IAI SU-S-PN Instruction Manual

Functional safety unit

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F F u u n n c c t t i i o o n n a a l l S S a a f f e e t t y y U U n n i i t t

Instruction Manual

SU-S-PN/NP

First Edition

Overview

Specifications

Installation and

Wiring

Basic Operation

and Settings

Safety Function

Parameters

Maintenance

and Inspection

Troubleshooting

Functional Safety

Unit Setting Tool

Warranty

ME0459-1C

Chapter

Table of Contents

Troubleshooting

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Summary of Contents for IAI SU-S-PN

Page 1 F F u u n n c c t t i i o o n n a a l l S S a a f f e e t t y y U U n n i i t t SU-S-PN/NP...
Page 3: Please Read Before Use
Please downloaded the user’s manual from our website. You can download it free of charge. User registration is required for the first time downloading. URL : www.iai-robot.co.jp/data_dl/CAD_MANUAL/ When using the product, print out of the necessary portions of the relevant manual, or please display it on your computer, tablet terminal, etc.
Page 4 Functional Safety Unit Instruction Manual Configuration Control Product name Instruction manual name number SCON2 SCON2 Instruction Manual ME0458 Functional Safety Unit Functional Safety Unit ME0459 Instruction Manual (this document) Functional Safety Unit Functional Safety Unit ME0460 First Step Guide IA-OS First Step Guide PC Teaching Software ME0391 * Refer to the guidance feature stored in...
Page 5: Table Of Contents
Contents Safety Guide ·································································································· Intro-1 Caution about This Product ··············································································· Intro-8 Residual Risk ································································································· Intro-9 Precautions for Handling ·················································································· Intro-12 Overseas Standard Compliance ········································································· Intro-13 Actuator Coordinate System ·············································································· Intro-14 Chapter 1 Overview Overview ················································································ 1-1 1.1.1 Product Guideline ················································································ 1-1 1.1.2 Features ····························································································...
Page 6 Safety I/O Signal Specifications ·················································· 2-14 2.6.1 Safety Input Signals ············································································ 2-14 2.6.2 Safety Output Signals ········································································· 2-15 Chapter 3 Installation and wiring Overview Layout ······································································ 3-1 Installation ·············································································· 3-2 3.2.1 Installation Environment ······································································ 3-2 3.2.2 Storage and Preservation Environment ··················································· 3-2 3.2.3 Countermeasure for Noise ···································································...
Page 7 Diagnosis by Test Pulse ···························································· 4-12 4.6.1 Diagnosis by Test Pulse of Safety Input Signal ··········································· 4-12 4.6.2 Diagnosis by Test Pulse of Safety Output Signal ········································ 4-15 Chapter 5 Safety Function STO (Safe Torque OFF) Function ················································ 5-1 5.1.1 Function Overview ··············································································...
Page 8 5.8.1 Function Overview ·············································································· 5-26 5.8.2 Description of Operation ········································································ 5-27 5.8.3 Parameter Setting ·············································································· 5-31 SBC (Safe brake control) Function ··············································· 5-33 5.9.1 Function Overview ·············································································· 5-33 5.9.2 Description of Operation ········································································ 5-34 5.9.3 Parameter Setting ·············································································· 5-37 5.10 Safety Mode Input ···································································· 5-38 5.10.1 Function Overview ···············································································...
Page 9 Chapter 8 Troubleshooting Action to Be Taken upon Occurrence of Problem ···························· 8-1 List of Alarms and Warnings ······················································· 8-2 8.2.1 Alarm Level ························································································ 8-2 8.2.2 Alarm List ··························································································· 8-3 Chapter 9 Functional Safety Unit Setting Tool Overview ················································································ 9-1 9.1.1 Introduction ························································································...
Page 10 10.5 Conformance with Applicable Standards/Regulations, etc., and Application Conditions ························································· 10-2 10.6 Other Items Excluded from Warranty ············································ 10-2 Revision history ·············································································· Post-1 ME0459-1C...
Page 11: Safety Guide
Safety Guide Safety Guide “Safety Guide” has been written to use the machine safely and so prevent personal injury or property damage beforehand. Make sure to read it before the operation of this product. Safety Precautions for Our Products The common safety precautions for the use of any of our robots in each operation. Operation Description Description...
Page 12 Safety Guide Operation Description Description Transportation ● When carrying a heavy object, do the work with two or more persons or utilize equipment such as crane. ● When the work is carried out with 2 or more persons, make it clear who is to be the “leader”...
Page 13 Safety Guide Operation Description Description Installation and (2) Cable Wiring Start ● Use our company’s genuine cables for connecting between the actuator and controller, and for the teaching tool. ● Do not scratch on the cable. Do not bend it forcibly. Do not pull it. Do not coil it around.
Page 14 Safety Guide Operation Description Description Installation and (4) Safety Measures Start ● When the work is carried out with 2 or more persons, make it clear who is to be the “leader” and who to be the “follower(s)” and communicate well with each other to ensure the safety of the workers.
Page 15 Safety Guide Operation Description Description Trial Operation ● When the work is carried out with 2 or more persons, make it clear who is to be the “leader” and who to be the “follower(s)” and communicate well with each other to ensure the safety of the workers. ●...
Page 16 Safety Guide Operation Description Description Maintenance ● When the work is carried out with 2 or more persons, make it clear who is to and Inspection be the “leader” and who to be the “follower(s)” and communicate well with each other to ensure the safety of the workers. ●...
Page 17: Alert Indication
Safety Guide Alert Indication The safety precautions are divided into “Danger”, “Warning”, “Caution” and “Notice” according to the warning level, as follows, and described in the instruction manual for each model. Level Degree of Danger and Damage Symbol This indicates an imminently hazardous situation which, if the product Danger Danger is not handled correctly, will result in death or serious injury.
Page 18: Caution About This Product
Caution about This Product Caution about This Product In order to prevent injury or damage to peripherals, read the following basic caution notes related to safety carefully. ● Installation, startup, repair and other related works of the equipment that this device is installed should only be permitted to a qualified operator (Note 1) ●...
Page 19: Residual Risk
(Refer to [1.2 Safety Function List]) of this product. IAI will not take any responsibility on damage or injury caused by the residual risks. (1) Make sure that risk assessment is conducted on devices or on the whole equipment.
Page 20 Residual Risk (11) STO/SS1-t functions are the functions to disable the performance to supply energy to the servomotor electrically, but not to shut off the connection between the controller and the servomotor physically. Therefore, STO/SS1-t functions are not capable of removing the risk of electric shock.
Page 21 Residual Risk (21) When an actuator is installed vertically, the slider may move with gravity while a safety stop function is being executed. In the list below shows a reference of the slider drop amount when each safety stop function is executed under a certain condition. Consider this content and perform risk assessment.
Page 22: Precautions For Handling
*1 It is not capable of connecting an actuator in incremental / absolute / spurious absolute types. Those with “R□” at the end of S/N described in “Name Plate Sticker” on an actuator of IAI are available for connection. (Refer to [Section 2.1.5])
Page 23: Overseas Standard Compliance
Overseas Standard Compliance Overseas Standard Compliance This product complies with the following overseas standards. Refer to [the Overseas Standard Compliance Manual (ME0287)] for more detailed information. Certified by RoHS3 Directive CE Marking UL Certification Functional Safety Standards ○ ○ ○ ○...
Page 24: Actuator Coordinate System
● For models with which change is not possible, the actuator must be replaced. Contact IAI if anything is unclear. The “0” in the figure below shows home. The parentheses show home reverse specification. (1) Rod type Motor side ＋...
Page 25 Actuator Coordinate System (2) Slider type Motor side ＋＋ (3) Table type Motor side ＋＋＋ Intro-15 ME0459-1C...
Page 26 Actuator Coordinate System Intro-16 ME0459-1C...
Page 27: Chapter 1 Overview
Functional Safety Unit Chapter Overview Overview ·································································· 1-1 1.1.1 Product Guideline ·································································· 1-1 1.1.2 Features ·············································································· 1-2 Safety Function List ···················································· 1-3 Functional Block Diagram ············································· 1-5 1.3.1 Block Diagram for Functions of SCON2 and Functional Safety Unit ··· 1-5 Name for Each Parts and Their Functions ························...
Page 29: Product Guideline
“Safety Unit”. * Keep this manual to a place easy to access when necessary to read again. * The contents in this manual should cover everything considerable, however, please contact IAI in case of any awareness to mistakes or consideration.
Page 30: Features
1.1 Overview 1.1.2 Features The characteristics of this product are as shown below. ● Product Specifications • By connecting to a controller, extension of the safety function is available. • There are 14 types of the safety functions. They are applicable for Category 3, PLe, SIL 3 or Category 3, PLd, SIL 2 (depending on the safety function).
Page 31: Safety Function List
1.2 Safety Function List Safety Function List The safety functions that can be used in this product are as follows. Safety Function Functional Overview • Deceleration is initiated by an input signal or by the execution of another safety function, and the drive energy is electronically Safe torque off (STO) shut off after a specified time.
Page 32 1.2 Safety Function List Safety Function Functional Overview • This function monitors the motor for movement in the wrong direction (minus side). • Starts monitoring the amount of movement in the specified Safe direction - (SDI-) direction based on the input signal and executes the stop function (SS1-t or SS2-t) when the specified amount of movement is exceeded.
Page 33: Functional Block Diagram
1.3 Functional Block Diagram Functional Block Diagram 1.3.1 Block Diagram for Functions of SCON2 and Functional Safety Unit Here shows a block diagram for the function of SCON2 and the functional safety unit. M : Motor, BK : Brake, ENC : Encoder ME0459-1C...
Page 34: Name For Each Parts And Their Functions
1.4 Name for Each Parts and Their Functions Name for Each Parts and Their Functions 1.4.1 Name for Each Parts The names of each part on the functional safety unit are as follows. (1) LED Display (2) Safety I/O connector A (3) Safety I/O connector B ME0459-1C...
Page 35: Functions Of Each Part
1.4 Name for Each Parts and Their Functions 1.4.2 Functions of Each Part (1) LED Display The operational status of the functional safety unit should be displayed. LED Displays Contents of display Condition of Turning Colour Condition of Illuminating Condition of Blinking Name Initialization process Power not supplied...
Page 36 1.4 Name for Each Parts and Their Functions [Blinking Status of SM1, SM2 and SM3] (2) Safety I/O connector A It is a connector to transfer input and output signals of the safety unit. Refer to [2.6 Safety I/O Signal Specifications] for details of the specifications and [3.3 Safety Input / Output Connector] for how to assign and details of each signal.
Page 37: Startup Procedure
1.5 Startup Procedure Startup Procedure Here explains how to start up the functional safety unit below. Refer to [Items Described in Reference] in the table for details of each process. Procedures Content Reference Connecting Controller Confirm that a controller and safety unit are [3.2.4] and Safety Unit connected.
Page 38 1.5 Startup Procedure 1-10 ME0459-1C...
Page 39 Functional Safety Unit Chapter Specifications Product Check ··························································· 2-1 2.1.1 Parts ··················································································· 2-1 2.1.2 Teaching Tool ········································································ 2-2 2.1.3 How to Read Rating Name Plate ·············································· 2-3 2.1.4 How to Read the Model ·························································· 2-4 2.1.5 Applicable Actuator ································································ 2-5 Safety Performance ····················································...
Page 40 Safety I/O Signal Specifications ····································· 2-14 2.6.1 Safety Input Signals ······························································ 2-14 2.6.2 Safety Output Signals ··························································· 2-15...
Page 41: Product Check
2.1 Product Check Product Check 2.1.1 Parts Shown in the table below are the product structures in the standard types. Check the accessories in the packaging details. If you find any fault in the contained model or any missing parts, contact us or our distributor. Part Name Shape Quantity...
Page 42: Teaching Tool
2.1 Product Check 2.1.2 Teaching Tool The setting of the parameters on this product should be established using “Functional Safety Unit Setting Tool”. The “IA-OS” instruction manual (first step guide) is an introduction booklet for introduces the way to installation procedures and launch. For how to operate, [Chapter 9 Functional Safety Unit Setting Tool] or [Functional Safety Unit Setting Tool Screen Guide and Help] follow the instructions in a window.
Page 43: How To Read Rating Name Plate
How to Read Rating Name Plate The places to attach the rated code plates on this product and how to read them are as shown below. Company Names Model MODEL ：SU-S-PN Serial Number SERIAL No. ：B40xxxxxx Input Electricity Rating INPUT ：DC24V 0.2A...
Page 44: How To Read The Model
2.1 Product Check 2.1.4 How to Read the Model Shown below is how to read the model codes. – S – P N <Series> SU Functional Safety Unit <I/O Type> <Type> PN : PNP Specification (Source Type) S : For SCON (Standard) NP : NPN Specification (Sink.
Page 45: Applicable Actuator
2.1 Product Check 2.1.5 Applicable Actuator The actuator applicable for Functional Safety Unit is as stated below. • Capable of Connecting to SCON2. • Equipped with battery-less absolute type encoder applicable for Function Safety Unit. Caution ● If an actuator not applicable is connected, Alarm Code: 8B “Safety Unit Initialization Error”...
Page 46: Safety Performance
2.2 Safety Performance Safety Performance 2.2.1 Safety Performance and Reaction Time Here explains the safety performance of this product. [Safety performances] Item Standard Value IEC 61508 SIL2 SIL3 Safety Integrity Level IEC 62061 SILCL2 SILCL3 (*1) IEC 61508 6.0×10 2.7×10 (Probability of dangerous failure per [1/h] [1/h]...
Page 47 2.2 Safety Performance [Reaction Time] Range available Item Definition Value for setting with parameter (default) Since STO demand is enabled Parameter No.42 + 8ms 8 to 12ms until energy to motor gets cut off or less (*1) (12ms) Since SS1-t demand is enabled Parameter No.42 + No.9 8 to 10011ms SS1-t...
Page 48 2.2 Safety Performance [Example of Calculation for Reaction Time of Monitoring Function by Safety Mode] Example 1: When SLS is set to SM1 and it is set to make the safety stop at SS1-t when the setting value is executed, the reaction time. (*) As the internal SS1-t should be used at that time, the reaction time of SS1-t should be Parameter No.
Page 49: Basic Specifications
2.3 Basic Specifications Basic Specifications 2.3.1 Basic Specifications The specifications of this product are as shown below. Item Specification Values Point Input 6 point, Output 8 point Duplication Input / output Voltage 24V DC ±10% specifications Power supply 1.0A Max. (When load of input all points on / output all points at 50mA) current CE Marking EMC : IEC/EN 61800-3, IEC/EN 61000-6-2...
Page 50: Environmental Specifications
2.3 Basic Specifications 2.3.2 Environmental Specifications Specification Requirement Operating ambient temperature 0 to 60°C（No condensation or freezing） Operating ambient humidity 5 to 85%RH（No condensation or freezing） Operating ambient atmosphere Refer to [3.2.1 Installation Environment] Storage ambient temperature -20 to 70°C（No condensation or freezing） Storage ambient humidity 5%RH to 85%RH（No condensation or freezing）...
Page 51: Safety Features And Safety Standards (Sil)
2.4 Safety Features and Safety Standards (SIL) Safety Features and Safety Standards (SIL) Safety Integrity level: SIL Complete Safety Safety Function Safe torque off (STO) Safe Stop 1 time controlled (SS1-t) Safe stop 2 time controlled (SS2-t) Safe operating stop (SOS) Safely-limited speed (SLS) Safely-limited torque (SLT) Safely-limited position (SLP)
Page 52: External Dimensions
2.5 External Dimensions External Dimensions 2.5.1 Safety Unit Individual Unit 2-12 ME0459-1C...
Page 53: Scon2 + Safety Unit
2.5 External Dimensions 2.5.2 SCON2 + Safety Unit 2-13 ME0459-1C...
Page 54: Safety I/O Signal Specifications
2.6 Safety I/O Signal Specifications Safety I/O Signal Specifications 2.6.1 Safety Input Signals Item Specifications Remarks ON-Input voltage range 24V±10% OFF-Input voltage range 2.0V (Max.) Input current 7.6mA (Typ.) It is a value for 1ch. Safety Input Circuit * The input device should be connected in combination with the paired signals for duplication.
Page 55: Safety Output Signals
2.6 Safety I/O Signal Specifications 2.6.2 Safety Output Signals Specifications Item Remarks min. typ. max. Voltage range 24V±10% Load current 50mA Refer to caution below Max. voltage drop when ON 3.0V Leak current when OFF 0.1mA Safety Output Circuit * The output device should be connected in combination with the paired signals for duplication.
Page 56 2.6 Safety I/O Signal Specifications 2-16 ME0459-1C...
Page 57 Functional Safety Unit Chapter Installation and wiring Overview Layout ························································ 3-1 Installation ································································ 3-2 3.2.1 Installation Environment ························································ 3-2 3.2.2 Storage and Preservation Environment ···································· 3-2 3.2.3 Countermeasure for Noise ····················································· 3-3 3.2.4 Assembling of Functional Safety Unit ······································· 3-5 3.2.5 About Assembly ····································································...
Page 59: Overview Layout
3.1 Overview Layout Overview Layout The following shows the system configuration. Controller Functional Safety Unit (SCON2) (SCON ) Dummy Plug * Do Not Connect. PC software ～ Safety Input and Output AC power supply Devices 24V Power Supply PSA-24 Actuator Functional Grounding Protective Grounding...
Page 60: Installation
3.2 Installation Installation 3.2.1 Installation Environment This product is capable for use in the environment of pollution degree 2 or equivalent. * 1 Pollution Degree 2 : Environment that may cause non-conductive pollution or transient conductive pollution by frost (IEC60664-1) Do not use this product in the following environment.
Page 61: Countermeasure For Noise
3.2 Installation 3.2.3 Countermeasure for Noise (1) Countermeasure for Noise Grounding (Frame ground) Do not share the ground wire with or connect to other equipment. Ground each controller. ME0459-1C...
Page 62 3.2 Installation (2) Precautions regarding wiring method Refer to [3.4.1 Wiring Method] for the cable size to use. • Make sure to insert a serge absorber on the power input (line) side when a noise filter is to be used. •...
Page 63: Assembling Of Functional Safety Unit
3.2 Installation 3.2.4 Assembling of Functional Safety Unit Here explains how to assemble a controller and functional safety unit. Take off the connector cover on the controller side by pushing it up with a slotted screwdriver. Align the positions of the snap feature on the front of Safety Unit, positioning pins and attachment holes on the SCON2 side.
Page 64 3.2 Installation Confirm that all of the snap features at two points on the shorter side, two points on the front side and extrusion on the snap feature are absolutely inside the SCON2 cover. This is the end of assembling Safety Unit. ME0459-1C...
Page 65: About Assembly
3.2 Installation 3.2.5 About Assembly (1) Heat Radiation and Installation Consider such facts as size of control panel, layout of a controller and cooling performance in design and setup so the ambient temperature falls into the range from 0 to 60°C. In order to fix it in the contr3-73-7ol panel, use screw holes or DIN rail.
Page 66: Safety Input / Output Connector
3.3 Safety Input / Output Connector Safety Input / Output Connector 3.3.1 Pin Assignment on Safety Input and Output Connector The pin assignment on the safety input and output connector for the functional safety unit should be as shown below. Safety Input / Output Connector A Signal Name Signal Name...
Page 67: Detail Of Safety Input And Output Signals
3.3 Safety Input / Output Connector 3.3.2 Detail of Safety Input and Output Signals Here explains the function of each terminal on the safety input and output connector. (1) Safety input signal Function Signal Name Function Description Name (Pin No.) An input signal that activates the STO function.
Page 68 3.3 Safety Input / Output Connector (2) Safety output signal Signal Name Function Function Description (Pin No.) Name Output signal during STO function operation. STO_OUT_A(A.2) • ON ( Conduction ) : STO function is not operating STO Output STO_OUT_B(B.2) • OFF ( Open ) : STO function is operating Output signal during SBC function operation.
Page 69 3.3 Safety Input / Output Connector (3) Power Supply and FG (Frame ground) Signal Name Function Function Description (Pin No.) Name It is a common terminal for the input signals. • PNP Type: 24V DC power supply on negative side to Input Common IN_COM_A(A.17) be connected...
Page 70: Connection Of Safety Input And Output
3.3 Safety Input / Output Connector 3.3.3 Connection of Safety Input and Output Here shows an example of connection for the safety input and output below. Signal Name Signal Name Example of Safety Input and Output Signal Connection (PNP Type) Signal Name Signal Name Example of Safety Input and Output Signal Connection (NPN Type)
Page 71: Wiring Method
3.4 Wiring Method Wiring Method 3.4.1 Connector Specifications When connecting to a safety input and output connector, perform the wiring to a connector enclosed to a functional safety unit. Item Specifications Model B2CF 3.50/20/180F SN BK BX Maker Weidmuller Ltd. Applicable AWG30 to AWG16 Cable Diameter...
Page 72: Connector Wiring Method
3.4 Wiring Method 3.4.2 Connector wiring Method The way to wire a connector is as shown below. 10mm Unsheathe the cable for about 10mm and twist the core wires slightly. Precision screwdriver Open the plate spring by pushing the pusher with using a precision screwdriver. Insert a cable with its sheath peeled to the cable inlet.
Page 73: Wiring On Sbc Output
3.5 Wiring on SBC Output Wiring on SBC Output By constructing an external circuit shown in the diagram below, the brake can be activated linked to STO/SS1-t, which can prevent such a risk as a drop of a vertical axis. Build a construction to have a control of the brake power supply (BKPOW24V) using such as the safety PLC and receiving SBC_OUT_A/B.
Page 74 3.5 Wiring on SBC Output Reference ● Even if the SBC output is not used, brake control (non-safety feature) linked to behavior of a system such as servo-on/off should be performed. If the SBC function is not used as the safety function, this wiring is not necessary to be conducted. 3-16 ME0459-1C...
Page 75 Functional Safety Unit Chapter Basic Operation and Settings Power ON Sequence ··················································· 4-1 4.1.1 Power ON ··········································································· 4-1 4.1.2 Power Cutoff ········································································· 4-1 Basic Setup Related to Safety Unit Setting ······················· 4-2 4.2.1 Setting Controller Parameter ·················································· 4-3 4.2.2 Setting Safety Parameters ····················································· 4-4 Diagnosis Function ·····················································...
Page 76 4.5.1 Safety Output Signal ······························································ 4-10 4.5.2 Output Signal Status in Startup / Error Detection ·························· 4-11 Diagnosis by Test Pulse ··············································· 4-12 4.6.1 Diagnosis by Test Pulse of Safety Input Signal ···························· 4-12 4.6.2 Diagnosis by Test Pulse of Safety Output Signal ·························· 4-15...
Page 77: Power On Sequence
4.1 Power ON Sequence Power ON Sequence 4.1.1 Power ON For power supply sequence, check in the [sections for “power supply sequence” in an instruction manual of SCON2]. Set up the initialization time for 5s or more after the power is supplied when using Safety Unit. 4.1.2 Power Cutoff Conduct it in the process in the back order of turning the power on.
Page 78: Basic Setup Related To Safety Unit Setting
4.2 Basic Setup Related to Safety Unit Setting Basic Setup Related to Safety Unit Setting When using Safety Unit, it is necessary to set up the parameters on a controller and the parameters on Safety Unit. In this manual, the parameters in a controller is called as “Controller Parameters” and the parameters in Safety Unit as “Safety Parameters”.
Page 79: Setting Controller Parameter
4.2 Basic Setup Related to Safety Unit Setting 4.2.1 Setting Controller Parameter Here explains the parameters to be set up related to connection of Safety Unit. In order to show the status whether to mount Safety Unit on a controller or not, set up Controller Parameter No.
Page 80: Setting Safety Parameters
4.2 Basic Setup Related to Safety Unit Setting 4.2.2 Setting Safety Parameters Here explains the basic setting parameters necessary when the safety functions in Safety Unit is to be used. (1) Safety function enable / disable selection The “safety functions” that the functional safety unit possesses can be switched enable / disable. Default Unit No.
Page 81 4.2 Basic Setup Related to Safety Unit Setting [How to Settings] The setup of the safety parameters should be performed using “Functional Safety Unit Setting Tool”. Refer to [Chapter 9 Functional Safety Unit Setting Tool] for details such as how to use Functional Safety Unit Setting Tool.
Page 82: Diagnosis Function
4.3 Diagnosis Function Diagnosis Function Item Content Duplicating Safety Input Diagnosis performed to check the condition of the duplicated Mismatch Detection safety input signals are matched. Safety Input Circuit Test Pulse Diagnosis performed to confirm the safety input circuit is not Diagnosis bonded while it is on.
Page 83: Input Output Function (Safety Input Signal)
4.4 Input Output Function (Safety Input Signal) Input Output Function (Safety Input Signal) 4.4.1 Safety Input Signal The safety input signal is a signal to request an operation of a safety function. The safety functions should be executed once the safety input signal is input. In improve the safety, each input signal is duplicated to “Safety Input Signal A”...
Page 84: Condition And Behavior Of Safety Input Signals
4.4 Input Output Function (Safety Input Signal) 4.4.2 Condition and Behavior of Safety Input Signals Even with one signal turned off (execution command) in the doubled safety input signals, the safety function should be activated. Also, the safety functions should get canceled when both of the signals turn on (execution canceled).
Page 85: Setting Input Filter
4.4 Input Output Function (Safety Input Signal) 4.4.3 Setting Input Filter A filter purchasing to remove noise can be set to the safety input signals. Longer this time, durability to chattering and noise could improve, however, slower the response to an safety input signal gets. The input filter should be set in Safety Parameter No.
Page 86: Input Output Function (Safety Output Signal)
4.5 Input Output Function (Safety Output Signal) Input Output Function (Safety Output Signal) 4.5.1 Safety Output Signal The safety output signal is a signal to show the status of the executed safety function. In improve the safety, each input signal is duplicated to “Safety Input Signal A” and “Safety Input Signal B”.
Page 87: Output Signal Status In Startup / Error Detection
4.5 Input Output Function (Safety Output Signal) 4.5.2 Output Signal Status in Startup / Error Detection (1) In Startup Each safety output signal should be kept off until the initialization is finished after the power to the functional safety unit is supplied. (2) In Error Detection When Functional Safety Unit detects an error, it transfers to the STO status internally and STO_OUT and SBC_OUT in the safety output signals should turn off.
Page 88: Diagnosis By Test Pulse
4.6 Diagnosis by Test Pulse Diagnosis by Test Pulse 4.6.1 Diagnosis by Test Pulse of Safety Input Signal By flowing a pulse signal that turns a safety input signal off temporarily while it is on, malfunction diagnosis of the internal circuit should be conducted. Parameters can perform enable/disable of a diagnosis by the test pulse and also setting of pulse width when “enable”...
Page 89 4.6 Diagnosis by Test Pulse (1) When No Diagnosis Feature on External Device [Wiring Diagram] Safety unit External equipment External equipment 24V DC Safety input / output connector (such as Switch) ) STO_IN_A A.1 Test pulse A When Enabled: Regular Frequency OFF, always ON Input signal A IN_COM_A...
Page 90 4.6 Diagnosis by Test Pulse (2) When Diagnosis Feature Equipped on Connected Device [Wiring Diagram] External equipment External equipment Safety unit (such as Safety PLC) Safety input / output connector Test pulse Safety output Test pulse A STO_IN_A When Disabled: Always On Input signal A A.17...
Page 91: Diagnosis By Test Pulse Of Safety Output Signal
4.6 Diagnosis by Test Pulse 4.6.2 Diagnosis by Test Pulse of Safety Output Signal By flowing a pulse signal that turns a safety output signal off temporarily while it is on, malfunction diagnosis of the internal circuit should be conducted. By flowing a pulse signal that turns a safety output signal off temporarily while it is on, malfunction diagnosis of the internal circuit should be conducted.
Page 92 4.6 Diagnosis by Test Pulse [Wiring Diagram] External equipment 24V DC (such as Safety PLC) Safety input / output connector A.18 Output signal A OUT_COM_A When Test Pulse Enabled: Regular Frequency OFF when Output ON Test pulse confirmation input A STO_OUT_A Safety input Figure 4.6-5 Example of Wiring for Test Pulse of Safety Output Signal...
Page 93 Functional Safety Unit Chapter Safety Function STO (Safe Torque OFF) Function ··································· 5-1 5.1.1 Function Overview ······························································· 5-1 5.1.2 Description of Operation ························································· 5-2 SS1-t (Safe Stop 1 Time Controlled) Function ··················· 5-3 5.2.1 Function Overview ······························································· 5-3 5.2.2 Description of Operation ························································· 5-4 5.2.3 Parameter Setting ································································...
Page 94 5.5.1 Function Overview ······························································· 5-13 5.5.2 Description of Operation ························································· 5-13 5.5.3 Parameter Setting ································································ 5-16 SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function ······························ 5-18 5.6.1 Function Overview ······························································· 5-18 5.6.2 Description of Operation ························································· 5-18 5.6.3 Parameter Setting ································································...
Page 95: Sto (Safe Torque Off) Function
5.1 STO (Safe Torque OFF) Function STO (Safe Torque OFF) Function 5.1.1 Function Overview STO (Safety Torque Off) Function shuts off the power supply to a motor electrically based on the safety input signal. This function corresponds to Stop Category 0 in IEC/EN 60204-1. * When Safety Unit is connected, Safety Function built in a controller should get deactivated.
Page 96: Description Of Operation
5.1 STO (Safe Torque OFF) Function 5.1.2 Description of Operation Turning off STO_IN_A/B Input (STO Command = Enabled) and STO_OUT_A/B Output should turn off within the reaction time, and SBC feature gets executed (by the parameter setting) and the energy to a motor should shut off. Also, STO Function should be executed in the cases as stated below: ●...
Page 97: Ss1-T (Safe Stop 1 Time Controlled) Function
5.2 SS1-t (Safe Stop 1 Time Controlled) Function SS1-t (Safe Stop 1 Time Controlled) Function 5.2.1 Function Overview SS1-t (Safety Stop 1-hour Control) Function should have a motor start decelerating and should execute STO Function after the time set in the safety parameter has passed. This function corresponds to Stop Category 1 in IEC/EN 60204-1.
Page 98: Description Of Operation
5.2 SS1-t (Safe Stop 1 Time Controlled) Function 5.2.2 Description of Operation Once SS1_IN_A/B Input is turned off (SS1-t Command = Enable), the motor should start decelerating (Non-Safety Function), and SS1_OUT_A/B Output should be off after the latency (*1) (Safety Parameter No. 9) set in the parameter has passed and STO Function is executed. Also, the following operation should be conducted as a supplemental feature even though it is a safety function.
Page 99: Parameter Setting
5.2 SS1-t (Safe Stop 1 Time Controlled) Function 5.2.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Stop processing transition wait 0 to 9,999 6.1.2 (4) time...
Page 100: Ss2-T (Safe Stop 2 Time Controlled) Function
5.3 SS2-t (Safe Stop 2 Time Controlled) Function SS2-t (Safe Stop 2 Time Controlled) Function 5.3.1 Function Overview SS1-t (Safety Stop 1-hour Control) Function should have a motor start decelerating and should execute SOS Function after the time set in the safety parameter has passed. This function corresponds to Stop Category 2 in IEC/EN 60204-1.
Page 101 5.3 SS2-t (Safe Stop 2 Time Controlled) Function Deceleration operation SOS status SS1_IN_A OFF (Safety Function Execution Demand) SS1_IN_B (*1) (*2) SIDT SSWT + Max.8ms Motor rotation speed (*3) SSSL SS1_OUT_A OFF (shuts off) SS1_OUT_B Internal SOS request (SOS execution) * 1 SIDT : Safe input detection delay time [ms] (Safety Parameter No.42) * 2 SSWT...
Page 102: Parameter Setting
5.3 SS2-t (Safe Stop 2 Time Controlled) Function 5.3.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Stop processing transition wait 6.1.2 (4) 0 to 9,999 time...
Page 103: Sos (Safe Operating Stop) Function
5.4 SOS (Safe Operating Stop) Function SOS (Safe Operating Stop) Function 5.4.1 Function Overview SOS (Safety Operation Stop) Function monitors to ensure the position and velocity would not exceeds the indicated range while energy is supplied to a motor. STO Function should be activated when it goes out of the range.
Page 104 5.4 SOS (Safe Operating Stop) Function SOS status STO status Internal SOS request OFF (Safety Function Execution Demand) SM DT (*1) SSSL Feedback speed 0mm/s (*3) SSPL Feedback position Min. SOS_OUT_A OFF (Shuts off) SOS_OUT_B OFF (Safety Function Execution Demand) Internal STO request Energy supply to Supply...
Page 105 5.4 SOS (Safe Operating Stop) Function SOS status STO status OFF (Safety Function Execution Demand) Internal SOS request (*1) SSSL Feedback speed 0mm/s (*3) SSPL Feedback position (*2) SM DT Min. SOS_OUT_A OFF (Shuts off) SOS_OUT_B OFF (Safety Function Execution Demand) Internal STO request Energy supply Supply...
Page 106: Parameter Setting
5.4 SOS (Safe Operating Stop) Function 5.4.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Speed limit during safe stop mm/s 1.00 6.1.2 (5) 0.00 to 1,000.00...
Page 107: Sls (Safely-Limited Speed) Function And Ssm (Safe Speed Monitor) Function
5.5 SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function 5.5.1 Function Overview SLS (Safety Velocity Limit) Function is a feature to monitor velocity of a motor (feedback velocity) based on the safety input signal.
Page 108 5.5 SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function [Speed Limit While Executing SLS] The actuator velocity can be controlled at the velocity specified in the parameter for operation while SLS Function is being executed. (*) Set Controller Parameter No. 200 “Reduce speed during SLS” to “1”, and this command should get enabled.
Page 109 5.5 SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function Delay time Speed being Monitored In SS1-t Operation STO status SMx_IN_A OFF (Safety Function Execution Demand) SMx_IN_B (SLS request) (*1) SMWx (*3) (*3) SMDx SMDx Feedback speed (*2) SLSx 0mm/s SMx_OUT_A OFF (Shuts off)
Page 110: Parameter Setting
5.5 SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function 5.5.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Unit Default in No. Bit No. Parameter Name Input Range Reference Delivery (Display) Safety mode 1 SS1 / SS2 0 : Stop at SS1-t setting...
Page 111 5.5 SLS (Safely-Limited Speed) Function and SSM (Safe Speed Monitor) Function Unit Default in No. Bit No. Parameter Name Input Range Reference Delivery (Display) Safety mode 1 anomaly 0 to 9,999 detection time Safety mode 2 anomaly 6.1.2 (14) 0 to 9,999 detection time Safety mode 3 anomaly 0 to 9,999...
Page 112: Slt (Safely-Limited Torque) Function And Stm (Safe Torque Monitor) Function
5.6 SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function 5.6.1 Function Overview SLT (Safety Torque Limit) Function is a feature to monitor current of a motor (motor torque) based on the safety input signal.
Page 113 5.6 SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function Speed being Monitored Delay time In SS1-t Operation STO status SMx_IN_A OFF (Safety Function Execution Demand) SMx_IN_B (SLT request) (*1) SMWx 100% SMDx SMDx Feedback current SLTx SMx_OUT_A OFF (Shuts off) SMx_OUT_B (SLT status) Internal...
Page 114: Parameter Setting
5.6 SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function 5.6.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 SS1 / SS2 0 : Stop at SS1-t setting 1 : Stop at SS2-t...
Page 115 5.6 SLT (Safely-Limited Torque) Function and STM (Safe Torque Monitor) Function Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 anomaly 0 to 9,999 detection time Safety mode 2 anomaly 6.1.2 (14) 0 to 9,999 detection time Safety mode 3 anomaly 0 to 9,999...
Page 116: Slp (Safely-Limited Position) Function And Spm (Safe Position Monitor) Function
5.7 SLP (Safely-Limited Position) Function and SPM (Safe Position Monitor) Function SLP (Safely-Limited Position) Function and SPM (Safe Position Monitor) Function 5.7.1 Function Overview SLP (Safety Position Limit) Function is a feature to monitor position of a motor based on the safety input signal.
Page 117 5.7 SLP (Safely-Limited Position) Function and SPM (Safe Position Monitor) Function Delay time In Position Monitoring In SS1-t Operation STO status SMx_IN_A SMx_IN_B OFF (Safety Function Execution Demand) (SLP request) (*1) SMWx Max. (*4) SMDx (*4) SM Dx (*2) SLHx Feedback position ※...
Page 118: Parameter Setting
5.7 SLP (Safely-Limited Position) Function and SPM (Safe Position Monitor) Function 5.7.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 SS1 / SS2 0 : Stop at SS1-t setting 1 : Stop at SS2-t...
Page 119 5.7 SLP (Safely-Limited Position) Function and SPM (Safe Position Monitor) Function Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 anomaly 0 to 9,999 detection time Safety mode 2 anomaly 6.1.2 (14) 0 to 9,999 detection time Safety mode 3 anomaly 0 to 9,999...
Page 120: Sdi- (Safe Direction Minus) Function And Sdi+ (Safe Direction Plus) Function
5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function 5.8.1 Function Overview It is a feature to monitor the direction of motor movement based on the safety input signal. When it is SDI-, the stop feature (SS1-t or SS2-t) should be executed when movement to the negative side is detected.
Page 121: Description Of Operation
5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function 5.8.2 Description of Operation [SDI- (Safe Direction minus) Function] Set SDI- to the safety Mode x, SDI- Command should be assigned to SMx_IN_A/B Input while SDI- Status to SMx_OUT_A/B Output. Once SMx_IN_A/B Input gets turned off (SDI- Command = Enable), SDI- Function should be executed and SMx_OUT_A/B Output should turned off (SDI- Command = Disable), and the feedback position should get monitored after the time period in the setting has passed...
Page 122 5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function In Position Monitoring Delay time In SS1-t Operation STO status SMx_IN_A SMx_IN_B OFF (Safety Function Execution Demand) (SDI- request) SMWx Max. SDM x Feedback position SM Dx Min. SMx_OUT_A SMx_OUT_B OFF (Shuts off)
Page 123 5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function [SDI+ (Safe Direction plus) Function] Set SDI+ to the safety Mode x, SDI- Command should be assigned to SMx_IN_A/B Input while SDI+ Status to SMx_OUT_A/B Output. Once SMx_IN_A/B Input gets turned off (SDI+Command = Enable), SDI+ Function should be executed and SMx _OUT_A/B Output should turned off (SDI+Command = Enable), and the feedback position should get monitored after the time period in the setting has passed (*1)
Page 124 5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function Delay time In Position Monitoring STO status In SS1-t Operation SMx_IN_A OFF (Safety Function Execution Demand) SMx_IN_B (SDI+ request) • SMWx Max. (*2) SDPx SMDx Feedback position Min. SMx_OUT_A SMx_OUT_B OFF (Shuts off)
Page 125: Parameter Setting
5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function 5.8.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 SS1 / SS2 0 : Stop at SS1-t setting...
Page 126 5.8 SDI- (Safe Direction Minus) Function and SDI+ (Safe Direction Plus) Function Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 0 to 9,999 anomaly detection time Safety mode 2 6.1.2 (14) 0 to 9,999 anomaly detection time Safety mode 3 0 to 9,999...
Page 127: Sbc (Safe Brake Control) Function
5.9 SBC (Safe brake control) Function SBC (Safe brake control) Function 5.9.1 Function Overview SBC (Safety Brake Control) Function should output a signal for control of an actuator retaining brake. It can be utilized to prevent such as a drop of a vertical axis. Caution ●...
Page 128: Description Of Operation
5.9 SBC (Safe brake control) Function 5.9.2 Description of Operation SBC_OUT_A/B Output should get turned off (cutoff) linked with a stop feature (STO and SS1-t). Caution ● Set up the wiring and parameters before use. Refer to [3.5 Wiring for SBC Output] for details regarding wiring. 5-34 ME0459-1C...
Page 129 5.9 SBC (Safe brake control) Function STO status STO_IN_A (Safety Function Execution Demand) STO_IN_B SIDT (*1) + Max.8ms Motor rotation speed OFF (Shuts off) STO_OUT_A STO_OUT_B OFF (Shuts off) SBC_OUT_A SBC_OUT_B Electromagnetic Contact Electromagnetic Contact Operation Time Operation Time OFF (Shuts off) Brake power supply Brake Operation Time...
Page 130 5.9 SBC (Safe brake control) Function Deceleration operation STO status SS1_IN_A (Safety Function Execution Demand) SS1_IN_B (*2) SSWT (*1) SIDT + Max.8ms Motor rotation speed (*3) SSSL SS1_OUT_A OFF (Shuts off) SS1_OUT_B SBC_OUT_A OFF (Shuts off) SBC_OUT_B Electromagnetic Contact Electromagnetic Contact Operation Time Operation Time OFF (Shuts off) Brake power...
Page 131: Parameter Setting
5.9 SBC (Safe brake control) Function 5.9.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery 0 : SBC function disabled SBC enable / disable selection 6.1.2 (9) 1 : SBC function enabled ●...
Page 132: Safety Mode Input
5.10 Safety Mode Input 5.10 Safety Mode Input 5.10.1 Function Overview It is a feature to assign the safety functions to Safety Mode Input 1 to 3 (SMx_IN_A, SMx_IN_B). The safety features can be selected from SLS, SLT, SLP, SDI- and SDI+, and multiple selection is also available.
Page 133: Parameter Setting
5.10 Safety Mode Input 5.10.3 Parameter Setting The parameters related to this function are as stated below. ● Safety Parameter Default Unit No. Bit No. Parameter Name Input Range Reference (Display) Delivery Safety mode 1 0 : Disabled, 1 : Enabled SLS enable / disable selection Safety mode 1 0 : Disabled, 1 : Enabled...
Page 134: Safety Mode Output
5.11 Safety Mode Output 5.11 Safety Mode Output 5.11.1 Function Overview It is a feature to output the status of the safety functions assigned to Safety Mode 1 to 3 (SMx_OUT_A, SMx_OUT_B). The safety features can be selected from SLS, SLT, SLP, SDI- and SDI+, and multiple selection is also available.
Page 135: Safety Mode Stop Control
5.12 Safety Mode Stop Control 5.12 Safety Mode Stop Control 5.12.1 Function Overview It is a feature to execute the safety stop function (SS1-t or SS2-t) when the safety function is enabled and it exceeds the setting value. SS1-t and SS2-t are available to select in the parameter.
Page 136 5.12 Safety Mode Stop Control 5-42 ME0459-1C...
Page 137 Functional Safety Unit Chapter Parameters Safety Parameter ······················································· 6-1 6.1.1 Safety Parameter List ··························································· 6-2 6.1.2 Detail Explanation of Safety Parameters ··································· 6-6 Controller Parameters ················································· 6-18 6.2.1 Controller Parameter List ························································ 6-18 6.2.2 Detail of Controller Parameter ················································· 6-19...
Page 139: Safety Parameters
● Carefully keep the password so it would not get lost. It is necessary to have the password set for each safety unit. Consult with IAI if you forgot the password set to a safety unit. ME0459-1C...
Page 140: Safety Parameter List
6.1 Safety Parameter 6.1.1 Safety Parameter List Shown below is the list of the safety parameters. Safety parameter list (1/4) Default Unit Parameter Name Input Range Reference (Display) Delivery Safety function enable / disable 0 : Safety unit function enable 6.1.2 (1) selection 1 : Safety unit function disable...
Page 141 6.1 Safety Parameter Safety parameter list (2/4) Default Unit Parameter Name Input Range Reference (Display) Delivery Safety mode 2 0 : Stop at SS1-t SS1 / SS2 setting 1 : Stop at SS2-t Safety mode 2 0 : Disabled, 1 : Enabled SLS enable / disable selection Safety mode 2 0 : Disabled, 1 : Enabled...
Page 142 6.1 Safety Parameter Safety parameter list (3/4) Default Unit Parameter Name Input Range Reference (Display) Delivery Safety mode 1 0.00 -9999.99～9999.99 position limit range lower limit Safety mode 2 0.00 -9999.99～9999.99 position limit range lower limit Safety mode 3 0.00 -9999.99～9999.99 position limit range lower limit 6.1.2 (17)
Page 143 6.1 Safety Parameter Safety parameter list (4/4) Default Unit Parameter Name Input Range Reference (Display) Delivery Safety mode 1 output test pulse 0 : Enabled, 1 : Disabled enable / disable selection Safety mode 2 output test pulse 0 : Enabled, 1 : Disabled enable / disable selection 6.1.2 (26) Safety mode 3 output test pulse...
Page 144: Detail Explanation Of Safety Parameters
6.1 Safety Parameter 6.1.2 Detail Explanation of Safety Parameters (1) Safety function enable / disable selection (Parameter No.1) Default Unit Parameter Name Input Range (Display) Delivery Safety function enable / disable selection 0 to 1 The “safety functions” that the functional safety unit possesses can be switched enable / disable. Set Value Content Safety unit function enable...
Page 145 6.1 Safety Parameter (3) Unit operation selection (Parameter No.3 to 8) Default Unit Parameter Name Input Range (Display) Delivery Safety setting value 1 In accordance with actuator Safety setting value 2 In accordance with actuator Safety setting value 3 In accordance with actuator Safety setting value 4 In accordance with actuator Safety setting value 5...
Page 146 6.1 Safety Parameter (6) Limit change amount during safe stop (Parameter No.11) Default Unit Parameter Name Input Range (Display) Delivery Limit change amount during safe stop 10.00 0.00 to 100.00 It is used to judge if it gets out of the stop status during the safety stop monitoring. Continuing the condition that movement is made for the distance of or above the parameter from the stop position at the start of monitoring in SOS for the time set in Safety Parameter No.12 “Limit deviation duration during safe stop”...
Page 147 6.1 Safety Parameter (9) During safe stop Movement request time interval (Parameter No.14) Default Unit Parameter Name Input Range (Display) Delivery SBC enable / disable selection 0 to 1 Set enable/disable of SBC function. Set Value Content SBC function disabled SBC function enabled Set it to “1”, and SBC Function (SBC_OUT_A/B) should also get linked when STO/SS1-t.
Page 148 6.1 Safety Parameter (11) Safety mode 2 function selection setting (Parameter No.16) Default Unit Parameter Name Input Range (Display) Delivery Safety mode 2 SLS enable / disable selection 0 to 1 Safety mode 2 SLT enable / disable selection 0 to 1 Safety mode 2 SLP enable / disable selection 0 to 1 Safety mode 2 SDI- enable / disable selection...
Page 149 6.1 Safety Parameter (13) Safety mode 1 to 3 monitoring start time (Parameter No.18 to 20) Default Unit Parameter Name Input Range (Display) Delivery Safety mode 1 monitoring start time 0 to 9,999 Safety mode 2 monitoring start time 0 to 9,999 Safety mode 3 monitoring start time 0 to 9,999 The standby time before starting monitoring of Safety Mode 1 to 3 should be set.
Page 150 6.1 Safety Parameter (16) Safety mode 1 to 3 current limit (Parameter No.27 to 29) Default Unit Parameter Name Input Range (Display) Delivery Safety mode 1 current limit 100.00 30.00 to 7,000.00 Safety mode 2 current limit 100.00 30.00 to 7,000.00 Safety mode 3 current limit 100.00 30.00 to 7,000.00...
Page 151 The directions of + and - should be the same as the directions of positive and negative in the coordinates constructed in an actuator connected to an IAI controller. SDI- is allowed for a movement to the positive direction in the coordinates, but it should be limited for a movement to the negative direction by this parameter.
Page 152 The directions of + and - should be the same as the directions of positive and negative in the coordinates constructed in an actuator connected to an IAI controller. SDI+ is allowed for a movement to the positive direction in the coordinates, but it should be limited for a movement to the positive direction by this parameter.
Page 153 6.1 Safety Parameter (22) Input test pulse enable / disable selection (Parameter No.44) Default Unit Parameter Name Input Range (Display) Delivery STO input test pulse enable / disable 0 to 1 selection SS1 input test pulse enable / disable 0 to 1 selection SS2 input test pulse enable / disable 0 to 1...
Page 154 6.1 Safety Parameter (24) Input terminal test pulse time (Parameter No.46) Default Unit Parameter Name Input Range (Display) Delivery Input terminal test pulse time 0.5, 1.0, 1.5 The pulse band width of the test pulse on the input terminals should be set. The parameter setting can be made in 0.5 pitch (select from 0.5, 1.0 and 1.5).
Page 155 6.1 Safety Parameter (26) Output test pulse enable / disable selection (Parameter No.48) Default Unit Parameter Name Input Range (Display) Delivery Safety mode 1 output test pulse enable / 0 to 1 disable selection Safety mode 2 output test pulse enable / 0 to 1 disable selection Safety mode 3 output test pulse enable /...
Page 156: Controller Parameters
● Also, make sure to keep a record as you work so that it can be restored at any time. ● If you face problems which cannot be resolved, contact IAI. 6-18...
Page 157: Detail Of Controller Parameter
6.2 Controller Parameters 6.2.2 Detail of Controller Parameter Shown below is a list of parameters on a controller related to the functional safety units. (1) Safety unit enable / disable select (Parameter No.199) Default Unit Parameter Name Input Range (Display) Delivery Safety unit enable / disable select 0 : Not be used, 1 : Use...
Page 158 6.2 Controller Parameters (4) Micro-movement during safety stop (Parameter No.202) Default Unit Parameter Name Input Range (Display) Delivery Micro-movement during safety stop 0 : Disabled, 1 : Enabled It is a parameter related to SOS, SLS, SLP, SDI± Function. Setting whether to receive micro-movement command from the safety unit can be established. 0 : Disabled 1 : Enabled Refer to [4.3 Diagnosis Function [About Encoder Bonded Diagnosis]] for micro-movement...
Page 159: Maintenance And Inspection
Functional Safety Unit Chapter Maintenance and Inspection Periodic Inspection ····················································· 7-1 7.1.1 Periodic Inspection Items ······················································· 7-2 Requests When Replacing Units ···································· 7-4 Consumable Parts ······················································ 7-5 How to Replace Unit ··················································· 7-6 7.4.1 Replacement of Functional Safety Unit ····································· 7-6...
Page 161: Periodic Inspection
If static electricity is not discharged, functional safety unit and controller breakdowns or malfunctions may result. ● The password set in the safety unit returned to IAI for a repairing inspection should be initialized.
Page 162: Periodic Inspection Items
7.1 Periodic Inspection 7.1.1 Periodic Inspection Items This product contain electronic components that may degrade due to the operating environment and require periodic inspection. It is standard to conduct periodic inspection once every 6 months to one year, but the interval should be shortened in accordance with operating environment.
Page 163 7.1 Periodic Inspection Inspectio Judgment Inspection Details Countermeasures n items Criteria Connection Wiring connectors loose? Insert until the lock engages. status (Safety input / output, No looseness Tighten up certainly if there are connector) screws equipped. Check visually and replace the Wiring cable frayed? No visual abnormalities cable.
Page 164: Requests When Replacing Units
• Changing the combination of the safety unit and controller should generate an alarm. The setting of parameters needs to be established when combination is changed. * The password set in the safety unit returned to IAI for a repairing inspection should be initialized.
Page 165: Consumable Parts
7.3 Consumable Parts Consumable Parts There is no component related to product life in this product. ME0459-1C...
Page 166: How To Replace Unit
7.4 How to Replace Unit How to Replace Unit 7.4.1 Replacement of Functional Safety Unit (1) Removal of safety unit * It is necessary to have a slotted screwdriver for disassembly. Prepare it in advance. Put a slotted screwdriver into the snap feature on the shorter direction with no divider to release the snap feature.
Page 167 7.4 How to Replace Unit (2) Attachment of safety unit Align the positions of the snap feature on the front of Safety Unit, positioning pins and attachment holes on the SCON2 side. Insert Safety Unit in parallel to SCON2. Confirm that all of the snap features at two points on the shorter side, two points on the front side and extrusion on the snap feature are absolutely inside the SCON2 cover.
Page 168 7.4 How to Replace Unit ME0459-1C...
Page 169: Troubleshooting
Functional Safety Unit Chapter Troubleshooting Action to Be Taken upon Occurrence of Problem ··············· 8-1 List of Alarms and Warnings·········································· 8-2 8.2.1 Alarm Level ·········································································· 8-2 8.2.2 Alarm List ············································································· 8-3...
Page 171: Action To Be Taken Upon Occurrence Of Problem
8.1 Action to Be Taken upon Occurrence of Problem Action to Be Taken upon Occurrence of Problem If a problem occurs, check the following points first in order to ensure quick recovery and prevent recurrence of the problem. (1) Status Display LED on Controller and Functional Safety Unit and PIO check. (2) Check whether an alarm occurs on the host controller (PLC, etc.).
Page 172: List Of Alarms And Warnings
● If the same error occurs again after resetting the alarm, it means that the cause of the alarm has not been removed. ● If a controller or actuator is found malfunctioned, consider to repair or replace it. You will be able to apply for a repair in the IAI homepage. https://www.iai-robot.co.jp/support/repair/index.html Point ! ●...
Page 173: Alarm List
8.2 List of Alarms and Warnings 8.2.2 Alarm List All the alarms related to the functional safety unit should be the “cold start level”. It is necessary to have the power to a controller reboot or software reset after the cause is removed when having a recovery.
Page 174 8.2 List of Alarms and Warnings Alarm Alarm Name Cause Treatment Code Microcomputer A on the safety unit (1) The safety input signals in Safety Unit has detected an error. duplication do not match. (On Microcomputer A one side, off on one side） Error Check on wiring and signals.
Page 175: Chapter 9 Functional Safety Unit Setting Tool
Functional Safety Unit Chapter Functional Safety Unit Setting Tool Overview ·································································· 9-1 9.1.1 Introduction ·········································································· 9-1 Specifications of this tool and preparation ························ 9-2 9.2.1 Executed Environment ···························································· 9-2 9.2.2 Installation ············································································ 9-2 9.2.3 Preparation of Safety Unit ······················································· 9-3 How to Operate Tool ···················································...
Page 176 9.4.2 Safety Unit Cannot be Searched ··············································· 9-27 9.4.3 Safety Unit cannot be found in Searching ··································· 9-28 9.4.4 Cannot Go Further from Safety Unit Information Confirmation Screen ··· 9-29 9.4.5 Warning Comes up at Start of Parameter Edit ····························· 9-29 9.4.6 Inappropriate Parameter ·························································...
Page 177: Introduction
9.1 Overview Overview 9.1.1 Introduction In this section explains how to operation the functional safety unit configuration tool (hereinafter called as this tool). This tool is a dedicated tool to set up the necessary parameters when using the functional safety unit.
Page 178: Specifications Of This Tool And Preparation
9.2 Specifications of this tool and preparation Specifications of this tool and preparation 9.2.1 Executed Environment In order to use this tool, it is necessary to prepare a PC that satisfies the following conditions. Item Content Applicable OS Windows11, Windows10, Windows8.1, Windows8, Windows7 Computer body Personal computer available for applicable OS (Windows) to operate Complied with memory capacity necessary for applicable...
Page 179: Preparation Of Safety Unit
9.2 Specifications of this tool and preparation 9.2.3 Preparation of Safety Unit Connect the controller and the safety unit and conduct all the wirings to have the actuator available for operation. After that, set the parameter to accept the use of the safety unit in Edit Parameter in IA-OS.
Page 180: How To Operate Tool
When it is required to change a parameter in the functional safety unit, start up this tool first. The main way to start it up is as follows. ● Select the functional safety unit configuration tool from IAI Tool Box Figure 9.3-1 IAI Tool Box ●...
Page 181 Figure 9.3-4 Display Setting Window (at Initial Startup) When it is started up from the IAI tool box or IA-OS, this window should not be displayed as it should be started up with the same language as the origin of startup.
Page 182: Searching Safety Unit Subject To Edit
9.3 How to Operate Tool 9.3.2 Searching Safety Unit Subject to Edit First, search the safety unit available to edit. Select “Search Safety Unit” menu in “Communication” menu, and the communication setting window should be displayed. (It should automatically proceed to this status after the tool is started up) Figure 9.3-6 Communication Settings...
Page 183: Start Editing Parameters
If it is in the condition that OK cannot be clicked, there is a concern that the tool version is old and the safety unit in use is not applicable. Check the latest version in our homepage. (HP Address：https://www.iai-robot.co.jp/download/pcsoft/index.html) Click OK in the safety unit information confirmation window and the parameters should be acquired from the safety unit and the edit box should be displayed in the main window.
Page 184 9.3 How to Operate Tool The parameter values of a controller is set in the input box of the parameter values of the safety unit. * As the safety unit is not transferred in this moment, perform the transfer after other parameters are changed.
Page 185 9.3 How to Operate Tool The password is to be set to the safety unit. The safety unit once the password is set will not show this window from the next time. When it is required to change the password, select “Change Password”...
Page 186: Edit Parameter
9.3 How to Operate Tool 9.3.4 Edit Parameter There are three ways to change the parameter values to set in the safety unit. ● Direct Input ● Parameter File Read-in ● Controller Parameter Collation In these, refer to [9.3.3 When Starting Editing Parameters] for the controller parameter collation. (1) Direct Input in Parameters A parameter can have its value changed to any in the effective range of the parameter.
Page 187 9.3 How to Operate Tool Figure 9.3-13 Current Limit[mA] Setting Window 4 ) Effective Range and Inappropriate Parameter There are values available for setting (effective range) defined for each parameter. ● For Numeric Input Type While a setting cell for a parameter is selected, the input range should be displayed on the left bottom of the window.
Page 188 9.3 How to Operate Tool ● Expression of Inappropriate Parameter All the parameters will be checked when parameter edit is to start, data is read in from a parameter file, transfer the data or save the data. At this moment, if there is a parameter not set in its effective range, an error massage should be displayed.
Page 189 9.3 How to Operate Tool (2) Reading in Parameter File The data in a parameter file saved in the past can be read in as the transferred values. Select “Read in Parameter File” in the safety unit menu. The file selection dialog should be displayed. Figure 9.3-14 File selection dialog (Reading in parameter file) Select a parameter file to read in.
Page 190 9.3 How to Operate Tool (3) Transferring parameter The parameters in the safety unit would not be updated unless the parameters are transferred. Click Transfer . The password release screen should appear. Figure 9.3-16 Password release screen Input the password set in the safety unit and click OK . If you fail to input the correct password here, an error message should show up and you will not be allowed to proceed further.
Page 191 9.3 How to Operate Tool Parameters should be transferred. A window describing parameters in transfer and the transfer complete message should appear after the transfer is finished. Figure 9.3-18 Transferring Parameter Figure 9.3-19 Transfer complete message Click OK and the confirmation process of the transfer result should be conducted next. In order to reflect the result of transfer an to acquire, the software reset should be conducted and the parameters should be read in first.
Page 192 9.3 How to Operate Tool The parameter values transferred from the tool to the safety unit should be displayed in the setting value column while the values written in the safety unit as a result of the parameter transfer in the current value column.
Page 193 9.3 How to Operate Tool Click Save and if the parameter file is created in normal condition, a message showing the saving complete should appear. Figure 9.3-23 Saving complete message 9-17 ME0459-1C...
Page 194: Other Features
9.3 How to Operate Tool 9.3.5 Other Features (1) Confirming parameter File It is a feature to confirm the details of parameter files saved in this tool. As well as information regarding parameters when saved, information regarding a safety unit and controller used can also be confirmed.
Page 195 9.3 How to Operate Tool Figure 9.3-26 Parameter File Data Display Window (Parameter) As it is shown in [Figure 9.3-35 and Figure 9.3-26], the information regarding the safety unit and controller, and also the edit values of the parameters at that time can be confirmed. And also, with the print button on the top of this window, the data in the parameter file (data displayed in the window) can be printed out.
Page 196 9.3 How to Operate Tool Figure 9.3-27 Communication cutoff confirmation message Figure 9.3-28 Edit complete confirmation message Cutoff of communication should also be conducted when finishing the tool. If there is no opportunity to use this tool later, there is also a way described in [9.3.5 (2) Close (or Cross Button)] to execute the feature.
Page 197 9.3 How to Operate Tool Figure 9.3-30 Software reset standby screen Figure 9.3-31 Software reset complete message (5) Change Password It is a feature to change the password that a safety unit possesses. It is available to execute only to a safety unit that parameter edit is in process. Select “Change Password” in “Safety Unit” menu. Figure 9.3-32 Change password screen (Left: Password not set, Right: Password already set) 9-21 ME0459-1C...
Page 198 “here” portion in “Click here if you forgot the password” in the change password window (right figure in [Figure 9.3-32]). As a contact information comes up, consult with IAI. (Refer to [4.10 in this manual] for how to treat it.) Figure 9.3-33 Contact information screen...
Page 199 9.3 How to Operate Tool (6) Information Display It is a feature to display model information of a safety unit that parameter edit is in process. Click on the Display Information button in the parameter edit part. It is the same as the safety unit information confirmation window that is displayed when the parameter edit is started.
Page 200 9.3 How to Operate Tool Figure 9.3-36 Printing preview screen The content to be printed out should be the name of the tool, version (title in main window), date of printout, person in charge (details input in the previous window), file pass (if executed from parameter file data display window), safety unit model information (display details in information display feature) and parameters (details in table on parameter edit part).
Page 201 9.3 How to Operate Tool Figure 9.3-37 Printer setting screen Set a printer to use, orientation of paper, size, number of prints and so on if necessary and click on the OK button. The data should get output from the indicated printer. 9-25 ME0459-1C...
Page 202: Troubleshooting Of This Tool
OS Inappropriate (1) OS not supported is used (*1) Change the PC. (2) The version of the used Check the latest version in IAI configuration tool is old homepage. Multiple Startup (1) There is already another tool (1) This tool is capable of starting started up.
Page 203: Safety Unit Cannot Be Searched
The following causes can be (2) Install the USB driver for IAI considered. controller. The cable is not inserted to (3) Supply power to the controller. the PC. Or, it is not inserted to the controller.
Page 204: Safety Unit Cannot Be Found In Searching
9.4 Troubleshooting of This Tool 9.4.3 Safety Unit cannot be found in Searching When a message stating no safety unit was found after searching is shown, or some safety units were shown but the one subject to is not shown, the following caused may be considered. Error Name Possible Cause Check/Treatment...
Page 205: Cannot Go Further From Safety Unit Information Confirmation Screen
Download displayed, the screen cannot go a new version of a tool in the IAI further to the next windows. homepage. 9.4.5 Warning Comes up at Start of Parameter Edit Here, explains warnings and error messages displayed at the start of parameter edit.
Page 206: Inappropriate Parameter
9.4 Troubleshooting of This Tool 9.4.6 Inappropriate Parameter The patterns that a value in a parameter is inappropriate are as follows. Error Name Possible Cause Check/Treatment A value not available for setting in Set the value in the appropriate Setting value is out of effective the subject parameter is set in.
Page 207: Parameter Transfer Fails
9.4 Troubleshooting of This Tool 9.4.8 Parameter Transfer Fails Error Name Possible Cause Check/Treatment Writing of parameter does not The safety unit has continued the Either conduct the software reset complete writing process of a parameter for or reboot the power before a certain period of time transferring parameters again and the phenomenon may get...
Page 208: Forgot Password
9.4 Troubleshooting of This Tool 9.4.10 Forgot Password Consult with IAI if you forgot the password set for the safety unit. 9-32 ME0459-1C...
Page 209: Warranty
Functional Safety Unit Chapter Warranty 10.1 Warranty Period ························································· 10-1 10.2 Scope of the Warranty ················································· 10-1 10.3 Honoring the Warranty ················································· 10-1 10.4 Limited Liability ·························································· 10-2 10.5 Conformance with Applicable Standards/Regulations, etc., and Application Conditions ··········································· 10-2 10.6 Other Items Excluded from Warranty ······························ 10-2...
Page 211: Warranty Period
Our products are covered by warranty when all of the following conditions are met. Faulty products covered by warranty will be replaced or repaired free of charge: (1) The breakdown or malfunction in question pertains to our product as delivered by IAI or our authorized dealer.
Page 212: Limited Liability
● Equipment used to handle cultural assets, art or other irreplaceable items (3) Contact IAI in advance if our product is to be used in any condition or environment that differs from that specified in the catalog or instruction manual.
Page 213: Revision History
Revision history Revision history Revision date Revised content 2023.10 First Edition 2024.04 1B Edition Function Safety Unit Complied with UL ・Prelims: Overseas Standard Compliance UL section description changed and note added ・2.1.3 Rating label printed contents changed ・2.3.1 Items added for UL standard ・3.4.1 Correction made in connector pin assignment (No.

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