOLD Safemaster Pro User Manual

Configurable safety system
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Summary of Contents for DOLD Safemaster Pro

  • Page 3: Table Of Contents

    Connection terminals, BusExtender module UG6918 ............20 EXAMPLE OF CONNECTION TO THE MACHINE CONTROL SYSTEM ......21 Calculation of safety distance of an ESPE connected to SAFEMASTER PRO ...... 22 CHECKLIST AFTER INSTALLATION ..................22 PROJECT development DIAGRAM .................... 23 SIGNALS ............................
  • Page 4 How to install SAFEMASTER PRO DESIGNER ..............57 Fundamentals ........................... 58 Standard tool bar ........................59 Create a new project (configure the SAFEMASTER PRO system) ........60 EDIT CONFIGURATION (composition of the various units) ..........61 Change user parameters ....................... 61 OBJECTS - OPERATOR - CONFIGURATION tool bars ............
  • Page 5 Project validation ........................65 Project report ........................... 66 Connect to SAFEMASTER PRO ....................67 Sending the configuration to the SAFEMASTER PRO ............67 Download a configuration from a SAFEMASTER PRO ............67 Configuration LOG ........................ 68 System composition ......................68 Disconnecting System .......................
  • Page 6 Configurable safety system SAFEMASTER PRO NOR ............................ 107 XOR ............................ 107 XNOR ..........................108 LOGICAL MACRO ......................108 MULTIPLEXER ........................109 MEMORY OPERATORS......................110 D FLIP FLOP (max number = 16) ..................110 SR FLIP FLOP ........................110 T FLIP FLOP ........................110 USER RESTART MANUAL (max number = 16 USER RESTART at all) ......

  • Page 7: Introduction

    This symbol indicates an important instruction.  SAFEMASTER PRO is built to the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4 in accordance with the applicable standards. However, the definitive SIL and PL of the application will depend on the number of safety components, their parameters and the connections that are made, as per the risk analysis.

  • Page 8: Abbreviations And Symbols

    Performance Level Probability of a dangerous failure per Hour SIL = Safety Integrity Level SILCL = Safety Integrity Level Claim Limit Applicable standards SAFEMASTER PRO complies with the following European Directives: • 2006/42/EC "Machinery Directive" • 2004/108/EC "Electromagnetic Compatibility Directive"...

  • Page 9: Overview

    OA6911 memory chip (accessory). The configuration can therefore quickly be copied to another control unit UG6911.10 unit.  The SAFEMASTER PRO system is certified to the maximum safety level envisaged by the applicable industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4). 0265525 09.05.2017 LA822P...

  • Page 10: Control Unit And I/O Expansion Modules

    Configurable safety system SAFEMASTER PRO Control unit and I/O expansion modules • The control unit UG6911.10 and the I/O Expansion module UG6916.10 have 8 safety inputs, 2 independent programmable dual channel safety outputs (OSSD), 2 status outputs and 4 test outputs to monitor the presence of short-circuits on the inputs.

  • Page 11: Busextender Module Ug6918

    Configurable safety system SAFEMASTER PRO BusExtender module UG6918 • UG6918 is an expansion module which allows the connection of the control unit UG6910.10 with other slave modules placed at great distances <50m ). Through the use of a shielded cable (with RS485 compatible double twister pair shielded cable) two BusExtender modules UG6918 placed at the desired distance can be linked together.

  • Page 12: Product Composition

    INSTALLATION Mechanical fastening Fix the SAFEMASTER PRO system units to a 35mm DIN rail as follows: 1. Fix the IN-RAIL-BUS to the DIN 35mm (EN 5022) rail. 2. Fasten the units to the rail, arranging the contacts on the base of the IN-RAIL-BUS. Press the unit gently until you feel it snap into place.

  • Page 13: Electrical Connections

    Configurable safety system SAFEMASTER PRO Electrical connections USB input The SAFEMASTER PRO control unit UG6911.10 includes a USB 2.0 connector for connection to a Personal Computer where the SAFEMASTER PRO DESIGNER configuration software resides. A USB cable is available as an accessory (OA6920).

  • Page 14: Safemaster Pro Memory Chip Oa6911

    OA6911, all you need to do is insert the memory chip OA6911 in the new control unit UG6911.10 and switch on the SAFEMASTER PRO system, that will immediately load the backup configuration. In this way, the work interruptions will be minimized.

  • Page 15: Connection Terminals

    We recommend the use of separate power supplies for the safety unit and for other electrical power equipment (electric motors, inverters, frequency converters) or other sources of disturbance. Connections of each single SAFEMASTER PRO system unit are listed in the table below: 0265525 09.05.2017 LA822P 13/139...

  • Page 16: Connection Terminals, Control Unit Ug6911.10

    Configurable safety system SAFEMASTER PRO Connection terminals, control unit UG6911.10 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply MASTER_ENABLE1 Input Master Enable 1 "Type 2" according to EN 61131-2 MASTER_ENABLE2 Input Master Enable 2 "Type 2" according to EN 61131-2...

  • Page 17: Connection Terminals, Input Module Ug6913.16 With 16 Inputs

    Configurable safety system SAFEMASTER PRO Connection terminals, input module UG6913.16 with 16 inputs TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("Type 2" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("Type 2" according to EN 61131-2 )

  • Page 18: Connection Terminals, Input Module Ug6913.12 With 12 Inputs

    Configurable safety system SAFEMASTER PRO Connection terminals, input module UG6913.12 with 12 inputs TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("Type 2" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("Type 2" according to EN 61131-2 )

  • Page 19: Connection Terminals, Output Module Ossd Ug6912.04 With 4 Ossd

    Configurable safety system SAFEMASTER PRO Connection terminals, output module OSSD UG6912.04 with 4 OSSD TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("Type 2" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("Type 2" according to EN 61131-2 )

  • Page 20: Connection Terminals, Output Module Relay Ug6912.28 With 2 Ossd

    Configurable safety system SAFEMASTER PRO Connection terminals, output module relay UG6912.28 with 2 OSSD TERMINAL SIGNAL TYPE DESCRIPTION OPERATION Feedback common for ZONE 1 and FBK_A1_A2_1 Input ZONE 2 0VDC power supply OSSD1_A Input Control ZONE 1 PNP active high...

  • Page 21: Connection Terminals, Output Module Relay Ug6914.04/000

    Configurable safety system SAFEMASTER PRO Connection terminals, output module relay UG6914.04/000 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("Type 2" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("Type 2" according to EN 61131-2 )

  • Page 22: Connection Terminals, Speed Monitoring Module Ug6917

    Configurable safety system SAFEMASTER PRO Connection terminals, Speed monitoring module UG6917 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("Type 2" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("Type 2" according to EN 61131-2 )

  • Page 23: Example Of Connection To The Machine Control System

    Configurable safety system SAFEMASTER PRO EXAMPLE OF CONNECTION TO THE MACHINE CONTROL SYSTEM Figure 5 0265525 09.05.2017 LA822P 21/139...

  • Page 24: Calculation Of Safety Distance Of An Espe Connected To Safemaster Pro

    CHECKLIST AFTER INSTALLATION The SAFEMASTER PRO system is able to detect the faults that occurs in each own unit. Anyway to have the system perfect operation, perform the following checks at start up and at least...

  • Page 25: Project Development Diagram

    Configurable safety system SAFEMASTER PRO PROJECT DEVELOPMENT DIAGRAM Mechanical fastening Electrical connections between the SAFEMASTER® PRO Units and with the external sensors Designing the diagram Validation sw OK ? Connection via USB with UG6911.10 Downloading the diagram to UG6911.10 Configuration check...

  • Page 26: Signals

    MASTER_ENABLE2.  These signals must both be permanently set to logic level 1 (24VDC) for the SAFEMASTER PRO to operate. If the user needs to disable the SAFEMASTER PRO simply lower these inputs to logic level 0 (0VDC). NODE SEL...

  • Page 27: Restart_Fbk

    Configurable safety system SAFEMASTER PRO RESTART_FBK The RESTART_FBK signal input allows the SAFEMASTER PRO to verify an EDM (External Device Monitoring) feedback signal from the external contactors (series of contacts), and to monitor Manual/Automatic operation (See the list of possible connections in Table Each OSSD has a RESTART_FBK corresponding input.

  • Page 28: Outputs

    • An input. • An output. • A node of the logic diagram designed using the SAFEMASTER PRO DESIGNER software. OUT TEST The OUT TEST signals must be used to monitor the presence of short-circuits on the inputs.  The maximum number of controllable inputs for each output OUT TEST is: - 2 INPUT (parallel connection) (UG6911.10,...

  • Page 29: Safety Relays (Output Module Relay Ug6912.14, Ug6912.28 With 1/2 Ossd)

    Configurable safety system SAFEMASTER PRO Each OSSD output can be configured as shown in 8: The output is activated according to the configurations set by the SAFEMASTER PRO DESIGNER Automatic software only if the corresponding RESTART_FBK input is connected to 24VDC.

  • Page 30: Internal Contacts Diagram

    Configurable safety system SAFEMASTER PRO Internal contacts diagram FBK_A1_ 2 FBK_A1_A2_1 FBK_A1_1 FBK_A1_2 FBK_A2_2 UG6912.14 Figure 7 UG6912.28 Example: connection static OSSD outputs from control unit UG6911.10 to output module relay UG6912.14 with 1 OSSD UG6912.14 FBK_A1_1 FBK_A1_2 Figure 8 28/139 0265525 09.05.2017 LA822P...

  • Page 31: Switching Operation Timing Diagram

    Configurable safety system SAFEMASTER PRO Switching operation timing diagram. Figure 9 If a relay unit is connected, the response time of the OSSD linked, must be increased of 12ms. 0265525 09.05.2017 LA822P 29/139...

  • Page 32: Technical Features

    Configurable safety system SAFEMASTER PRO TECHNICAL FEATURES GENERAL SYSTEM CHARACTERISTICS Safety level parameters Parameter Value Standard See the technical data tables for each module IEC 61508: 2 edition SILCL IEC 62061:2005 Type EN 61496-1 High EN ISO 13849-1:2008 MTTFd (years) 30 ÷...
  • Page 33 Configurable safety system SAFEMASTER PRO 10,6ms ÷ 12,6ms + T Filter_Input control unit 11,8ms ÷ 26,5ms + T Filter_Input UG6911.10 + 1 Slave 12,8ms ÷ 28,7ms + T Filter_Input UG6911.10 + 2 Slaves 13,9ms ÷30,8ms + T Filter_Input UG6911.10 + 3 Slaves OSSD Response time 15ms ÷...

  • Page 34: Enclosure

    Configurable safety system SAFEMASTER PRO Enclosure Electronic housing max 24 pole, Description with locking latch mounting Enclosure material Polyamide Enclosure protection class IP 40 Terminal blocks protection class IP 20 Fastening Quick coupling to rail according to EN 60715 Dimensions (h x l x d)

  • Page 35: Control Unit Ug6911.10

    Configurable safety system SAFEMASTER PRO Control unit UG6911.10 99,8% (IEC 61508: 2 edition) 6.86E-9 437,63 MTTF EN ISO 13849-1:2008 99,0% 24VDC ± 20% / Remote Class 2 Source or limited voltage limited Nominal voltage current Nominal consumption 3W max inrush current max.

  • Page 36: Input/Output Module Ug6916.10 Io

    Configurable safety system SAFEMASTER PRO Input/output module UG6916.10 IO 99,8% (IEC 61508: 2 edition) 5,68E-9 458,21 MTTF EN ISO 13849-1:2008 99,0% 24VDC ± 20% / Remote Class 2 Source or limited voltage limited Nominal voltage current Nominal consumption 3W max inrush current max.

  • Page 37: Input Modules Ug6913.08 - Ug6913.16 With 8 / 16 Inputs

    Configurable safety system SAFEMASTER PRO Input modules UG6913.08 - UG6913.16 with 8 / 16 inputs Model UG6913.08 UG6913.16 99,7% 99,7% (IEC 61508: 2 edition) 4,45E-9 4,94E-9 473,00 396,47 MTTF EN ISO 13849-1:2008 99,0% 99,0% 24VDC ± 20% / Remote Class 2 Source or limited voltage limited...

  • Page 38: Output Modules Ossd Ug6912.02 - Ug6912.04 With 2/4 Ossd

    Configurable safety system SAFEMASTER PRO Output modules OSSD UG6912.02 - UG6912.04 with 2/4 OSSD Model UG6912.02 UG6912.04 99,8% 99,8% (IEC 61508: 2 edition) 4,09E-9 5,84E-9 948,88 683,38 MTTF EN ISO 13849-1:2008 98,9% 24VDC ± 20% / Remote Class 2 Source or limited voltage limited...

  • Page 39: Output Module Relay Ug6912.14 - Ug6912.28 With 1/2 Ossd

    Taking in account that the Relay feedback contact connection has been done as described in section EXAMPLE OF CONNECTION TO THE MACHINE CONTROL SYSTEM , every double channel connected to SAFEMASTER PRO module has the following safety values (PFH , SFF...

  • Page 40: Output Module Relay Ug6914.04/000 - Ug6914.04/008

    Configurable safety system SAFEMASTER PRO Output module relay UG6914.04/000 - UG6914.04/008 Model UG6914.04/000 UG6912. 04/008 99,9% 99,9% IEC 61508: 2 edition 2,90E-9 2,94E-9 99,0% 98,9% EN ISO 13849-1:2008 998,56 980,78 MTTFd 24VDC ± 20% / Remote Class 2 Source or limited voltage limited current...
  • Page 41 Configurable safety system SAFEMASTER PRO Conditions Relay Category 2 AC15 Load 3A@230V PL maximum obtainable: d 2.63E11 Maximum achievable SIL: 2 AC15 Load 1A@230V 6.57E11 DC13 Load 2A@24V 8.77E12 Conditions Relay Category 4 AC15 Load 3A@230V PL maximum obtainable: e 6.62E11...

  • Page 42: Speed Monitoring Module Ug6917

    Configurable safety system SAFEMASTER PRO Speed monitoring module UG6917 Modell UG6917/002 UG6917/102 UG6917/112 UG6917/202 UG6917/222 UG6917/302 UG6917/332 99,7% 99,7% 99,7% 99,7% 99,7% 99,7% 99,7% (IEC 61508: edition PFH d 5,98E-9 7,08E-9 8,18E-9 6,70E-9 7,42E-9 7,93E-9 9,89E-9 MTTF 500,33 337,72 254,88...

  • Page 43: Busextender Module Ug6918

    Configurable safety system SAFEMASTER PRO BusExtender module UG6918 24VDC ± 20% / Remote Class 2 Source or limited Nominal voltage voltage limited current Nominal consumption 3W max inrush current max. 10A, 0,3ms Connections 5-pole IN-RAIL-BUS - 4-pole Terminal blocks Maximum distance between 2 module UG6918 <50m (each section)

  • Page 44: Visualisations

    Configurable safety system SAFEMASTER PRO VISUALISATIONS Control unit UG6911.10 IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 MEANING GREEN ORANGE BLUE YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST OA6911 recognized (max (max 1s) Writing / Loading diagram to / from OA6911 card...

  • Page 45: Input/Output Module Ug6916.10

    Configurable safety system SAFEMASTER PRO Input/output module UG6916.10 IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 MEANING ORANGE GREEN YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST Table 22 - Opening Screen IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2...

  • Page 46: Input Modules Ug6913.08, Ug6913.12, Ug6913.16, With 8, 12 And 16 Inputs

    Configurable safety system SAFEMASTER PRO Input modules UG6913.08, UG6913.12, UG6913.16, with 8, 12 and 16 inputs MEANING IN FAIL EXT FAIL IN1÷16 GREEN ORANGE YELLOW Power on - initial TEST Table 24 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷8...

  • Page 47: Output Module Ug6912.02, Ug6912.04, With 2 Or 4 Ossd

    Configurable safety system SAFEMASTER PRO Output module UG6912.02, UG6912.04, with 2 or 4 OSSD MEANING IN FAIL EXT FAIL OSDD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 26 - Opening screen MEANING IN FAIL...

  • Page 48: Output Module Relay Ug6912.14/ Ug6912.28 With 1/2 Ossd

    Configurable safety system SAFEMASTER PRO Output module relay UG6912.14/ UG6912.28 with 1/2 OSSD MEANING OSSD1 GREEN NORMAL OPERATION GREEN with output activated Table 28 - UG6912.14 - Dynamic screen MEANING OSSD1 GREEN OSSD2 GREEN NORMAL OPERATION GREEN with output activated Table 29 - UG6912.28 - Dynamic screen...

  • Page 49: Output Module Relay Ug6914.04/000, Ug6914.04/008

    Configurable safety system SAFEMASTER PRO Output module relay UG6914.04/000, UG6914.04/008 STATUS 1÷4 MEANING IN FAIL EXT FAIL SEL 0/1 RELAY 1÷4 CLEAR 1÷4 (UG6914.04/008) GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 30 - Opening screen STATUS 1÷4...

  • Page 50: Speed Monitoring Module Ug6917/002, Ug6917/X02, Ug6917/Xx2

    Configurable safety system SAFEMASTER PRO Speed monitoring module UG6917/002, UG6917/x02, UG6917/xx2 MEANING IN FAIL EXT FAIL SEL 0/1 ENC * PROX GREEN ORANGE YELLOW YELLOW YELLOW Power on - initial TEST Table 32 - Opening screen MEANING IN FAIL EXT FAIL...

  • Page 51: Busextender Module Ug6918

    Configurable safety system SAFEMASTER PRO BusExtender module UG6918 MEANING IN FAIL EXT FAIL (GREEN) (GREEN) (RED) (RED) INITIAL TEST OFF > NORMAL OPERATION BLINKING > Operation OK Operation OK Table 34 - UG6918 - Dynamic screen Figure UG6918 0265525 09.05.2017 LA822P...

  • Page 52: Troubleshooting

    Configurable safety system SAFEMASTER PRO TROUBLESHOOTING Control unit UG6911.10 IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 MEANING REMEDY ORANGE BLUE GREEN YELLOW RED/GREEN YELLOW YELLOW 2 or 3 Return the unit to Internal fault flashes DOLD to be repaired 4 flashes •...

  • Page 53: Input/Output Module Ug6916.10

    Configurable safety system SAFEMASTER PRO Input/output module UG6916.10 IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 MEANING REMEDY GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW 2 or 3 Return the unit to DOLD to Internal fault flashes be repaired • Firmware version not...

  • Page 54: Input Module Ug6913.08, Ug6913.12, Ug6913.16 With 8, 12 Or 16 Inputs

    • Change the unit's address (see with same flashes flashes address detected Node detection 3 flashes 3 flashes • Return the unit to DOLD to be repaired circuit error Table 37 - Troubleshooting UG6913.08 Figure - UG6913.08, UG6913.12, UG6913.16 52/139 0265525 09.05.2017 LA822P...

  • Page 55: Output Modules Ug6912.02 / Ug6912.04 With 2/4 Ossd

    • Verify connections at 8, 12, 20, OSSD output state flashes Figure or short circuit CLEAR state UG6912.02 / UG6912.04 Error on node detection • Return the unit to DOLD to be 3 flashes circuit flashes repaired Table 38 - Troubleshooting UG6912.02/UG6912.04 0265525 09.05.2017 LA822P 53/139...

  • Page 56: Output Module Relay Ug6914.04/000, Ug6914.04/008

    • Check connections at pins OUT- OSSD output state Flashes overload detected state STATUS Error on node • Return the unit to DOLD to be detection circuit repaired Table 39 - Troubleshooting UG6914.04/000 and UG6914.04/008 Figure UG6914.04/000, UG6914.04/008 54/139 0265525 09.05.2017 LA822P...

  • Page 57: Speed Monitoring Module Ug6917/002, Ug6917/X02, Ug6917/Xx2

    GREEN ORANGE YELLOW YELLOW YELLOW Internal fault 2 or 3 • Return the unit to DOLD to be repaired • Firmware version not compatible with Compatibility error UIG6911.10, return to DOLD for FW Shows upgrade. • Encoder not connected but physical •...

  • Page 58: Busextender Module Ug6918

    Configurable safety system SAFEMASTER PRO BusExtender module UG6918 MEANING IN FAIL EXT FAIL (GREEN) (GREEN) (RED) (RED) INTERNAL FAULT DETECTED Follows UG6911.10 error B L I N K I N G (Not recoverable. Restart the system) codification FAULT DETECTED ON TERMINAL...

  • Page 59: Safemaster Pro Designer Software

    Configurable safety system SAFEMASTER PRO SAFEMASTER PRO DESIGNER SOFTWARE The "SAFEMASTER PRO DESIGNER" software can be used to configure a logic diagram of the connections between the SAFEMASTER PRO (control unit + expansions) and the components of the system being developed.

  • Page 60: Fundamentals

     Warning The PFHd, MTTFd and DC values which are shown in “Project report – SAFEMASTER PRO – Safety information” refer exclusively to the internal operation of SAFEMASTER PRO. For the calculation of the total PFHd values of the various safety functions implemented through SAFEMASTER PRO, however, the effect of the safety components connected with SAFEMASTER PRO has to be taken into account (e.g.

  • Page 61: Standard Tool Bar

    Configurable safety system SAFEMASTER PRO Standard tool bar The standard tool bar is shown in Figure 28. The meanings of the icons are listed below: 1 -> CREATE A NEW PROJECT 2 -> CHANGE CONFIGURATION (arrangement of the different modules) 3 ->...

  • Page 62: Create A New Project (Configure The Safemaster Pro System)

    (Figure 29). Figure 29 Next the SAFEMASTER PRO DESIGNER displays a window showing the UG6911 only. You may add the various units needed to create your system, using the pull-down menus at the top of the screen (select slave) and at the bottom to select the relative node (0÷4).

  • Page 63: Edit Configuration (Composition Of The Various Units)

    The dialog user identification request appears ( ). To accomplish this operation is not necessary to Log out from SAFEMASTER PRO. Generally it serves when a new user must create a new project (even using a previously created). Figure 31...

  • Page 64: Creating The Diagram (Figure 16)

    Configurable safety system SAFEMASTER PRO Creating the diagram (Figure 16) Once you have selected your system composition, you are ready to configure the project. The logic diagram is created using a DRAG&DROP function: • Select the objects as required from the windows described previously (each single object is described in detail in the following sections) and drag it into the design area.

  • Page 65: Use Of Mouse Right Button

    Configurable safety system SAFEMASTER PRO Use of mouse right button ON BLOCK INPUT / OUTPUT • Copy / Paste • Delete • Delete all the assigned pins • Alignment with other functional blocks (multiple selection) • On-line Help • on block Status: enable / disable input pin logical negation •...

  • Page 66: Print Logic Diagram

    Configurable safety system SAFEMASTER PRO Print logic diagram For print function, 3 symbols are available: The logic diagram is always one complete picture that can be printed via this symbol. Depending of printer configuration, the logic diagram is cut in several pages.

  • Page 67: Example Of A Project

    The UG6911 inputs (1, 2, and 3) for connecting the contacts of the safety components are shown on the left, in yellow. The SAFEMASTER PRO outputs (from 1 to 4) are activated according to the conditions defined in E-GATE and E-STOP (see the E-GATE E-STOP sections).

  • Page 68: Project Report

     Warning The PFHd, MTTFd and DC values which are shown in “Project report – SAFEMASTER PRO – Safety information” refer exclusively to the internal operation of SAFEMASTER PRO. For the calculation of the total PFHd values of the various safety functions implemented through SAFEMASTER PRO, however, the effect of the safety components connected with SAFEMASTER PRO has to be taken into account (e.g.

  • Page 69: Connect To Safemaster Pro

    "Password protection "). Figure 37 Sending the configuration to the SAFEMASTER PRO To send the saved configuration from a PC to UG6911 use the icon on the standard toolbar and wait the execution. UG6911 will save the project in its internal memory and (if present) in OA6911 memory.

  • Page 70: Configuration Log

    (Password Required: level 1). Figure 38 System composition The check of the actual composition of the SAFEMASTER PRO system is obtained using the icon . (Password Required: level 1). A pop-up window will appear with: - Connected units; - Firmware version of each unit;...

  • Page 71: Error Codes From Safemaster Pro Designer

    Configurable safety system SAFEMASTER PRO Error codes from SAFEMASTER PRO Designer In case of malfunction the SAFEMASTER PRO system transmits to the SAFEMASTER PRO Designer a code corresponding to the error detected by the UG6911.10 unit. To read the code, proceed as follows: connect the UG6911.10 (indicating Fail) to the PC using the USB-cable...

  • Page 72: Monitor (I/O Status In Textual)

    A pop-up window will appear (in real time) with: - Status of the inputs (when the object has two or more input connections to SAFEMASTER PRO, the MONITOR will show as active only the first), see the example in figure;...

  • Page 73: Monitor (I/O Status In Real Time - Textual - Graphic)

    Configurable safety system SAFEMASTER PRO MONITOR (I/O status in real time - textual - graphic) To activate/deactivate the monitor use the icon . (Password Required: level 1). The color of links (Figure 33) allows you to view the diagnostics (in real time) with:...

  • Page 74: Password Protection

     Should you forget either of these passwords, please contact DOLD which will provide an unlock file. When this file is saved in the directory in which the SAFEMASTER PRO DESIGNER software is installed, the following icon appears in the standard tool bar.

  • Page 75: Testing The System

    Configurable safety system SAFEMASTER PRO TESTING the system  After validating and uploading the project to the UG6911 and connecting all the safety devices, you must test the system to verify its correct operation. This is done by forcing a change of status for each safety device connected to the SAFEMASTER PRO to check that the status of the outputs actually changes.

  • Page 76: Object Function Blocks

    Configurable safety system SAFEMASTER PRO OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD (safety outputs) The OSSD semiconductor safety outputs require no maintenance, Output1 and Output2 supply 24VDC if the input is 1 (TRUE), whereas they supply 0VDC if the input is 0 (FALSE).

  • Page 77: Relay (Safety Output)

    Configurable safety system SAFEMASTER PRO Example of OSSD with correct Feedback signal: Example of OSSD with incorrect Feedback signal In this case ERROR OUT = FALSE (k external time exceeded): In this case ERROR OUT = TRUE RELAY (safety output) Relay Outputs are N.O.

  • Page 78: Status (Signal Output)

    States are represented with 2 bytes on the fieldbus. (For more detailed information, consult the fieldbus manual on the SAFEMASTER PRO Designer CD-ROM).  WARNING: the PROBE output is NOT a safety output 0265525 09.05.2017 LA822P...

  • Page 79: Input Objects

    Configurable safety system SAFEMASTER PRO INPUT OBJECTS E-STOP (emergency stop) The E-STOP function block verifies the status of the inputs of an emergency stop device. If the emergency stop button has been pressed the output is 0 (FALSE). If not the output is 1 (TRUE)

  • Page 80: E-Gate (Safety Gate Device)

    Configurable safety system SAFEMASTER PRO Filter (ms): This is used to filter the signals coming from the emergency stop. The filter can be configured to between 3 and 250ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time.

  • Page 81: Single E-Gate (Safety Gate Device)

    Configurable safety system SAFEMASTER PRO Output Test: This is used to select which test output signals are to be sent to the component contacts. This additional test makes it possible to detect and manage any short-circuits between the lines. There is a choice of up to 8 possible test output signals, Test Output 1 ÷...

  • Page 82: Lock Feedback

    Configurable safety system SAFEMASTER PRO Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

  • Page 83: Enable (Enable Key)

    Configurable safety system SAFEMASTER PRO ENABLE (enable key) The ENABLE function block verifies the status of the inputs of a manual key device. If the key is not turned the output is 0 (FALSE). Otherwise the output is 1 (TRUE).

  • Page 84: Espe (Optoelectronic Safety Light Curtain / Laser Scanner)

    Configurable safety system SAFEMASTER PRO Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts. Enable Error Out: If selected reports a fault detected by the function block.

  • Page 85: Footswitch (Safety Pedal)

    Configurable safety system SAFEMASTER PRO Enable Error Out: If selected reports a fault detected by the function block. Item Description: This allows a description of the component's function to be entered. The text is displayed in the top part of the symbol.

  • Page 86: Mod-Sel (Safety Selector)

    Configurable safety system SAFEMASTER PRO StartUp Test: If selected this enables the test at start-up of the external component. This test is performed by pressing the pedal to run a complete function test and enable the output. This test is only requested at machine start-up (when the unit is switched on).

  • Page 87: Photocell (Safety Photocell)

    Configurable safety system SAFEMASTER PRO PHOTOCELL (safety photocell) The PHOTOCELL function block verifies the status of the inputs of an optoelectronic safety photocell. If the beam of the photocell is occupied (photocell output FALSE) the output is 0 (FALSE). Otherwise with the beam clear and an output of 1 (TRUE) the output is 1 (TRUE).

  • Page 88: Two-Hand (Bimanual Control)

    Configurable safety system SAFEMASTER PRO TWO-HAND (bimanual control) The TWO HAND function block verifies the status of the inputs of a two hand control switch. Only if both the press-buttons are pressed within 500msec the output is 1 (TRUE). Otherwise the output is 0 (FALSE).

  • Page 89: Sensor

    Configurable safety system SAFEMASTER PRO SENSOR The SENSOR function block verifies the status of the input of a sensor (not a safety sensor). If the beam of the sensor is occupied (sensor output FALSE) the output is 0 (FALSE). Otherwise, with the beam clear and an output of 1 (TRUE) then the output is 1 (TRUE).

  • Page 90: S-Mat (Safety Mat)

    Configurable safety system SAFEMASTER PRO S-MAT (safety mat) The S-MAT function block verifies the status of the inputs of a safety mat. If a person stands on the mat the output is 0 (FALSE). Otherwise, with the mat clear, the output is 1 (TRUE)

  • Page 91: Switch

    Configurable safety system SAFEMASTER PRO SWITCH The SWITCH function block verifies the status of the input of a pushbutton or switch (not safety switches). If the pushbutton is pressed the output is 1 (TRUE). Otherwise, the output is 0 (FALSE).

  • Page 92: Enabling Grip Switch

    Configurable safety system SAFEMASTER PRO ENABLING GRIP SWITCH The ENABLING GRIP functional block checks the status of the In inputs of an enabling grip. If this is not gripped (position 1) or is gripped completely (position 3), the OUTPUT will be 0 (FALSE). If it is gripped to middle position (position 2), the OUTPUT will be 1 (TRUE).
  • Page 93 Configurable safety system SAFEMASTER PRO Test outputs: Permits selection of the test output signals to be sent to the enabling grip. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

  • Page 94: Testable Safety Device

    Configurable safety system SAFEMASTER PRO TESTABLE SAFETY DEVICE The TESTABLE SAFETY DEVICE functional block checks the status of the Inx inputs of a single or double safety sensor, both NO and NC. Refer to the tables below to check type of sensor and behavior.

  • Page 95: Solid State Device

    Configurable safety system SAFEMASTER PRO Test outputs: Permits selection of the test output signals to be sent to the contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).

  • Page 96: Fieldbus Input

    Up to 8 virtual inputs can be inserted and the bit on which status is to be modified must be selected for each. They are represented with one byte on the fieldbus. (For more detailed information, consult the fieldbus manual on the SAFEMASTER PRO Designer CD-ROM). Parameters...

  • Page 97: Llo, Ll1

    Configurable safety system SAFEMASTER PRO LLO, LL1 These allow a predefined logical level to be entered on a component’s input. LL0 -> logical level 0 LL1 -> logical level 1  IMPORTANT: LL0 and LL1 cannot be used to disable the logical operators (AND, OR, XOR ...) in the...

  • Page 98: Speed Control Type Function Blocks

    Configurable safety system SAFEMASTER PRO SPEED CONTROL TYPE FUNCTION BLOCKS SPEED CONTROL The Speed Control function block monitors the speed of a device generating an output 0 (FALSE) when the measured speed exceeds a predetermined threshold. In the case in which the speed is below the predetermined threshold the output will be 1 (TRUE).
  • Page 99 Configurable safety system SAFEMASTER PRO Threshold number: It allows you to enter the number of thresholds for the maximum value of speed. Changing this value will increase/decrease the number of thresholds that can be entered from a minimum of 1 to a maximum of 4. In the case of thresholds greater than 1, the...
  • Page 100 Configurable safety system SAFEMASTER PRO Rotary axis, rotary sensor. The frequency obtained is: Linear axis, rotary sensor. The frequency obtained is: KEY: f = frequency Rpm = rotational speed Resolution = measurement Speed = linear speed Pitch = sensor pitch Linear axis, linear sensor.

  • Page 101: Window Speed Control

    Configurable safety system SAFEMASTER PRO WINDOW SPEED CONTROL The Window Speed Control function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is within a prefixed range. Parameters Axis type: It defines the type of axis controlled by the device.
  • Page 102 Configurable safety system SAFEMASTER PRO (in the case of rotary sensor) or µm/pulse (linear sensor) relating to the sensor used. Verification: Enter in this field the number of pulses/revolution (in the case of rotary sensor) or µm/pulse (linear sensor) relating to the second sensor used.

  • Page 103: Stand Still

    Configurable safety system SAFEMASTER PRO STAND STILL The Stand Still function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is lower than a selected value. Parameters Axis type: It defines the type of axis controlled by the device.
  • Page 104 Configurable safety system SAFEMASTER PRO Verification: Enter in this field the number of pulses/revolution (in the case of rotary sensor) or µm/pulse (linear sensor) relating to the second sensor used. Gear Ratio: This parameter is active if there are two sensors on the selected axis. This parameter allows you to enter the ratio between the two sensors.

  • Page 105: Stand Still And Speed Control

    Configurable safety system SAFEMASTER PRO STAND STILL AND SPEED CONTROL The Stand Still and Speed Control function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is lower than a selected value. In addition, it generates the Over = 0 (FALSE) output if the measured speed exceeds a predetermined threshold.
  • Page 106 Configurable safety system SAFEMASTER PRO Threshold number: It allows you to enter the number of thresholds for the maximum value of speed. Changing this value will increase/decrease the number of thresholds that can be entered from a minimum of 1 to a maximum of 4. In the...

  • Page 107: Text Blocks

    Configurable safety system SAFEMASTER PRO Frequency: It shows the maximum calculated frequency values fM and fm (decreased by the hysteresis set). If the displayed value is GREEN, the calculation of frequency gave a positive result. If the displayed value is RED, it is necessary to change the parameters given in the following formulas.

  • Page 108: Operator Function Blocks

    Configurable safety system SAFEMASTER PRO OPERATOR FUNCTION BLOCKS All the input of these operators could be inverted (logical NOT). It could be done clicking with the right mouse key on the input to be inverted. A little circle will be showed on the inverted input. To cancel the inversion, simply click another time on the same input pin.

  • Page 109: Nor

    Configurable safety system SAFEMASTER PRO Logical OR returns an output of 1 (TRUE) if at least one of the inputs is 1 (TRUE). Parameters Number of inputs: this is used to set between 2 and 8 inputs. Logical NOR returns an output of 0 (FALSE) if at least one of the inputs is 1 (TRUE).

  • Page 110: Xnor

    Configurable safety system SAFEMASTER PRO XNOR Logical XNOR returns an output 1 (TRUE) if the input's number at 1 (TRUE) is even or the inputs are all 0 (FALSE). Parameters Number of inputs: this is used to set between 2 and 8 inputs.

  • Page 111: Multiplexer

    Configurable safety system SAFEMASTER PRO Enable (OUT1, OUT2) If selected, activates an output with the result of the first two operators. MULTIPLEXER Logical MULTIPLEXER forwards the signal of the inputs to the output according to the Sel selection. If the SEL1÷SEL4 have only one bit set, the selected In n is connected to the Output.

  • Page 112: Memory Operators

    Configurable safety system SAFEMASTER PRO MEMORY OPERATORS MEMORY operators can be used if you decide to save any data (TRUE or FALSE) from other project components. Status changes are performed according to the truth tables shown for each operator. D FLIP FLOP (max number = 16)

  • Page 113: User Restart Manual (Max Number = 16 User Restart At All)

    Configurable safety system SAFEMASTER PRO USER RESTART MANUAL (max number = 16 USER RESTART at all) The USER RESTART MANUAL operator saves the restart signal according to the following truth table. Clear Restart 1 Keep memory Rising edge 1 Falling edge 1 Keep memory Parameters Clear enable: If selected enables the saving process to be reset.

  • Page 114: Macro Restart Monitored (Max Number = 16 User Restart At All)

    Configurable safety system SAFEMASTER PRO Enable Clear: If selected enables the saving process to be reset. Enable Out: If selected activates an output with the result of the calculation done by the logic. MACRO RESTART MONITORED (max number = 16 USER RESTART at all) The MACRO RESTART MONITORED operator is used to combine a logic gate chosen by the user with the Restart Manual functional block ("USER RESTART MONITORED") in accordance with the...
  • Page 115 Configurable safety system SAFEMASTER PRO 3. The UnLock_cmd input can be connected freely in the diagram and determines the request to unlock (when in LL1 state). 4. The OUTPUT signal of this element is 1 (TRUE) if the guard is closed and locked. When an unlock command is applied to the UnLock_cmd input, the OUTPUT signal is set to "0"...

  • Page 116: Counter Operators

    Configurable safety system SAFEMASTER PRO COUNTER OPERATORS COUNTER operators can be used to generate a signal (TRUE) as soon as the set count is reached. COUNTER (max number = 16) The operator COUNTER is a pulse counter. There are 3 operating modes:...

  • Page 117: Monostable

    Configurable safety system SAFEMASTER PRO MONOSTABLE The MONOSTABLE operator generates a level 1 (TRUE) output activated by the rising edge of the input and remains in this condition for the set time Parameters Time: The delay can be set to between 10ms and 1093.3s.

  • Page 118: Monostable_B

    Configurable safety system SAFEMASTER PRO MONOSTABLE_B The MONOSTABLE_B operator generates a level 1 (TRUE) output activated by the rising edge of the input and remains in this condition for the set time. Parameters Time: The delay can be set to between 10ms and 1093.3s.

  • Page 119: Passing Make Contact

    Configurable safety system SAFEMASTER PRO PASSING MAKE CONTACT In the PASSING MAKE CONTACT operator output follows the signal on the input. However, if this is 1 (TRUE) for longer than the set time, the output changes to 0 (FALSE). When there is an input falling edge, the timer is cleared.

  • Page 120: Delay Line

    Configurable safety system SAFEMASTER PRO If not selected the logic is inverted, the output is set to 1 (TRUE) on the input signal's rising edge, the delay starts on the input signal's falling edge, at the end of the set time the output changes to 0 (FALSE) if the input is 0 (FALSE) otherwise it remains 1 TRUE.
  • Page 121 Configurable safety system SAFEMASTER PRO Unlike the DELAY operator, the DELAY LINE operator does not filter any interruptions in the IN input which are shorter than the set time. This operator is recommended when using delayed OSSD (the OSSD must be programmed with RESTART MANUAL).

  • Page 122: Muting Operators (Max Number = 4)

    Configurable safety system SAFEMASTER PRO MUTING OPERATORS (max number = 4)  At all, maximum 4 muting operators and maximum 4 muting override operators can be used is the system "Concurrent" MUTING The MUTING operator with "Concurrent" logic performs muting of the input signal through sensor inputs S1, S2, S3 and S4.

  • Page 123: Muting "L

    Configurable safety system SAFEMASTER PRO Select SENSOR Input Muting Blind Time: Only with Muting Close=Curtain, blind time is enabled if you know that after the complete transition of the pallet (muting cycle close) some protruding objects could still occupy the light curtain and send the input to 0 (FALSE). During blind time the input remains 1 (TRUE).

  • Page 124: Sequential" Muting

    Configurable safety system SAFEMASTER PRO "Sequential" MUTING The MUTING operator with "Sequential" logic performs muting of the input signal through sensor inputs S1, S2, S3 and S4.  Preliminary condition: The Muting cycle can only start if all the sensors are 0 (FALSE) and the inputs are 1 (TRUE) (barrier free).

  • Page 125: Muting "T

    Configurable safety system SAFEMASTER PRO Blind Time: Only with Muting Close=Curtain, blind time is enabled if you know that after the complete transition of the pallet (muting cycle close) some protruding objects could still occupy the light curtain and send the input to 0 (FALSE). During blind time the input remains 1 (TRUE).
  • Page 126 Configurable safety system SAFEMASTER PRO Override with pulsed action This function is enabled activating the Override command (OVERRIDE=1). Override ends when the light curtain and sensors are cleared (gap free) or on expiry of the timeout. The function can be restarted only if the Override command is re-activated (OVERRIDE=1)

  • Page 127: Miscellany (Special Function Blocks)

    Configurable safety system SAFEMASTER PRO Miscellany (special function Blocks) Serial output The Serial Output operator outputs the status of up to 8 inputs, serializing the information. Operating principles. This operator outputs the status of all the connected inputs in two different ways: Asynchronous serialization: 1) The status of the line in the idle condition is 1 (TRUE);...

  • Page 128: Network

    Configurable safety system SAFEMASTER PRO Network The Network operator is used to distribute Stop and Reset commands via a simple local network. Use Network_in and Network_out to exchange START, STOP and RUN signals between the different nodes. Operating principles: This operator allows stop and reset commands to be distributed simply in a local PLC network.
  • Page 129 Configurable safety system SAFEMASTER PRO Condition 1: With reference to the figure, at power-on: 1. The OUTPUTs of the various nodes are in the 0 (FASLE) condition; 2. The STOP signal is sent via the Network_out line; 3. When the RESET command is pressed on one of the nodes all the nodes that are present are started when the START signal is sent;...
  • Page 130 Configurable safety system SAFEMASTER PRO LED signals on UG6911.10 with active network NETWORK FUNKTONAL BLOCK SIGNALS Network out Network out Network in Reset in (OSSD) (STATUS) FAIL OSSD STATUS STOP CLEAR blinking red/green(blinking) blinking blinking STATUS green FAIL blinking LED corresponding to the input where is wired Network IN...

  • Page 131: Reset Ug6911

    Configurable safety system SAFEMASTER PRO RESET UG6911 This operator generates a system Reset when there is a double OFF-ON-OFF transition on the corresponding input which lasts less than 5 s. If > 5s, RESET is not generated. UG6911 firmware version 3.0 or higher It can be used to reset faults without disconnecting system power.

  • Page 132: Special Applications

    Configurable safety system SAFEMASTER PRO SPECIAL APPLICATIONS Output delay with manual reset If you need to have two OSSD output with one of them delayed (in MANUAL mode) use the following scheme: Figure 46 - Two outputs with one delayed (in MANUAL mode) ...

  • Page 133: Combination Of Two Hand With Other Safety Functions

    Configurable safety system SAFEMASTER PRO Combination of Two Hand with other safety functions If a two hand acts of the same output as other safety functions (for example ESPE or E-Stop) the two hands must absolutely be released after a deactivation of the OSSDs due to the other safety functions.

  • Page 134: Simulator

    Configurable safety system SAFEMASTER PRO SIMULATOR  This simulator is only designed to assist in the design of safety functions.  The results of the simulation do not constitute validation of the project.  The resulting safety function must always be validated, from the point of view of both...

  • Page 135: Graphic Simulation

    Configurable safety system SAFEMASTER PRO When you press "Play" to start the simulation, the amount of time that has elapsed is displayed next to the word "Time". This time is measured in "Step" units of time multiplied by the user-defined "KT"...
  • Page 136 Configurable safety system SAFEMASTER PRO Figure 50 – Example of a result of the graphic simulation Click on the icon to display the page shown below. Figure 51 – Menu for selecting the graphic simulation mode 134/139 0265525 09.05.2017 LA822P...
  • Page 137 Configurable safety system SAFEMASTER PRO Description of the menu items Template Stimuli: Used to save the template file with the desired name and disk location. This file will contain the names of the signals as shown in the diagram 52. Now you may use a text editor to enter the status of the input signals at a given moment in time as well as the duration of the simulation and the time step to be used.
  • Page 138 Configurable safety system SAFEMASTER PRO Bild 53 – Traces visibility  The traces that can be added to the graph are shown in the box on the left. The traces currently displayed and which can be removed from the graph are shown in the box on the right.

  • Page 139: Accessories And Spare Parts

    Mounting set IN-RAIL-Bus 250mm for DIN 7,5mm Rail 0064244 Mounting set IN-RAIL-Bus 250mm for DIN 15mm Rail BU6922 0064245 PN6919 Software SAFEMASTER PRO Designer 0064246 Please, visit the website www.dold.com for the list of the authorized representative of each Country. 0265525 09.05.2017 LA822P 137/139...

  • Page 140: Liability

    The implemented circuits and electrical diagrams and the system configuration parameter values, including those of SAFEMASTER PRO, are fully under the responsibility of the user. Characteristics are subject to change without prior notice. No part of this document may be reproduced unless authorized by DOLD.

  • Page 141: Declaration Of Conformity

    Configurable safety system SAFEMASTER PRO DECLARATION OF CONFORMITY 0265525 09.05.2017 LA 139/139...

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