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Safety Controller User`s Manual

1. Monitor the feedback contacts using an EDM function block It is not sufficient to connect the control outputs B1 or B1 B2 Additionally the feedback contacts Y 1 Y2 and Y3 Y4 on the WSO A4RO safety relay module must be monitored using an EDM function block in the Setting and Monitoring Tool logic editor The safety relay output module is not participating at the FLEXBUS backplane bus communication Control signals can therefore not be received from the CPU module A max of four WSO 4RO safety relay output modules can be connected to a MELSEC WS safety controller i e a maximum of 16 safe relay outputs are available WS0 4RO The WSO 4RO has two control inputs B1 B2 These control two times two internal relays that provide two independently redundant switch off paths Control input B1 controls two internal relays and provides a redundant switch off path consisting of two safe enabling circuits 13 14 23 24 dual channel and potential free asignaling circuit Y14 dual channel and connected to internal 24 V DC afeedback EDM Y1 Y2 dual channel and potential free Control input B2 controls two internal relays and forms a redundant switch off path consisting of 42 Chapter 3 Product description two safe enabling circuits 33 34 43 44 dual channel and potential free
2. OV Open Use the following terminal combinations for dual channel input wiring WSO XTIO I1 and X1 I2 and X2 I3 and X1 I4 and X2 I5 and X1 I6 and X2 I7 and X1 I8 and X2 WSO XTDI I1 and X1 I2 and X2 I3 and X3 I4 and X4 to I7 and X7 I8 and X8 118 Chapter 14 Figure 40 Wiring example of light curtain and laser scanner 119 Annex 3 Wiring of light curtains and laser scanners Connect a light curtain and a laser scanner to the MELSEC WS safety controller as shown below Sender 24 V DC Light curtain TL EBENEN ov FG gt Synchronization H Synchronization Receiver 7 WSO0 CPUO WSO0 XTIO WSO0 XTDI I5 le I7 18 Connect the OSSD1 and OSSD2 control outputs of the light curtain to the 11 to 18 input terminals Connect the OSSD1 and OSSD2 control outputs of the laser scanner to the 11 to 18 input terminals Laser scanner 24V DC OV OSSD1 OSSD2 The light curtain is connected to the WSO XTIO and the laser scanner is connected to the WSO XTDI in the above example Both elements can be connected to either module Annex Chapter 14 4 Wiring of contactors Connect a contactor to the MELSEC WS safety controller as shown below Ts Figure 41 Wiring example of contactor WSO CPUO WSO0 XT
3. esesssssss 55 4 3 1 Testable Type 2 single beam photoelectric safety switches 55 4 3 2 Testable Type 4 single beam photoelectric safety switches 56 4 3 3 Customized testable single beam photoelectric safety switches 57 4 3 4 Information for mounting testable single beam photoelectric safety switclies cesse etie deed ger de dla deetl ead eee a aA 57 4 4 Electro sensitive protective equipment ESPE ssssssssssssss 59 4 5 Safety outputs Q1 to Q4 ssssssssssssssseeeneee eene 59 4 6 EFI devices ii miei i e dic roter d aiv uc de es edd deuda eL ne d 59 4 6 1 Connection of EFI devices sssssssssseseeeeeeeemeerennen 59 4 T Flexi LinKz eet t UIN Rees 60 4 7 1 Flexi Link overview ssssssssssssese eene eren 60 4 7 2 System requirements and restrictions for Flexi Link 61 4 7 3 Connection of a Flexi Link system ssseeeeeeen 61 AO FISK LING zs erento hut nie E LR M ee ers td 64 4 8 1 Flexi Line overview ssssssssseseseeneeeeemeeene nnnm nnne 64 4 8 2 Connection of a Flexi Line system ssssseee eem 64 4 9 EMC measures for Flexi Link and Flexi Line ccceccseeeeeceeeeeeeeeeeeenees 66 10 5 Special furictiorns m acie ei Mead dete te oe a M Le RR edd 67 5 1 Enhanced Function Interface EFI 67 5 11 Deflni
4. sssseseeeenenenenenenenenn 115 14 3 Wiring examples eeesesse esee nenne enne dd nte nte nna 116 TAA Troubleshooting iii iei ec o oec tec EH pcd doit nd 125 14 4 1 Basics of troubleshooting sssseeeen enn 125 14 4 2 Troubleshooting flowchart for CPU module esses 126 14 4 3 Troubleshooting flowchart for safety I O module 132 14 4 4 Troubleshooting flowchart for safety relay output module 139 14 5 Example for the calculation of the response time of Flexi Line 142 14 6 SICK contact ies net a er ed n edi ded needa d uad eed 144 12 GENERIC TERMS AND ABBREVIATIONS 13 bae Description term abbreviation WSO0 MPLO The abbreviation for the WSO MPL000201 MELSEC WS safety controller memory plug WSO MPL1 The abbreviation for the WSO MPL100201 MELSEC WS safety controller memory plug WSO0 CPUO The abbreviation for the WSO0 CPUO000200 MELSEC WS safety controller CPU module WSO0 CPU1 The abbreviation for the WSO0 CPU130202 MELSEC WS safety controller CPU module WSO0 CPU3 The abbreviation for the WS0 CPUS320202 MELSEC WS safety controller CPU module WSO0 XTIO The abbreviation for the WS0 XTIO84202 MELSEC WS safety controller safety I O combined module WSO XTDI The abbreviation for the WSO XTDI80202 MELSEC WS safety controller safety input module WS0 4RO The a
5. Function Notes Possible for T4000 Compact Not necessary for T4000 Direct since self monitored T4000 Compact is not cascadable Testing Series connection cascading Take the max line resistance of 100 Q into account at the T4000 see Chapter 12 For further information refer to the manuals of the Transponder SICK T4000 Compact or T4000 Direct or in the manuals of devices used 4 3 Testable single beam photoelectric safety switches 4 3 1 Testable Type 2 single beam photoelectric safety switches Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO SICK Wx12 18 24 27 Vx18 Test input TE transmitter at X1 Output Q receiver at I1 SICK L21 L27 L28 Test input TE transmitter at X2 Output Q receiver at I2 x2 u 2 wc ne e Use protected or separate cabling for the test output of the module X1 X8 to the test input of the transmitter and for the output of the receiver to the safe input of the module 11 18 Otherwise a cross circuit between these signals can inhibit the error detection by this test Connecting devices Chapter 4 Table 42 Function Notes Functions of testable Type 2 Single beam photoelectric Testing Possible fet itch TP Series connection SICK Wx12 18 24 27 Vx18 cascading max 2 pairs per input can be cascaded with test gap 4 ms standard element max 5 pairs per input can be cascaded with
6. If the error is not eliminated after multiple repetition replace the module which displays amp Red 2 Hz If this is not the case use the diagnostic functions of the Setting and Monitoring Tool to narrow down the respective module 35 Table 13 Displays of the MS LED Table 14 Displays of the input output LEDs on WSO XTIO Product description Chapter 3 Input LEDs I1 18 Output LEDs Q1 Q4 O Meaning Input output is inactive Green Input output is active Green 1 Hz synchronous with the red MS LED Input output is inactive and there is a correctable error Green 1 Hz alternating with the red MS LED Input output is active and there is a correctable error Note The input and output LEDs display the states with a refresh rate of approx 64 ms Figure 8 Internal circuits WSO XTIO safe inputs and test outputs Figure 9 Internal circuits WSO XTIO outputs Q1 to Q4 3 8 3 Internal circuits FLEXBUS 5 24V ov k x1 ut c f x20 E Q 4 F z 5 16 1 ry e 7 Qo rig 1000000 Hy l md OO A1 24 V e 2 2 pes Q lt OV 36 Chapter 3 37 ATTENTION Product description 3 8 4 Disabling the test pulses of WSO XTIO outputs Q1 to Q4 It is possible to
7. Press the module downwards at the rear 1 and remove it from the DIN mounting rail in the direction of the arrow while keeping it pressed down 2 72 Chapter 7 73 Electrical installation Electrical installation Note ATTENTION Note 7 1 Electrical installation requirements This chapter deals with the electrical installation of the MELSEC WS safety controller in the control cabinet You will find additional information on the electrical connection of other devices to the MELSEC WS safety controller in the section on the respective device in Chapter 4 Switch off the entire machine system The system could start up unexpectedly while you are connecting the devices Observe the relevant safety standards All safety related parts of the installation cabling connected sensors and actuators configuration settings EDM must be according to the relevant safety standards e g IEC 62061 or ISO EN 13849 1 This may mean that safety related signals need to be redundant or that single channel signals need protected wiring or short circuit detection by using test outputs and or periodical function tests Take into account that short circuits between test outputs and the corresponding input cannot be detected Consider if protected or separate cabling is required for these signals The MELSEC WS safety controller fulfills the EMC requirements in accordance with the basic specification IEC 61000 6 2 for industri
8. and control cabinet star wiring of power supply 24 V and 0 V local separation of power parts and control parts Check the other diagnosis messages with almost the same time stamp 86 Chapter 10 87 Diagnostics Table 52 Error codes and error messages of the MELSEC WS safety controller and possible rectification measures 1 After one of the dual channel inputs is set to ON and another is OFF when the discrepancy time passes Discrepancy error at dual channel input li should occur This discrepancy can be cleared when both inputs turn OFF the left side figure below However both inputs turn ON during the discrepancy it is not cleared and this error should occur the right side figure below Error is cleard by _ Error is not cleard by li both inputs OFF li l l both inputs ON li 1 li 1 Discrepancy time H Discrepancy time Error Error Behavior of a discrepancy error 2 Unequal input data from safety I O module may occur by following signal inputs 1 A dual channel input has 2 single dips high to low with a time distance of 2ms ams Behavior of unequal input data 2 A signal channel input changes state in intervals of 4ms for a duration of 40ms or more Behavior of unequal input data Note Diagnostics Chapter 10 10 3 Additional error displays of SICK EFI compatible devices SICK EFI compatib
9. db SEM oF xTOp 4 E leve menter eren ce e rx ere men Gare SUITS Caeser eon 3b REAM XTIOO1 05 lt E27 xO 124 Chapter 14 Annex 14 4 Troubleshooting This section describes errors that may occur during system operation how to locate the errors and measures against the errors Note Check the LEDs of the module during troubleshooting 14 4 1 Basics of troubleshooting In order to increase the reliability of the system resuming the system operation promptly after correcting a problem is one of the important factors as well as using reliable devices To promptly start up the system the trouble cause must be located and eliminated correctly The basic three points to be followed in the troubleshooting are as follows 1 Visual inspection Visually check the following 1 Behavior of the safety controller and other connected devices 2 Applicability of the power supply 3 States of input and output devices 4 Installation states of the CPU module and safety I O modules 5 Wiring Power cable and I O lines 6 Display status of all indicators such as MS LED and CV LED After checking 1 through 6 connect the Setting and Monitoring Tool and monitor the operating status and logic processing of the MELSEC WS safety controller 2 Error checking Check how the error status changes by operating the following to the safety controller 1 Turn on or off the power supplied to the memory plug
10. max 25 pairs per input can be cascaded with test gap 8 ms customized element required Take the max line resistance of 100 O into account Note For further information refer to the manual of the testable Type 4 single beam photoelectric safety switches 56 Chapter 4 Note Note Figure 16 Minimum distance a to reflective surfaces correct mounting and alignment 57 Connecting devices 4 3 3 Customized testable single beam photoelectric safety switches For information on how to create customized elements please see the Safety Controller Setting and Monitoring Tool Operating Manual e Inthe Settings dialog for the customized element select the minimum value for the desired test gap Regardless of the test gap the overall off on delay of the cascade must be smaller than the Max off on delay of the respective test output as shown in the Setting and Monitoring Tool report 22 ms Otherwise the test gap will lead to switching off For WS0 XTIO or WSO XTDI module this value is 12 ms 2 ms 10 ms Use protected or separate cabling for the test output of the module X1 X8 to the test input of the transmitter and for the output of the receiver to the safe input of the module 11 18 Otherwise a cross circuit between these signals can inhibit the error detection by this test 4 3 4 Information for mounting testable single beam photoelectric safety switches Observe the information for mo
11. 3 Narrowing down the scope for identifying trouble cause Estimate the troubled part based on the check results of the items 1 and 2 above 1 MELSEC WS safety controller or external devices 2 CPU module or others 3 Configuration 125 Annex Chapter 14 14 4 2 Troubleshooting flowchart for CPU module This section describes how to identify errors and measures to eliminate the errors 1 Troubleshooting flowchart The following shows the error description according to the types of events Figure 47 Troubleshooting flowchart anaes for CPU module rror description MS LED has turned off When the MS LED has turned off NO MS LED has turned on red When the MS LED has turned on red NO MS LED is flashing red or When the MS LED is flashing red or flashing red and green flashing red and green NO Unable to communicate with Setting When the CPU module cannot communicate and Monitoring Tool with the Setting and Monitoring Tool 126 Chapter 14 Annex 2 When the MS LED has turned off Refer to the following flowchart when the MS LED of the CPU module has turned off at power on or during operation of the MELSEC WS safety controller Figure 48 Flowchart when the MS LED has turned off MS LED of the CPU module has turned off Is power supplied Supply power On or flashing How is the MS LED of the CPU module s the power supply voltage Supply power within wi
12. Minimum required firmware or software version WS0 XTIO Setting and Feature COREN WS0 XTDI Monitoring Tool Logic offline simulation Eo V1 2 0 Logic import export V1 3 0 Automatic wiring diagrams V1 3 0 Online edit V1 3 0 Central tag name editor V1 3 0 Flexi Link only with WSO V2 01 E V1 3 0 CPU1 3 Revision 2 xx Flexi Line only with WSO V3 02 m V1 7 0 CPUS Revision 3 xx Function block documentation within the V1 3 0 Setting and Monitoring Tool Input output relation matrix V1 3 0 Invertable inputs for the AND V2 01 OR RS Flip Flop and Revision 2 xx V1 3 0 Routing N N function blocks Ramp down detection V1 11 V1 3 0 function block Revision 1 xx Adjustable on delay timer v2 01 and Adjustable off delay um V1 3 0 Revision 2 xx timer function blocks o E IA eS V2 01 V2 00 ed ERA DAN Revision 2x Revision 2o ui It is possible to deactivate the v2 00 test signals on Q1 Q4 on the A V1 3 0 XTIO Revision 2 xx Verification without identical V2 01 B V1 0 0 hardware possible Revision 2 xx i Status input data and Status V2 01 V2 00 V1 3 0 output data in logic Revision 2 xx Revision 2 xx Data recorder Me V170 Revision 2 xx Extended cross circuit v3 10 detection time for switching be V1 7 0 loads with high capacitance Revision 3x Adjustable filter time for On Off filters and Of
13. of the test output Use the greater value of both test outputs b Testable type 4 sensors e g L41 Test period of the test output C All other sensors Test gap of the test output if test gap is gt 1 ms a From logic via FLEXBUS 4 5 ms b From Fast Shut Off 1 5 ms Total In1 Total Out1 Occurrence If EFI functions are used via SICK EFI compatible devices In2 Input from EFI device Response time of the EFI data source as a rule a sensor for external OSSDs via EFI or Flexi Link remote station Out2 Output to EFI device Response time of the message receiver e g scanner with protective field switching via EFI Constant EFI cycle time of the EFI receiver a Scanner e g S3000 3 5 ms 24 ms b Light grid e g 1 5 ms 4ms C4000 M4000 c Flexi Link 0 5 ms 4ms Total In2 Total Out2 Occurrence In3 Network module data from the Out3 Network module data to the network network General Response time field bus for data input to Response time field bus for data from network module e g from network module e g to programmable programmable controller controller General 2 x internal update interval for data from 2 x internal update interval for data from the the network module to the CPU module CPU module to the network module If 1 network module 5ms 8ms If 2 network modules 4ms 4ms
14. Limited short circuit recognition An WSO XTDI has two test signal generators One test signal generator is responsible for the odd numbered test outputs X1 X3 X5 and X7 the other for the even numbered test outputs X2 X4 X6 and X8 Short circuits between test signal generators on MELSEC WS I O modules are detected also between test signal generators on different modules provided the test gaps are lt 4 ms and the test periods are 2 200 ms for the relevant test outputs Short circuits to 24 V DC stuck at high at inputs connected to test outputs are detected independently of the test gap time Please be aware that at the WSO XTDI the odd numbered test outputs X1 X3 X5 and X7 are connected to one common test signal generator and that the even numbered test outputs X2 X4 X6 and X8 are connected to another common test signal generator Therefore short circuits between test outputs X1 X3 X5 and X7 cannot be detected The same applies respectively for test outputs X2 X4 X6 and x8 Take this into consideration during the wiring e g separate routing sheathed cables Reverse current at WS0 XTIO WSO XTDI inputs in case of ground interruption In case of an internal or external ground interruption there can be a reverse current from the power supply of the CPU module memory plug terminal A2 to the safe inputs 11 18 of WSO XTIO WSO XTDI modules This must be considered if other inputs are connected in parallel to these input
15. PFHd for Flexi Line station CPU1 CPU3 0 40 x 10 20 years EN ISO 13849 1 General data Humidity Protection class IIl IEC 61140 Enclosure rating IP 20 IEC 60529 Ambient temperature in operation 25 55 C Storage temperature 25 70 C 10 95 non condensing Climatic conditions Operating altitude 55 C 95 relative humidity IEC 61131 2 No corrosive gases Max 2000 m above sea level 80 kPa Vibration resistance 5 150 Hz 1 g EN 60 068 2 6 10 500 Hz 5 g IEC 60068 2 6 Shock resistance Continuous shock 10 g 16 ms IEC 60068 2 29 Single shock 30 g 11 ms IEC 60068 2 27 Electromagnetic compatibility Class A IEC 61000 6 2 EN 55011 Number of EFI interfaces 0 2 Number of Flexi Line interfaces 0 CPU1 0 CPU3 2 Data interface Backplane bus FLEXBUS Configuration interface RS 232 CPU1 RS 232 CPU3 RS 232 USB2 0 miniB 98 Chapter 12 99 Technical data WSO0 CPUO WS0 CPU1 3 Cross section of connecting wires Single core or finely stranded 1 x 0 14 2 5 mm2 AWG 26 13 or 2 x 0 14 0 75 mm2 AWG 26 18 Finely stranded with ferrules 1 x 0 25 2 5 mm2 AWG 23 13 or 2 x 0 25 0 5 mm2 AWG 23 20 EFI connection method Flexi Line connection method Cross section of EFI connecting wires Dual level spring clamp terminals Single core or finely stranded 1 x 0 2
16. WS0 CPUO WSO WSO0 XTIO or codes CPU1 or WSO CPU3 WS0 XTDI MS Red 1 Hz One or more safety I O CPU module If WSO CPU1 EFI device address Change the EFI device address EFI 2 Red 1 Hz modules 0x0014000A conflict with Setting and Monitoring Tool MS Red 1 Hz There are at least 2 CPU modules either of the CPU module or of the firmware V2 00 0 with the same EFI address connected device or connected MS Red green CPU module If WSO CPU1 and Flexi Link Wrong Check wiring between the Flexi Link 1 Hz firmware 0x0015000A Flexi Link ID stations EFI1 connected with EFI1 V1 xx 0 EFI1 and EFI2 is swapped in the and if applies EFI2 with EFI2 wiring Connect Flexi Link stations with There is at least 1 CPU module matching Flexi Link IDs with a different Flexi Link ID Download configuration to all Flexi connected Link stations with same Flexi Link IDs CPU module Configuration in memory plug is Download a configuration with the 0x001F0006 incompatible for at least one safety I O same module type and the same or 0x00230006 module a smaller firmware version for all 0x00234006 Wrong type or version of module safety I O modules 0x001F4006 whose MS LED is flashing red or e Replace the affected safety I O red green module in the hardware installation Too many safety I O modules are by a module with the same module connected whose MS LED is type and the same or smaller flashing red or r
17. 61 3 9497 4100 1800 33 48 02 tollfree E Mail sales sick com au Belgium Luxembourg Phone 32 0 2 466 55 66 E Mail info sick be Brasil Phone 55 11 3215 4900 E Mail sac sick com br Cesk Republika Phone 420 2 57 91 18 50 E Mail sick sick cz China Phone 852 2763 6966 E Mail ghk sick com hk Danmark Phone 45 45 82 64 00 E Mail sick sick dk Deutschland Phone 49 211 5301 260 E Mail info sick de Espana Phone 34 93 480 31 00 E Mail info sick es France Phone 33 1 64 62 35 00 E Mail info sick fr GreatBritain Phone 44 0 1727 831121 E Mail info sick co uk India Phone 91 22 4033 8333 E Mail info sick india com Israel Phone 972 4 9990590 E Mail info sick sensors com Italia Phone 39 02 27 43 41 E Mail info sick it Japan Phone 81 0 3 3358 1341 E Mail support sick jp Nederlands Phone 31 0 30 229 25 44 E Mail info sick nl Norge Phone 47 67 81 50 00 E Mail austefjord sick no Osterreich Phone 43 0 22 36 62 28 8 0 E Mail office sick at Polska Phone 48 22 837 40 50 E Mail info sick pl Republic of Korea Phone 82 2 786 6321 4 E Mail kang sickkorea net Republika Slovenija Phone 386 0 1 47 69 990 E Mail office sick si Romania Phone 40356171120 E Mail office sick ro Russia Phone 7 495 775 05 34 E Mail info sick automation ru Schweiz Phone 41 41 619 29 39 E Mail contact sick ch Singapore Phone 65 6744 3732 E Mail admin sicksgp com sg Suomi Phone 358 9 25 15 800
18. E Mail sick sick fi Sverige Phone 46 10 110 10 00 E Mail info sick se Taiwan Phone 886 2 2375 6288 E Mail sales sick com tw Turkiye Phone 90 216 587 74 00 E Mail info sick com tr United Arab Emirates Phone 971 4 8865 878 E Mail info sick ae USA Canada M xico Phone 1 952 941 6780 1800 325 7425 tollfree E Mail info sickusa com 144 WARRANTY 2 Limits of Warranties a MELCO does not warrant or guarantee the design 1 Limited Warranty and Product Support specify manufacture construction or installation of a Mitsubishi Electric Company MELCO warrants that for a period of eighteen 18 months after date of delivery from the point of manufacture or one year from date of Customer s purchase whichever is less Mitsubishi Safety Controller the Products will be free from defects in material and workmanship b At MELCO s option for those Products MELCO determines are not as warranted MELCO shall either repair or replace them or issue a credit or return the purchase price paid for them For this warranty to apply 1 Customer shall give MELCO i notice of a warranty claim to MELCO and the authorized dealer or distributor from whom the Products were purchased ii the notice shall describe in reasonable details the warranty problem iii the notice shall be provided promptly and in no event later than thirty 30 days after the Customer knows or has reason to believe that Produc
19. Total In3 Total Out3 Table 53 Calculation of the response times of the MELSEC WS safety controller in ms 1 Take the values from the Setting and Monitoring Tool report 2 Time values have a tolerance of 10 ms i e for each selected value 10 ms must be considered additionally for the response time E g for a 10 ms off delay 20 ms must be used for the calculation 3 Take values from the corresponding manual 4 Switch off is delayed until the signal has been Low for at least the filter time selected For WSO XTIO and WSO XTDI firmware version lt V2 00 the filter time is fixed at 8 ms 92 Chapter 12 93 Technical data 5 The update interval between the CPU and a network module depends on the amount of data to be transferred and the number of network modules used in the system Take the values from the Setting and Monitoring Tool report The update interval amounts to a multiple of 4 ms for each 10 bytes to be transferred to or from the network module if the system contains one network module If 2 network modules are used the update rate amounts to a multiple of 8 ms Figure 29 Example of a MELSEC WS safety controller Technical data Example 1 Chapter 12 Calculation of the response time for a MELSEC WS safety controller consisting of a WS0 CPU1 and a WSO XTIO A1 A2 LAT A2J MITSUBISHI JE E TT A B A B 1 EFI 2 Execution Time V 100 3 T Blocks 1 Used 4 YO matrix InjOutS
20. asignaling circuit Y24 dual channel and connected to internal 24 V DC afeedback EDM Y3 Y4 dual channel and potential free Figure 13 Int fi ti Wed men Y1Y3 Y14Y24 13233343 24V B1 B2Y2Y4 internal 1424 3444 3 10 2 Display elements and terminal description Figure 14 WS0 4RO display elements 13 23 33 43 Y14 Y1 Y24 Y3 PWR kqp 8 Y 13 n vu Y2 14 24 n K3 4 gy va 33 43 LINIJ Otay YA 34 44 Y24 4RO B1 Y2 B2 Y4 14 24 34 44 Table 17 i WS0 4RO displays Display Meaning PWR green Supply voltage via safety bus is applied K1 2 green Relay K1 K2 safety contacts closed K3 4 green Relay K3 K4 safety contacts closed 43 Table 18 WSO 4RO terminals Product description Chapter 3 Assignment Description B1 Connecting relay K1 K2 B2 Connecting relay K3 K4 13 14 and 23 24 Safety contacts for switch off circuit outputs K1 K2 33 34 and 43 44 Safety contacts for switch off circuit outputs K3 K4 Y1 Y2 Feedback EDM K1 K2 NC contact Y3 Y4 Feedback EDM K3 K4 NC contact Y14 NO safety contact K1 K2 current limited see Chapter 12 v NO safety contact K3 K4 current limited see Chapter 12 44 Chapter 4 45 Connecting devices Connecting devices ATTENTION Note This chapter describes the connection of safety sensors and actuators to the MELSEC WS safety controller and provides configuration information for the selected func
21. e The MELSEC WS safety controller is only suitable for mounting in a control cabinet with at least IP 54 degree of protection Failure to meet the installation method may cause the module to fail or malfunction due to the deposition of dust or the adhesion of water Wiring Precautions NWARNING e Shut off the external power supply all phases used in the system before wiring Failure to do so may result in electric shock or damage to the product The system could start up unexpectedly while you are connecting the devices NCAUTION e Individually ground the GND wires of the MELSEC WS safety controller with a ground resistance of 100 Q or less Failure to do so may result in electric shock or malfunction e Check the rated voltage and terminal layout before wiring to the module and connect the cables correctly Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or failure e Tighten the terminal screw within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction e Prevent foreign matter such as dust or wire chips from entering the module Such foreign matter can cause a fire failure or malfunction e Mitsubishi MELSEC WS safety controllers must be installed in control cabinets Connect the main power supply to the MELSEC WS safety co
22. safety controller 113 Annex 14 1 EC declaration of conformity EC Declaration of Conformity Manufacturer Mitsubishi Electric Corporation Nagoya Works Address 1 14 5 chome Yada Minami Higashi ku Nagoya 461 8670 Japan Products Type Programmable Controller Open Type equipment Installation category Il Modet WS Series Applicable units identified in Appendix These products comply with the following European directives 2006 42 EC Machinery Directive Further details of conformity to these directives are contained in the appendices BCN P9999 0625 This declaration is based on the conformity assessment of following Notified Body T V RHEINLAND INDUSTRIE SERVICE GMBH T V Rheinland Group NB 0035 Am Grauen Stein D 51105 K ln Germany Phone 49 221 8060 Fax 49 221 806114 Email is de tuv com Website http www tuv com Authorised Signature T Takahashi Senior Manager FA System Department Date signature 2 6 20 7h Rye PL Authorised Representative Mitsubishi Electric Europe BV in the European Community Gothaer Str 8 40880 Ratingen Germany through Responsible person Signature H P tz Executive Vice President amp Deputy Product Marketing Director FA European Business Group Date signas re pus c A CX AS X CoM S AN ie i E The appendices are part of this declaration This declaration certifies the conformity with the directives mentioned but
23. 14 4 mA at5 V 3mAat24V Input capacitance Max 10 nF 10 Discrepancy times 4 ms 30 s configurable Number of inputs 8 Technical data Test outputs X1 X8 Chapter 12 Number of outputs 8 with 2 test pulse generators Output type PNP semiconductor short circuit protected cross circuit monitoring Output voltage 15 30 V DC max 1 8 V drop to terminal A1 of CPU module Output resistance Low lt 33 Q 10 96 current limited at approx 10 mA Output current Max 120 mA at each of the two test signal generators X1 X3 X5 X7 or X2 X4 X6 X8 This means that a maximum of 8 testable sensor cascades per module with max 30 mA each are possible The total current for the MELSEC WS safety controller for all outputs X1 X8 and XY1 XY2 is limited to a maximum of 1 28 A This corresponds to e g a maximum of 32 testable sensor cascades with 30 mA each plus 64 tactile sensors on inputs on safety I O modules with 5 mA each Test pulse rate test period 1 25 Hz configurable Test pulse duration test gap 1 100 ms configurable Load capacity 1 uF for test gap 2 4 ms 0 5 uF for test gap 1 ms Cable resistance 100 0 1 Do not switch other safety inputs in parallel if the reverse current could lead to a High state at the other input 106 Chapter 12 Technical data 12 2 4 WS0 4RO safety relay output mod
24. 18 months after manufacturing whichever is less The onerous repair term after discontinuation of production shall be for four 4 years Mitsubishi shall mainly replace the product that needs a repair t may take some time to respond to the problem or repair the product depending on the condition and timing Specifications General specifications of the products differ MELSEC WS MELSECQ MELSEC Qs Operating ambient temperature 25 to 55 C 0 to 55 C 0 to 55 C Operating ambient humidity 10 to 95 RH 5 to 95 RH 5 to 95 RH Storage ambient temperature 25 to 70 C 25 to 75 C 40 to 75 C Storage ambient humidity 10 to 95 RH 5 to 95 RH 5 to 95 RH 1 When the WS0 GCC100202 is included in the system operating ambient temperature will be 0 to 55 C EMC standards that are applicable to the products differ MELSEC WS MELSEC Q MELSEC QS EMC standards EN61000 6 2 EN55011 EN61131 2 e SAFETY PRECAUTIONS e Read these precautions before using this product Before using this product please read this manual and the relevant manuals carefully and pay full attention to safety to handle the product correctly In this manual the safety precautions are classified into two levels N WARNING and AN CAUTION I Indicates that incorrect handling may cause hazardous
25. 5 Extended diagnostics esee nennen tenete tnn 88 11 Maintenance eet reb eer o rr uetus 89 11 1 Regular inspection of the protective device by qualified safety personnel ssssssssssssssseee enm 89 11 2 Device replacemoent ie Reed eti HEBR EE n Haa a 90 12 Technical data oreet erae tere Gee eer gered 91 12 1 Response times of the MELSEC WS safety controller 91 12 1 1 Calculation of the response times sessssssssssseee 92 12 1 2 Min switch off time emere ener 97 12 2 Data sheet RR Hen PREIS 98 12 2 1 CPU modules WS0 CPUO WSO CPU1 and WSO CPUS 98 12 2 2 WSO XTIO safety input output combined module 100 12 2 3 WSO XTDI safety input module ssen 104 12 2 4 WS0 4RO safety relay output module seeeeeee 107 12 3 Dimensional drawings oireen a nene 111 12 3 1 WS0 CPUXx module with memory plug eeee 111 11 12 3 2 WSO XTIO module WSO XTDI module and WSO A4RO module 111 13 Ordering informatlon ic eti Lei beet e eee Lg ee ER peace tn ps 112 13 1 Available modules and accessories sssssssseeeee 112 13 2 Recommended products 112 14 AriniGX un ed don Eg end i dede deed a soeur te ad ed Me 113 14 1 EC declaration of conformity esses eee 113 14 2 Manufacturers checklist
26. 9 TT Commissioning Commissioning ATTENTION Do not commission without a check by qualified safety personnel Before initial commissioning of a system using a MELSEC WS safety controller it must be checked and released by qualified safety personnel Check the hazardous area Ensure that no one is located in the hazardous area before commissioning Check the hazardous area and secure it against being entered by people e g set up warning signs attach blocking ropes or similar Observe the relevant laws and local regulations 9 1 Full approval of the application System commission may only be carried out if full approval was successful Full approval may only be performed by professionals trained accordingly The full approval includes the following items to be checked Check whether all safety related parts of the installation cabling connected sensors and actuators configuration settings are according to the relevant safety standards e g EN ISO 13849 1 or IEC 62061 Check the devices connected to the safety controller in accordance with the test notes in the accompanying manual Label all connections connection cables and plugs at the safety controller clearly and without ambiguity to avoid confusion Since the MELSEC WS safety controller has several connections of the same design ensure that disconnected cables or plugs cannot be connected back unintentionally to the wrong connection Check the si
27. CPU3 you can connect intelligent SICK EFl compatible devices and sensors to your CPU module 4 6 1 Connection of EFI devices If shielding is required for example for EMC reasons when connecting the EFI devices use an earth terminal that is placed in the control cabinet near the CPU module for this purpose Connect this earth terminal with the shielding No external termination resistor is required for EFI connections on the CPU module e The CPU module and all connected SICK EFI compatible devices must have the same 0 V DC of the power supply The maximum permitted voltage at EFI inputs is 30 V to terminal A2 0 V DC e You will find information on connecting SICK EFl compatible devices incl pin assignments in the manuals for the corresponding devices Cables SICK offers cables for the connection of SICK EFI compatible devices For cables please contact your local SICK representative see Section 14 5 http www sens control com Table 46 Note Available process data bits depending on the connection method Note Connecting devices Chapter 4 EMC measures To increase the EMC resistance of the EFI communication it is recommended to connect the EFI cable shield on one or both sides to functional earth Connect this shield to the same DIN mounting rail to which the functional earth FE of the MELSEC WS safety controller is connected in order to minimize interferences on the EFI cable The connection
28. I O Module User s Manual WS IO U HW E Hardware 139292 Safety Controller Safety Relay Output Module User s Manual WS SR U HW E Hardware 139293 Safety Controller Ethernet Interface Module User s Manual WS ET U HW E Hardware 13JZ95 Safety Controller CC Link Interface Module User s Manual WS CC U HW Hardware 13J209 1 2 Target group This manual is addressed to the planning engineers designers and operators of systems which are to be protected by a MELSEC WS safety controller It also addresses people who integrate the MELSEC WS safety controller into a machine commission it initially or who are in charge of servicing and maintaining the unit 1 3 Depth of information This manual contains information on the MELSEC WS safety controller in the following subjects mounting electrical installation hardware commissioning error diagnostics and remedying part numbers e conformity and approval Planning and using other company s protective devices also require specific technical skills which are not detailed in this documentation When operating the MELSEC WS safety controller the national local and statutory rules and regulations must be observed For the acquisition of Setting and Monitoring Tool please contact your local Mitsubishi representative The SICK EFI compatible devices and SICK configuration and diagnostics software CDS are the products of SICK For details of the SICK products
29. Line update rate Where N the number of connection segments between the stations If the Flexi Line function is used in a station the response time is increased by the logic execution time of this station Technical data 12 1 1 Chapter 12 Calculation of the response times The following table can be used to calculate the response times of corresponding paths within the MELSEC WS safety controller Evaluation 1 Inputs Response time of the considered input in the In1 or In2 or In3 or In4 from table below signal path 2 Logic a Response time of CPU module logic 2 x logic execution time Delay through logic application e g On or Off delay timer function block b Response time of the routing applies only for No delay 0 ms output to network module c Response time of Fast shut off logic applies No delay 0 ms only for WSO XTIO modules 3 Outputs Response time of the considered output in the Out1 or Out2 or Out3 or Out4 from table signal path below Total response time Occurrence In1 Digital inputs Out1 Digital outputs General Response time of the sensor Response time of the actuator General Input processing time 6 5 ms Output processing time If On Off filter enabled min filter time If 11 18 is connected at the test output X1 X8 a Safety mats and bumpers Max off on delay of used test output Long gap of used test output Test period
30. Monitoring Tool Diagnostics of the MELSEC WS safety controller with the Setting and Monitoring Tool Assignment PC Plug socket Pin Signal Color sided RS 232 D Sub 9 pins 1 Reserved Brown 2 RxD White Pin3 3 GND Internally electrically connected with connection A2 of Blue Pin 5 the CPU module 4 TxD Black Pin 2 e Ifthe RS 232 interface at the CPU module is connected permanently for usage as an alternative to a network module the maximum permissible cable length is 3 m Avoid ground loops between the GND of the RS 232 interface and the connection A2 of the CPU module e g by using optocouplers 3 6 CPU module WS0 CPU1 3 6 1 Description The WSO CPU1 module has the same functions as the WSO CPUO Please observe the notes in Section 3 6 The CPU module WSO0 CPU1 can only be operated together with the memory plug WSO MPLO In addition this module has 2 EFI interfaces If SICK EFl compatible devices are connected the following additional functions can be used Transferring the configuration from the Setting and Monitoring Tool to the memory plug and to the connected SICK EF l compatible devices Uploading the configuration from the memory plug and the connected SICK EFI compatible devices to the Setting and Monitoring Tool Diagnostics of the MELSEC WS safety controller and the connected SICK EFI compatible devices with the Setting and Monitoring Tool P
31. See also Section 12 1 Enabling or disabling of test pulses for outputs Q1 to Q4 with firmware version V2 00 0 or higher and Setting and Monitoring Tool version V1 3 0 or higher The WSO XTIO module cannot be used alone and always requires a WSO CPUO or WS0 CPU1 module See the Safety Controller Setting and Monitoring Tool Operating Manual The simultaneous use of several WSO XTIO modules is possible see Section 3 2 Voltage for the internal logic and the test outputs is supplied from the memory plug via the FLEXBUS backplane bus Voltage for the WSO XTIOs outputs Q1 Q4 must be supplied directly via A1 A2 on the respective module Short circuits between test signal generators on MELSEC WS safety controller I O module are detected also between test signal generators on different modules provided the test gaps are lt 4 ms and the test periods are 2 200 ms for the relevant test outputs Short circuits to 24 V DC stuck at high at inputs connected to test outputs are detected independently of the test gap time 34 Chapter 3 Product description 3 8 2 Display elements and terminal description Figure 7 Display elements WSO0 XTIO LED MS Module Status Table 12 Terminal Assignment Terminal assignment WSO XTIO X1 X2 Test outputs 1 and 2 11 14 Safe inputs 1 to 4 A1 24 V A2 GND 15 18 Safe inputs 5 to 8 Q1 Q4 Outputs 1 to 4 MS LED Meaning Notes O Supply v
32. When the operator opens the side gate or crossing the laser protected area the robots stop their operation Both robots stop when any one of the emergency stop switches is activated Reset the safety device after activation Safety This system meets the performance level d in accordance with EN ISO13849 1 122 Chapter 14 Annex 1 Wiring Figure 44 Wiring of an application L L example 24 V DC ul I5 Ge si ux Tom mesana Rezoa Rezoa mesana q NO Fo i M6 SA113 1 i RE21 DA i RE21 DA i M6 SA113 1 xd WH vel 12 OA 1 12 241 WH e EFI WSO CPU1 WSO XTIO KE e rrr sl gt N l EFI2 i l A B OGE The WS0 4RO cannot be used alone The WS0 4RO performs the ON OFF control via the WSO XTIO Connect the output terminals Q1 to Q4 of the WSO XTIO to the input terminals B1 and B2 123 Annex Chapter 14 2 Configuration in the Setting and Monitoring Tool a Hardware configuration Figure 45 Hardware configuration of an application example aoc H 2 I3 n4 Y14 Y1 Y24 Y3 A1_A2 X1 X2 A1 u3 23 3 43 Y14 Y1 Y24 Y3 MITSUBISHI nos MS XTIO 56 67 8 Q1 Q2 Q3 Q4 I5 6 I7 I8 GO Elele b Logic Figure 46 Logic of an application example RE E B1 4RO XTIO 1 01 e E i oo db HEM yF xon Med r a DIM Mu
33. disable the test pulses on one or several outputs of WSO XTIO modules with firmware version V2 00 0 and higher Disabling the test pulses of any output reduces the safety parameters of all outputs Disabling the test pulses of one or more outputs of an WSO XTIO module will reduce the parameters for all outputs Q1 to Q4 of this module Consider this to ensure that your application conforms to an appropriate risk analysis and avoidance strategy For detailed information on the safety parameters see chapter 12 Use protected or separate cabling If you disable the test pulses of one or more outputs Q1 to Q4 you have to use protected or separate cabling for the outputs with disabled test pulses because a Short circuit to 24 V can not be detected if the output is High This could inhibit the Switch off capability for the other outputs in case of an internal detected hardware failure due to reverse powering Perform cyclic tests if the test pulses of any safety output are disabled If you disable the test pulses of one or more safe outputs Q1 to Q4 at least once per year either all outputs without test pulses have to be switched off at the same time for at least one second as a result of the logic program of the CPU module Alternatively a power reset of the safety controller has to be performed How to disable the test pulses of an XTIO output Q1 to Q4 gt Connect an output element to the WSO XTIO module Double click the output element usin
34. displayed in the Diagnostics view of the Setting and Monitoring Tool if you are connected to the MELSEC WS safety controller Monitoring Tool Operating Manual e For information on how to perform diagnostics see the Safety Controller Setting and Error displays for the individual modules and error elimination are described in the sections on the individual modules see Sections 3 5 to 3 10 LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures WS0 CPUO WSO WS0 XTIO or codes CPU1 or WSO CPU3 WS0 XTDI MS Red 1 Hz All safety I O modules CPU module Configuration in memory plug is Download a configuration with the MS Red 1 Hz 0x000E4006 incompatible because it is for a same CPU module type as in the firmware 2 V2 00 0 0x00160005 different CPU module type hardware installation or 0x000F0013 Memory plug has been used before Replace the CPU module in the MS Red green in a system with different CPU hardware installation by a module 1 Hz firmware module type e g WS0 CPUO with the same module type as V1 xx 0 instead of WSO CPU1 or vice selected in the project file versa Wrong CPU module type is used in the hardware installation CPU module Configuration in memory plug is Download a configuration with the 0x00170005 incompatible because it is for a newer same or a smaller CPU firmware 0x000F0013 firmware version of the C
35. does not contain any warranted qualities The installation usage and safety directions of the product documentation have to be observed BCN P9999 0624 A Annex Chapter 14 Appendix WS Series Programmable Controllers Range of products WS0 4RO4002 WSO XTDI80202 WS0 CPU000200 WSO XTIO84202 WS0 CPU130202 The conformity of the above mentioned products with the regulations of the directive 2006 42 EC for machinery is shown by the application of a Technical Construction File This is supported by selected product tests to the following standards directly and indirectly when Generic standards are used Note The mentioned products must be used as directed by the associated documentation in order to provide full compliance Harmonized European Standards Reference No Date of Issue EN 1SO13849 1 2008 Signature Miauobire B palme Mitsushiro Fujishima Safety Control Systems Development Section FA Systems Dept 2 Revision record 5December09 The list is created A 07 July 14 WSO CPU320202 WS0 MPL100201 added to the list BCN P9999 0625 A 114 Chapter 14 Table 66 Example of the checklist for installation of the MELSEC WS safety controller 115 Annex 14 2 Manufacturers checklist Checklist for the manufacturer installer for installation of the MELSEC WS safety controller The specifications for the following items listed must be available at least for t
36. is limited Maximum total current for all safety relay output modules on Y14 and Y24 is 80 mA Table 61 PFHd values WS0 4RO Technical data Safety specific characteristics All these data are based on an ambient temperature of 40 C Chapter 12 Safety integrity level SIL3 IEC 61508 SIL claim limit SILCL3 IEC 62061 Category Category 4 EN ISO 13849 1 Performance Level PL e EN ISO 13849 1 PFD 1 6 x 107 PFHd at 0 75 A switching frequency h see also Table 61 1 2 x 10 B10d value switching frequency h SFF 99 6 0 75 A AC 15 4 150 000 see also Table 61 DC 99 Tm mission time Depending on PFHd value ambient temperature load and switching operations see Table 61 No of mechanical switching Min 200 000 operations Load Switching operations IA Switching frequency ISR B10d PFHd type per annum 0 1 1 h 8760 10 000 000 5 00 x 10 0 75 1 h 8760 4 150 000 1 20 x 107 AC15 08 3 1 h 8760 400 000 1 20 x 10 5 1 h 8760 70 000 7 20 x 1079 1 1 h 8760 2 000 000 2 50 x 10 OO Oe ee 3 1 h 8760 450 000 1 10 x 10 2 1 h 8760 1 000 000 5 00 x 10 AC1 09 4 1 h 8760 600 000 8 40 x 10 In order to reach SILCL3 in accordance with IEC 62061 see chapter 12 the following test must be made at least every 365 days ATTENTION The MELSEC WS safety controll
37. of action accrues g Each of the limitations on remedies and damages set forth in these terms is separate and independently enforceable notwithstanding the unenforceability or failure of essential purpose of any warranty undertaking damage limitation other provision of these terms or other terms comprising the contract of sale between Customer and MELCO 4 Delivery Force Majeure a Any delivery date for the Products acknowledged by MELCO is an estimated and not a promised date MELCO will make all reasonable efforts to meet the delivery schedule set forth in Customer s order or the purchase contract but shall not be liable for failure to do so b Products stored at the request of Customer or because Customer refuses or delays shipment shall be at the risk and expense of Customer c MELCO shall not be liable for any damage to or loss of the Products or any delay in or failure to deliver service repair or replace the Products arising from shortage of raw materials failure of suppliers to make timely delivery labor difficulties of any kind earthquake fire windstorm flood theft criminal or terrorist acts war embargoes governmental acts or rulings loss or damage or delays in carriage acts of God vandals or any other circumstances reasonably beyond MELCO s control 5 Choice of Law Jurisdiction These terms and any agreement or contract between Customer and MELCO shall be governed by the laws of the State of New Yo
38. opened Low pair has to be Low Low for equivalent or I7 18 e Defect sensor one of both signals dual channel inputs and Low High for Green 1 Hz does not change to the complementary dual channel inputs corresponding state to the other input within the configured discrepancy time Opening or closing of safety door was too slow so that the 2 contacts Switches e g reed contacts did not Switch within the configured discrepancy time Only one of both inputs has caused the switch off condition and has changed back to the on condition without the other input having changed at all sequence error MS Red MS 6 Red CPU module e Power supply 0 V at WSO XTIO e Check connection of terminal A2 of OxXXXCXXXX module missing firmware V1 xx O WSO0 XTIO modules to 0 V of Safety I O only power supply modules e Internal error in safety I O module Check installation for EMC OxCXXX Internal error in CPU module influence earthing of DIN mounting X any value rail e To reset the error power cycle the CPU module e Ifthe error persists then replace modules MS Red MS Red 2 Hz CPU module Internal error in safety I O module e Check installation for EMC with firmware 2 OxXXXCXXXX whose MS LED is flashing influence earthing of DIN mounting V2 00 0 Safety I O rail modules Toresetthe error power cycle the OxCXXX CPU module X any value e Ifthe error persists then replace the module whose MS L
39. please contact your local SICK representative see Section 14 5 http www sens control com EDM EFI ESPE NC NO OSSD PFHd SIL SILCL Recommendation Note e O gt Action ATTENTION About this document Chapter 1 1 4 Scope These operating instructions are original operating instructions This manual is valid for all modules of the MELSEC WS safety controller with the exception of the network modules This document is the original manual To configure and undertake diagnostics on these devices you will need version V1 7 0 or later of the Setting and Monitoring Tool To check the version of the software on the Extras menu select Info 1 5 Abbreviations used External device monitoring Enhanced function interface safe SICK device communication Electro sensitive protective equipment e g light curtains Normally closed Normally open Output signal switching device Probability of dangerous failure per hour Safety integrity level safety class Safety integrity level claim limit 1 6 Symbols used Recommendations are designed to give you some assistance in your decision making process with respect to a certain function or a technical measure Notes provide special information on the device LED symbols describe the state of a diagnostics LED Examples e The LED is illuminated constantly The LED is flashing O The LED is off Instructions for taking action are shown by an arrow Read car
40. representative 90 Chapter 12 Technical data Technical data Figure 28 Response times within a MELSEC WS safety controller Note 91 12 4 Response times of the MELSEC WS safety controller In order to calculate the response times of a MELSEC WS safety controller all paths have to be taken into consideration XTIO Fast Shut Off ia in ld E b y i N Pita Out1 N Digital ios Digital inputs N A Outputs A N 1 d FLEXBUS FLEXBUS p o o N mna N M N oh Input from Logic Outputto i Fieldbus TEWE p eee Routing eer gt Fieldbus module x p module EFI EFI fo n2 N 7 Out2 A Input from v Outputto EFL jJ EH device device Fast Shut Off The Fast Shut Off function can be realized on a single WSO0 XTIO module A response time of 8 ms can be reached this way The Fast Shut Off function has only an effect on the inputs and outputs of the same WSO XTIO module Flexi Link The response time in a Flexi Link system is increased for a remote input compared to a local input by 4 5 ms 2 x logic execution time of the remote Flexi Link station Flexi Line The response time in a Flexi Line system is increased for a remote input by the input time of the remote station E1 to E4 from Table 53 the logic response time of the station that evaluates this input item 2 a from Table 53 and N x 10 ms 2 x Flexi
41. required to configure the MELSEC WS safety controller Configuration and verification of devices that are connected to the safety controller is generally not carried out via the Setting and Monitoring Tool These devices have their own mechanisms for configuration and verification One exception are SICK EFl compatible devices connected to the WS0 CPU1 or WSO CPUS the SICK EFI compatible devices can be found under EFI elements in the elements window These devices can be configured directly in the Setting and Monitoring Tool by double clicking the icon or alternatively configured and verified locally at the device via its RS 232 interface The SICK configuration and diagnostics software CDS is required for the configuration of the SICK EFl compatible devices The SICK configuration and diagnostics software CDS included in Setting and Monitoring Tool is the product of SICK For the CDS please contact your local SICK representative see Section 14 5 http www sens control com The system configuration of the complete MELSEC WS safety controller with exception of the SICK EFl compatible devices is stored in the memory plug This offers the advantage when safety I O modules or network modules are replaced that the system does not have to be reconfigured The data stored in the memory plug is retained when the voltage supply is interrupted The transfer of configuration information via the EFI interface is possible 76 Chapter
42. test gap 12 ms customized element required SICK L21 max 10 pairs per input can be cascaded with test gap 4 ms standard element max 25 pairs per input can be cascaded with test gap 8 ms customized element required SICK L27 L28 max 7 pairs per input can be cascaded with test gap 4 ms standard element max 18 pairs per input can be cascaded with test gap 12 ms customized element required Take the max line resistance of 100 Q into account Note For further information refer to the manual of the testable Type 2 single beam photoelectric safety switches 4 3 2 Testable Type 4 single beam photoelectric safety switches Table 43 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Connection of testable Type 4 single beam photoelectric safety switches SICK L41 Test input TE transmitter at X1 i Output Q receiver at 11 Note Use protected or separate cabling for the test output of the module X1 X8 to the test input of the transmitter and for the output of the receiver to the safe input of the module 11 18 Otherwise a cross circuit between these signals can inhibit the error detection by this test Table 44 Function Notes Functions of testable Type 4 single beam photoelectric Testing Necessary safety switches X Series connection SICK L41 cascading max 10 pairs per input can be cascaded with test gap 4 ms standard element
43. 1 5 mm AWG 24 15 Finely stranded with ferrules 1 x 0 25 1 5 mm AWG 23 15 Dimensions W x H x D 22 5 x 96 5 x 120 8 mm 22 5 x 101 7 x 120 8 mm Weight CPU1 119 g 5 o 111 g 5 CPU3 133 g amp 5 Power supply A1 A2 via memory plug WSO MPLO or WS0 MPL1 Supply voltage 24 V DC 16 8 30 V DC Supply voltage UL CSA applications 24 V DC Type of supply voltage PELV or SELV The current of the power supply unit for the CPU module has to be limited to a maximum of 4 A either by the power supply unit itself or by a fuse Overvoltage category Il EN 61 131 2 Power consumption Max 2 5 W Switch on time Max 18 s Technical data Chapter 12 12 2 2 WSO0 XTIO safety input output combined module Safety related parameters This information relates to an ambient temperature of 40 C which is normally used for the statistical calculation of the values Table 58 n Data sheet WSO XTIO Safety Integrity Level SIL3 IEC 61508 SIL claim limit SIL CL3 IEC 62061 Category For single channel outputs with Category 4 EN ISO 13849 1 test pulses enabled for all safe outputs Q1 Q4 For single channel outputs with Category 3 EN ISO 13849 1 test pulses disabled for this or any other safe output Q1 Q4 For dual channel outputs with or Category 4 EN ISO 13849 1 without test pulses disabled for this or any other safe output
44. 3 modules and to network modules Check installation for EMC aspects 0x0005C013 disturbed due to EMC disturbance FE connection of DIN mounting 0x000CC013 FLEXBUS communication rail and control cabinet star wiring backplane communication to I O of 24 V power supply local modules and to network modules separation of power parts and disturbed due to critical fault in I O control parts modules In this case this is a follow Check the other diagnosis on error and there will be also other messages with almost same time critical faults with almost the same stamp time stamp 1 s in the diagnosis history CPU module Unequal input data from safety I O To reset the error power cycle the 0x002AC006 module CPU module e A dual channel input at WSO XTIO e Change the configuration by module or WSO XTDI module has 2 activating the ON OFF filter and signal dips High to Low with a time activating the OFF ON filter for distance of 2 ms e g test gaps of inputs of the effected WSO an OSSD output or bouncing relay XTIO WSO XTDI module Please contacts be aware that this increases the A signal channel input at WSO response time for this signal by at XTIO module or WSO XTDI module least 8 ms changes state in intervals of 4 ms for a duration of 40 ms or more e g proximity switch to a tooth wheel WSO0 XTIO e Internal hardware failure of WSO Toresetthe error power cycle the WSO0 XTDI XTIO or WSO XTDI module CPU modul
45. 4 ms 30 s configurable Number of inputs 8 3 Do not switch other safe inputs in parallel if the reverse current could lead to a High state at the other input 102 Chapter 12 103 Technical data Test outputs X1 X2 Number of outputs 2 with 2 test pulse generators Output type PNP semiconductor short circuit protected short circuit monitoring selectable Output voltage High 15 30 V DC max 1 8 V drop to terminal A1 of CPU module Output resistance Low lt 33 Q 10 current limited at approx 10 mA Output current Max 120 mA at each test output X1 or X2 This means that a maximum of 8 testable sensor cascades per module with max 30 mA each are possible The total current for the MELSEC WS safety controller for all outputs X1 X8 and XY1 XY2 is limited to a maximum of 1 28 A This corresponds to e g a maximum of 32 testable sensor cascades with 30 mA each plus 64 tactile sensors on inputs on safety I O modules with 5 mA each Test pulse rate test period 1 25 Hz configurable Test pulse duration test gap 1 100 ms configurable Load capacity 1 uF for test gap 2 4 ms 0 5 uF for test gap 1 ms Cable resistance 100 0 Safe outputs Q1 Q4 Number of outputs 4 Output type PNP semiconductor short circuit protected short circuit monitoring selectable Output voltage High 16 30 V DC m
46. 42 General Information BESS ccce TATA iL 1 30208 1 3 0 208 1 3 0208 1 3 0208 1 30208 1 3 0 208 1 3 0 208 Machine Operator CPU1 module 0x733D1555 Not vertfied Vertfied 4 26 2011 1 08 PM Module Type Code Step Address CPU1 WSO CPU1 V 2xx 0 xrio WSO XTIO Vix 1 XTDI WSO XTDI V 1xx 2 4 3 CPU 4 3 1 CPU1 General Information Type Code Serial Firmware Hardware Version Memory number version version Usage UI Logic WSQ CPU1 0822 0011 v 200 0 1 00 1 0 200V 2xx 2 36 1 36 WS0 MPL 0951 0070 1 3 0 208 4 3 2 CPU1 IO 47 Table 19 Connection of emergency stop pushbuttons Table 20 Functions of emergency stop pushbuttons Note Connecting devices Chapter 4 4 1 Safety command devices and electro mechanical safety switches 4 1 1 Emergency stop pushbuttons e g SICK ES21 Electrical connection Example from Setting and Monitoring Tool with WSO XTIO Single channel Contact between 24 V and I1 24v a n Ci connected to 24 V Single channel Contact between X2 and I2 connected to test X2 a output Dual channel Channel 1 Contact between 24 V and I3 S 9x connected to 24 V zl Channel 2 Contact between 24 V and 14 Dual channel Channel 1 Contact between X1 and 15 connected to test x xoc WX Channel 2 Contact between X2 and I6 output The dual channel emergency stop pushbuttons preconfigured in the Setting and Monitoring Tool have equivalent s
47. CO does not supply such personnel MELCO is not responsible for designing and conducting tests to determine that the Product functions appropriately and meets application standards and requirements as installed or incorporated into the end user s equipment production lines or systems e MELCO does not warrant any Product 1 repaired or altered by persons other than MELCO or its authorized engineers or FA Centers 2 subjected to negligence carelessness accident misuse or damage 3 improperly stored handled installed or maintained 4 integrated or used in connection with improperly designed incompatible or defective hardware or software 5 that fails because consumable parts such as relay batteries backlights or fuses were not tested serviced or replaced 6 operated or used with equipment production lines or systems that do not meet applicable and commensurate legal safety and industry accepted standards 7 operated or used in abnormal applications 8 installed operated or used in contravention of instructions precautions or warnings contained in MELCO s user instruction and or safety manuals technical bulletins and guidelines for the Products 9 used with obsolete technologies or technologies not fully tested and widely accepted and in use at the time of the Product s manufacture 10 subjected to excessive heat or moisture abnormal voltages shock excessive vibration physical damage o
48. ED is flashing MS MS Red CPU module Internal error in CPU module or inthe Check installation for EMC X Red 2 Hz OxXXXCXXXX system influence earthing of DIN mounting with firmware Safety I O rail V2 01 0 modules Toreset the error power cycle the OxCXXX CPU module X any value If the error persists then replace subsequently CPU module and safety I O modules 84 Chapter 10 Diagnostics LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures WS0 CPUO WSO WSO XTIO or codes CPU1 or WS0 CPU3 WS0 XTDI MS Red or MS Red CPU module Follow on error for other critical Check the other diagnosis X Red 2 Hz with or Red 2 Hz 0x0006C002 errors messages for critical faults with firmware 2 V2 01 0 with firmware 0x0007C002 e Disturbance of CPU module internal almost the same time stamp or V2 00 0 0x0001C005 signals due to heavy EMC To reset the error power cycle the MS Red or 0x0003C006 disturbance CPU module firmware V1 xx 0 MS Red 0200096009 e Hardware failure in CPU module or If error persists then replace firmware V1 xx 0 0x0029C006 any safety I O module subsequently CPU module and 0x0003C013 safety I O modules CPU module FLEXBUS communication e To reset the error power cycle the 0x0001C013 backplane communication to I O CPU module 0x0004C01
49. G 24 15 Finely stranded with ferrules 0 25 1 5 mm AWG 23 15 Data interface Backplane bus FLEXBUS Dimensions W x H x D Weight 22 5 x 106 5 x 120 8 mm 164 g 5 Technical data Power supply unit A1 A2 Chapter 12 Supply voltage 24 V DC 16 8 V DC 30 V DC Supply voltage 24 V DC UL CSA applications Type of supply voltage PELV or SELV The current of the power supply unit for the module has to be limited to a maximum of 4 A either by the power supply unit itself or by a fuse Power consumption Max 120 W 30 V x 4A determined by the load at the outputs Q1 to Q4 plus max 1 W power input for the internal circuit Switch on time Max 18 s Short circuit protection 4 A gG with tripping characteristic B or C Input circuit 11 18 Hardware version 2 V1 10 1 Input voltage High 13 30 V DC Input voltage Low 5 5 V DC Input current High 2 4 3 8 mA Input current Low 2 5 2 1 mA Input reverse current in case of ground interruption Hardware version V1 10 1 Max 20 mA 1 5 KQ effective reverse resistance to power supply Max 2 mA Switching current with mechanical contacts Input pulse filtering pulses within these limits have no effect Pulse width Pulse period 14 4 mA at 5 V 3 mA at 24 V Max 0 9 ms Min 4 ms Input capacitance Max 10 nF 10 Discrepancy times
50. ICK EFI compatible devices is available in the controller Transfer of configuration information Special functions Simultaneous protective field evaluation Protective field switching Function changeover Operating mode selection Signal routing Decentralized diagnostics information via Ethernet Information on the location of the protective field interruption at host guest applications Evaluation of signals and forwarding of the results 5 1 4 Benefits Reduction of the installation work only 2 wires when signals from several sensors are used Reduction of the required material through possibility of saving function blocks and I Os High availability through provision of the diagnostics information with high information contents for rapid and correct handling options 68 Chapter 5 69 Special functions 5 2 Muting Muting is the automatic temporary bypassing of safety oriented functions of the control system or of the safety device Muting is used when certain objects such as pallets with material may be moved into the hazardous area During this transportation through electro sensitive protective equipment ESPE such as a safety light curtain the muting function inhibits monitoring by the ESPE Observe the information in the Safety Controller Setting and Monitoring Tool Operating Manual for the further procedure Mounting Dismantling Chapter 6 Mounting Dismantling ATTENTION This chapter describes the m
51. IO Connect the NC contact of the contactor between the I1 to I8 input terminals and the X1 and X2 test output terminals gogg Contactor Connect the positive terminal of the contactor to the Q1 to Q4 output terminals and the negative terminal of the contactor to the A2 0 V terminal 120 Chapter 14 Annex 5 Wiring of contactors Category 3 4 The system meets the requirements of Category 3 even when the output of WSO XTIO Q1 to Q4 is a single channel structure When the output is a dual channel structure the system meets the requirements of Category 4 Properly connect the wires so that two wires will not simultaneously short out or break Figure 42 Wiring example of contactor Category 3 4 24 V DC b j p 1 WS0 CPUQ WS0 XTIO Connect the NC contact of the contactor between the 11 to 18 input terminals and the X1 and X2 test output terminals Contactor Connect the positive terminal of the contactor to the Q1 to Q4 output terminals and the negative terminal of the contactor to the A2 0 V terminal 121 Annex Chapter 14 Application example Simultaneous protection from danger Use of a laser scanner Figure 43 Application example Function Two independent robots are protected with one laser scanner S3000 An operator can access the dangerous area through the protective area or the side gates
52. MITSUBISHI ELECTRIC DIS LS DEdserie Safety Controller User s Manual WS0 CPUO WS0 CPU1 WS0 CPU3 WSO XTDI WS0 XTIO WS0 4RO AL_A2 X1 X2 Ai A2J Xi X2 X3 X4j 13 23 33 43 MITSUBISHI i H i Bu v14 y1 v24 v3 MS MS MS XTDI i5 16 7 I8 B1 Y2 B2 Y4 x5 X6 x7 x8l l4 24 34 44 Powered by MELSEC WS series products were jointly developed and manufactured by Mitsubishi and SICK AG Industrial Safety Systems in Germany Note that the warranty on MELSEC WS series products differs from that on MELSEC Q or MELSEC QS series products Refer to WARRANTY written in this manual This document is protected by the law of copyright whereby all rights established therein remain with the company Mitsubishi Electric Corporation Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law Alteration or abridgement of the document is not permitted without the explicit written approval of the company Mitsubishi Electric Corporation Precautions regarding warranty and specifications MELSEC WS series products are jointly developed and manufactured by Mitsubishi and SICK AG Industrial Safety Systems in Germany Note that there are some precautions regarding warranty and specifications of MELSEC WS series products Warranty The gratis warranty term of the product shall be for one 1 year after the date of delivery or for eighteen
53. PU module version e g V1 xx instead of Memory plug has been configured V2 xx for an incompatible higher CPU Replace the CPU module in the module firmware version e g V1 xx hardware installation by a module instead of V2 xx with an equal or higher firmware An older CPU module firmware version selected in the project file version is used in the hardware installation CPU module Configuration in memory plug is Download a configuration with a 0x000E4013 incompatible for at least one safety I O matching list of safety I O modules 0x00274006 module Add missing safety I O module in e Safety I O module is missing in the the hardware installation hardware installation CPU module Configuration in memory plug is invalid Download the configuration again Ox000E0006 The last configuration procedure and ensure that the power supply at 0x0005000D has not been completed the CPU module is on until the WSO0 XTIO successfully e g because the download procedure has been WSO XTDI power supply has been turned off completed 0x4901 before writing to the memory plug Replace the memory plug and 0x4904 has been completed download configuration again Memory plug hardware failure The memory plug is empty out of the box value 81 Diagnostics Chapter 10 LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures
54. Q1 Q4 Performance Level PL e EN ISO 13849 1 PFHd mean probability of a dangerous failure per hour For single channel outputs 4 8 x 10 For dual channel outputs 0 9 x 10 Tw mission time 20 years EN ISO 13849 1 Applies for single channel inputs and for dual channel inputs 2 If safe outputs are used without test pulses at least once per year either all safe outputs without test pulses have to be switched off at the same time for at least 1 second or alternatively a power reset has to be performed 100 Chapter 12 101 Technical data General data Protection class Ill IEC 61140 Enclosure rating Terminals IP 20 IEC 60529 Housing IP 40 IEC 60529 Ambient temperature in operation 25 55 C Storage temperature 25 70 C Humidity 10 95 non condensing Climatic conditions 55 C 95 relative humidity IEC 61131 2 No corrosive gases Vibration resistance 5 150 Hz 1 g IEC 60068 2 6 10 500 Hz 3 g RMS EN 60068 2 64 Shock resistance Continuous shock Single shock 10 g 16 ms IEC 60068 2 27 30 g 11 ms IEC 60068 2 27 Electromagnetic compatibility Class A IEC 61000 6 2 EN 55011 System connection Dual level spring clamp terminals Power input via FLEXBUS without currents to X1 X2 Max 2 2 W Cross section of connecting wires Single core or finely stranded 0 2 1 5 mm AW
55. RPOSE 3 Limits on Damages a MELCO S MAXIMUM CUMULATIVE LIABILITY BASED ON ANY CLAIMS FOR BREACH OF WARRANTY OR CONTRACT NEGLIGENCE STRICT TORT LIABILITY OR OTHER THEORIES OF RECOVERY REGARDING THE SALE REPAIR REPLACEMENT DELIVERY PERFORMANCE CONDITION SUITABILITY COMPLIANCE OR OTHER ASPECTS OF THE PRODUCTS OR THEIR SALE INSTALLATION OR USE SHALL BE LIMITED TO THE PRICE PAID FOR PRODUCTS NOT AS WARRANTED b Although MEL CO has obtained the certification for Product s compliance to the international safety standards IEC61508 and EN954 1 18013849 1 from TUV Rheinland this fact does not guarantee that Product will be free from any malfunction or failure The user of this Product shall comply with any and all applicable safety standard regulation or law and take appropriate safety measures for the system in which the Product is installed or used and shall take the second or third safety measures other than the Product MELCO is not liable for damages that could have been prevented by compliance with any applicable safety standard regulation or law c MELCO prohibits the use of Products with or in any application involving power plants trains railway systems airplanes airline operations other transportation systems amusement equipments hospitals medical care dialysis and life support facilities or equipment incineration and fuel devices handling of nuclear or hazardous materials or chemicals mining and drilling a
56. Replace the safety relay output module Completed 141 Annex Chapter 14 14 5 Example for the calculation of the response time of Flexi Line Calculation of the response time for a MELSEC WS safety controller Figure 62 LE a Flexi Line Station A Flexi Line Station E controller Digital Digital Digital Digital input output input output remote input local input Output to Input from Flexi Line Via Flexi Line Flexi Line Station B C and D Flexi Line Station A Logic execution time 4ms Flexi Line update rate 2ms Occurrence In1 Digital inputs Occurrence Out2 Output to EFI device General Tactile sensor Oms General Response time of the 40 0ms General Input processing time 6 5ms actuator Robot response time When On Off filter 8 0ms When Flexi Line logic execution time 4 0ms data are used When X1 X8 is connected General Output processing time 4 5ms at the test output Total Output 56 0ms Occurrence Output Output to Flexi Line Output to Flexi Line Total In1 6 5ms Total Output Oms Evaluation1 1 Inputs Response time of the considered input in In1 6 5ms the signal path 2 Logic 2 x logic execution time 8 0ms Response time of the logic XE Delay through logic application 3 Outputs Response time of the considered output in out2 56 0ms local Total r
57. U module 2 EFI connections 1 Flexi Line connection dual level spring clamp terminals WS0 XT1084202 Safety I O combined module 8 inputs 4 outputs dual level spring clamp terminals WS0 XTDI80202 Safety input module 8 inputs dual level spring clamp terminals WS0 4RO4002 Safety relay output module 4 NO contacts and 2 24 V DC signal outputs plug in terminals WS0 C20R2 Configuration cable 2m M8 D SUB WS0 C20M8U Configuration cable 2m M8 USB A WS0 UC 232A RS 232 USB converter RS 232 to USB WS0 GETH00200 Ethernet interface module for Ethernet WS0 GCC100202 CC Link interface module for CC Link WS0 TBC4 4 dual level spring clamp terminals for replacement WS0 TBS4 4 screw terminals for replacement Table 63 Model Type USB cable USB cable USB cable MR J3USBCBL3M USB A type USB miniB type 13 2 Recommended products The following is the reference product of a Flexi Link cable Table 64 Model Type Manufacturer Product No The reference product of a Flexi Link cable Flexi Link cable Shielded twisted pair SICK 6034249 2x2x 0 34mm per meter The following table lists the reference products of a Flexi Line cable Table 65 Theireferehce prod ctot a Model Type Manufacturer Product No Flexi Line cable UNITRONIC BUS Shielded twisted pair LAPP 2170269 CAN cable 1x2x0 75mm Flexi Line cable PVC per meter 40m maximum SICK 6029448 112 Chapter 14 Annex Figure 36 EC declaration of conformity for MELSEC WS
58. WSO XTIO outputs ssseeeees 39 3 9 WSO XTDI safety input module ssseeeee emn 40 3 9 1 Description Inde e RE Rabe tcd ad crines 40 3 9 2 Display elements and terminal description 41 So Nemal Grgu srren e et etes 41 3 10 WS0 4RO safety relay output module sses 42 3 10 1 Description ue Ie o Re eto tte b pnt b e 42 3 10 2 Display elements and terminal description 43 4 Connecting devices akc Saye eei ade i ra aes 45 4 1 Safety command devices and electro mechanical safety switches 48 4 1 1 Emergency stop pushbuttons e g SICK ES21 esssssss 48 4 1 2 Electro mechanical safety switches with and without interlock 49 4 1 3 Enabling switch e g SICK E100 50 4 1 4 Two harid Control uc eiie pet epe box ete ee aeu tate pene 51 4 1 5 Safety mats and bumpers sss eee 52 4 1 6 User mode switches ceccceccecedeeesccecesnenceteneeeceeeaneneedeneneceeeeneneeertenees 53 4 1 7 Potential free contacts ssssssssseeene nennen nene 53 4 2 Non contact safety sensors sssssssssseeeeeneeene rennen 54 4 2 1 Magnetic safety switches e g SICK RE seeee 54 4 2 2 Inductive safety switches e g SICK IN4000 and IN4000 Direct 54 4 2 3 Transponder e g SICK T4000 Compact and T4000 Direct 55 4 3 Testable single beam photoelectric safety switches
59. actile switch or output of testable sensor to 11 I2 or 18 e Defect testable sensor Cable interruption in wiring for safety mat a Cable interruption in wiring from X1 X2 or X8 to safety mat b Cable interruption in wiring from safety mat to 11 I2 or 18 Defect safety mat To reset the error turn off the effected input input state Low Low for equivalent dual channel inputs Low High for complementary dual channel inputs or power cycle the CPU module 83 Diagnostics Chapter 10 LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures WS0 CPUO WS0 WS0 XTIO or codes CPU1 or WS0 CPU3 WS0 XTDI MS Green One or more safety WSO0 XTIO Discrepancy error or sequence error at Check wiring of effected input and I O modules WSO XTDI dual channel inputs whose LEDs are check switching capability of both MS Red green 0x4429 or flashing green contacts outputs of the connected 1 Hz firmware 0x442A Cable interruption or short circuit to sensor V2 00 0 0 V at one of both input signals of e Check mechanical dependency of or the input pair both switches MS Red 1 Hz e Hardware failure of sensor e g one e Replace switch sensor in hardware firmware V1 xx 0 of both contacts outputs is installation and permanently closed High or To reset the error the effected input 11 12 or 13 14 or I5H6
60. afety controller fulfils the requirements of Class A industrial applications in accordance with the Interference emission basic specifications The MELSEC WS safety controller is therefore only suitable for use in an industrial environment and not for private use Installation Precautions WARNING e Do not use the MELSEC WS safety controller in flammable gas atmosphere or explosive gas atmosphere Doing so may result in a fire or explosion due to such as an arc caused by switching the relays NCAUTION e Use the MELSEC WS safety controller in an environment that meets the general specifications in this manual Failure to do so may result in electric shock fire malfunction or damage to or deterioration of the product e Latch the module onto the DIN mounting rail Incorrect mounting may cause malfunction failure or drop of the module e To ensure full electromagnetic compatibility EMC the DIN mounting rail has to be connected to functional earth FE Ensure that the earthling contact is positioned correctly The earthling spring contact of the module must contact the DIN mounting rail securely to allow electrical conductivity e Shut off the external power supply all phases used in the system before mounting or removing the module Failure to do so may result in damage to the product e Do not directly touch any conductive part of the module Doing so can cause malfunction or failure of the module
61. al are either trademarks or registered trademarks of their respective companies SH NA 080855ENG G SICK SICKAG Tel 49 7681 202 0 _http www sick com SH NA 080855ENG G 1408 MEE MODEL WS CPU U E MODEL CODE 13JZ32 MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN NAGOYA WORKS 1 14 YADA MINAMI 5 CHOME HIGASHI KU NAGOYA JAPAN When exported from Japan this manual does not require application to the Ministry of Economy Trade and Industry for service transaction permission Specifications subject to change without notice
62. al use Mitsubishi industrial safety devices are designed for local DC supply applications only If the device is used in power supply networks e g according to IEC 61326 3 1 additional protective measures have to be taken Machines where safety devices are used must be installed and designed according to the Lightning Protection Zone LPZ according to IEC 62305 1 Required immunity levels can be achieved through the use of external protective devices The installed surge protective devices SPD should meet the requirements according to IEC 61643 11 The installation must prevent common mode disturbances according to IEC 61000 4 16 in the frequency range from 0 Hz to 150 kHz To ensure full electromagnetic compatibility EMC the mounting rail has to be connected to functional earth FE e The MELSEC WS safety controller must be mounted in a control cabinet with at least IP 54 enclosure rating Electrical installation in accordance with IEC 60204 1 The voltage supply of the devices must be capable of buffering brief mains voltage failures of 20 ms as specified in IEC 60204 1 The voltage supply as well as all signals connected have to fulfill the regulations for extra low voltages with safe separation SELV PELV in accordance with IEC 60664 and EN 50178 equipment of electrical power installation with electronic devices You must connect all modules of the MELSEC WS safety controller the connected protective devi
63. als of the machine The Safety Controller Setting and Monitoring Tool Operating Manual describes the software supported configuration and parameterization of the MELSEC WS safety controller In addition the manual contains the description of the diagnostics functions that are important for operation and detailed information for the identification and elimination of errors Use the manual in particular for the configuration commissioning and operation of MELSEC WS safety controllers The user s manuals for each network module describe important information on the configuration of the network modules The user s manuals hardware are enclosed with each MELSEC WS module They inform on the basic technical specifications of the modules and contain simple mounting instructions Use the user s manual hardware when mounting the MELSEC WS safety controller 14 Chapter 1 Table 1 Overview of the MELSEC WS manuals Note 15 About this document The following shows the relevant manuals Title Number i WS CPU U E Safety Controller User s Manual 13J232 WS ET U E Safety Controller Ethernet Interface Module User s Manual 13J233 WS CC U E Safety Controller CC Link Interface Module User s Manual 13J245 Safety Controller Setting and Monitoring Tool Operating SW1DNN WSOADR B O E Manual 13JU67 Safety Controller CPU Module User s Manual Hardware We She EGE 13JZ91 Safety Controller Safety
64. ame reference potential Connect the reference potential to the protective earth conductor gt Connect the protective earth conductor to the external earth potential gt Connect both ends of the shield of the shielded cables to the reference potential directly at the entrance to the system control cabinet frame DIN mounting rail Connect the cable shield again to the reference potential as close as possible to the CPU module e g on the mounting rail using suitable cable clamps The cable clamps must completely enclose the cable shield Flexi Link cable Shrink tube Earthing Keep the stripped cable ends as short as possible gt Isolate the screening braiding end e g with a suitable shrink tube All connections must be made electrically well conducting with low impedance Stub lines or star shaped EFI wiring are not permitted Load cables e g for frequency changers electronic speed controllers contactors brakes etc and small signal cables e g measuring lines analog sensors field bus lines etc must be laid separately and with low inductive coupling 66 Chapter 5 Special functions Special functions 5 1 Enhanced Function Interface EFI The WSO CPU1 and WSO CPUS3 CPU modules have 2 EFI interfaces each This section describes the properties the functions and the benefits of these interfaces The general EFI function description and the possibilities for combining SICK produc
65. atible CPU modules Functions WSO0 MPLO WSO CPUO Electrical supply of the MELSEC WS safety WSO CPU1 controller Storing the system configuration without EFI compatible devices WSO MPL1 WS0 CPU3 Electrical supply of the MELSEC WS safety controller Storing the system configuration including EF l compatible devices e The CPU module the internal logic for all modules as well as the inputs 11 18 and test outputs X1 X8 on the safety I O modules are only supplied electrically via the memory plug On the other hand the outputs are supplied separately Q1 to QA Y1 to Y6 as well as IY7 and IY8 The data saved in the memory plug are also retained on an interruption in the supply of power f modules are replaced ensure that the memory plug is reconnected to the correct CPU module Mark all the connecting cables and plug connectors unambiguously on the MELSEC WS safety controller to avoid confusion e f you use a memory plug WSO MPLO then after the replacement of EFl compatible devices connected you must configure the devices again 3 5 CPU module WS0 CPUO 3 5 1 Description The WSO CPUO module is the central process unit of the entire system in which all the signals are monitored and processed logically in accordance with the configuration stored in the memory plug The outputs of the system are switched as a result of the processing whereby the FLEXBUS backplane bus serves as the data interfac
66. ax 0 8 V drop to terminal A1 of this module Leakage current Low Normal operation Max 0 1mA Fault case Hardware version lt V1 10 1 Max 1 6 mA Hardware version 2 V1 10 1 Max 2 0 mA Output current Max 2 0A Total current lsum Ta 45 C Max 4 0A Ta lt 55 C Max 3 2A For UL CSA applications Max 3 2A Test pulse width lt 650 ys or disabled Test pulse rate Max 5 Hz Capacitive load 0 5 uF Cable resistance Max 5 O e g 100 m x 1 5 mm 1 2 O Max permitted coil energy without external protection elements Hardware version V1 00 0 Hardware version 2 V1 01 0 0 22 J 0 37 J Response time Depending on the logic configuration for details see Table 53 Data interface Backplane bus FLEXBUS Table 59 Data sheet WSO XTDI Technical data Chapter 12 4 5 6 7 8 9 In the case of a fault 0 V cable open circuit with a load resistance of min 2 5 KQ maximally the leakage current flows from the safe output For smaller load resistors the leakage current may be greater but in this case the output voltage will be 5 V The connected device e g relay or fail safe programmable controller must detect this status as Low When active the outputs are tested cyclically brief switching to Low When selecting the downstream controllers make sure that the test pulses do not result in deactivation when using the above parameters or disable the
67. bbreviation for the WS0 4RO4002 MELSEC WS safety controller safety relay output module WS0 GETH The abbreviation for the WSO GETH00200 MELSEC WS safety controller Ethernet interface module WS0 GCC1 The abbreviation for the WS0 GCC100202 MELSEC WS safety controller CC Link interface module CPU module A generic term for the WSO CPUO WSO CPU1 and WS0 CPU3 Safety I O module A generic term for the WSO XTIO and WSO XTDI Network module A generic term for the WSO GETH and WS0 GCC1 About this document Chapter 1 About this document Please read this chapter carefully before working with the documentation and the MELSEC WS system 1 1 Function of this document For the MELSEC WS system there are three sets of manuals with clearly defined application as well as user s manuals hardware for each module All the MELSEC WS modules and their functions are described in detail in the user s manuals hardware Use this manual in particular for the planning of MELSEC WS safety controllers The hardware manual are designed to address the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting electrical installation commissioning as well as on operation and maintenance of the MELSEC WS safety controller The hardware manual does not provide instructions for operating machines on which the safety controller is or will be integrated Information on this is to be found in the manu
68. c Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual 2009 MITSUBISHI ELECTRIC CORPORATION CONTENTS SAFETY PREGCAUTIONS idee Porte ederet rca Rune eade Da Deed voe de Aaa 1 CONDITIONS OF USE FOR THE PRODUCT sssssssseee eee 7 REVISIONS 2 destin ie edes me ied m e mmis 8 CONTENTS 22 ER ER e redet BR A nee 9 GENERIC TERMS AND ABBREVIATIONS sss 13 1 About this dOCUMEN 2 c ccec00 caenecsses aaaea eed iid onde say dt iod aane p eaa sa Pad sedie 14 1 1 Function of this document ssssssssssssssseeeenee eene ene 14 te Target group et ea E Re Te e E a ER YI SEE HERE 15 1 3 Depth of information ccccccceceeeeeeeceneaececeeeeeseaaeeeceeeeesesneaeeeeeeeeeeesnenaees 15 1 4 5CODGL us com Lote Lt iR MM Ir M RIS ML ERR setas 16 1 5 Abbreviations used sssssssssssssssseeseseeeeren eren nnne n nennen 16 1 6 SYMBPOIS Used idt be qaid eg c been i qd tec ELA 16 c On safety coco omite tanta OD RR m 18 2 1 Qualified safety personnel ssssssseseene eee 18 2 2 Application areas for the device ssssssssssssseee 18 2 3 GOITG GU s6 ir mete m teat es Ya cde moh Salat 19 2 4 General protective notes and protective measures ssssssss 21 2 5 Environmental protection sss 22 2 5 Disp
69. cable official health and work safety regulations directives and generally recognized engineering practice e g DIN standards VDE stipulations engineering regulations from other EC member states that they can assess the work safety aspects of the power driven equipment and have access to the MELSEC WS manuals and have read and familiarized themselves with them and have access to the manuals for the protective devices e g light curtains connected to the safety controller and have read and familiarized themselves with them 2 2 Application areas for the device The MELSEC WS safety controller is a configurable controller for safety applications It can be used gt in accordance with IEC61508 to SIL3 in accordance with IEC 62061 to SILCL3 in accordance with EN ISO 13849 1 up to Performance Level e The degree of safety actually attained depends on the external circuit the realization of the wiring the parameter configuration the choice of the pick ups and their location at the machine Opto electronic and tactile safety sensors e g light curtains laser scanners safety Switches sensors encoders emergency stop pushbuttons are connected to the safety controller and are linked logically The corresponding actuators of the machines or systems can be switched off safely via the switching outputs of the safety controller 18 Chapter 2 19 ATTENTION ATTENTION On safety 2 3 Correct use T
70. ces e g the EFI devices as well as the voltage supply ies with the same 0 V DC GND The GND of the RS 232 interface is connected internally to the GND of the supply of the CPU module A2 e If the RS 232 interface at the CPU module is used as an alternative to a network module the maximum permissible cable length is 3 m ATTENTION Electrical installation Chapter 7 Avoid ground loops between the GND of the RS 232 interface and the connection A2 of the CPU module e g by using optocouplers Depending on the external loads especially for inductive loads additional external protective elements e g varistors or RC elements may be necessary in order to protect the outputs For operating limits see Chapter 12 Take into account that the response times may increase depending on the type of protective element f a module is replaced the correct terminal assignment has to be guaranteed for example by labelling or suitable cable routing e If standing behind the protective devices e g safety light curtain is possible mount the reset button so that it cannot be actuated by a person located in the hazardous area When operating the control device of the reset button the operator must have full visual command of the hazardous area Between the supply circuit and output circuit and between the input circuit and output circuit in the WSO A4RO module are isolated On the other hand those in the safety I O module are not isolated
71. conditions l N WARNING resulting in death or severe injury i T Indicates that incorrect handling may cause hazardous conditions NCAUTION resulting in minor or moderate injury or property damage See i i Under some circumstances failure to observe the precautions given under CAUTION may lead to serious consequences Observe the precautions of both levels because they are important for personal and system safety Make sure that the end users read this manual and then keep the manual in a safe place for future reference Design Precautions NWARNING e When the MELSEC WS safety controller detects a fault in the external power supply or itself it turns off the outputs Configure an external circuit so that the connected devices are powered off according to the output status off of the MELSEC WS safety controller Incorrect configuration may result in an accident e When a load current exceeding the rated current or an overcurrent caused by a load short circuit flows for a long time it may cause smoke and fire To prevent this configure an external safety circuit such as a fuse e For safety relays configure an external circuit using a device such as a fuse or breaker to protect a short circuit current e When changing data and operating status and modifying program of the running MELSEC WS safety controller from the PC configure a safety circuit in the sequence program or external to the MELSEC WS saf
72. d output in Out 44 5 ms pe peak the signal path path 1 Total response time 73 0 ms Table 54 Example for the calculation of the response time of path 1 of a MELSEC WS safety controller Occurrence In2 Input from EFI device Occurrence Out1 Digital outputs If EFI functions are used Response time of the 12 0 ms General Robot response time 40 0 ms via SICK EFl compatible EFI data source devices C4000 receiver stand alone Constant C4000 1 5 ms General Output processing time 4 5 ms Total In2 13 5 ms Total Out1 44 5 ms Evaluation 1 Inputs Response time of the considered input in the In2 13 5 ms i signal path path 2 D iest Easndnsa tia abe lodie 2 x logic execution time 8 0 ms oue P g Delay through logic application Response time of the considered output in Out1 44 5 ms Se Quipute the signal path path 2 Total response time 66 0 ms 95 Table 55 Example for the calculation of the response time of path 2 of a MELSEC WS safety controller Figure 31 Response times within a MELSEC WS safety Technical data Example 2 Calculation of the response time for a MELSEC WS safety controller Chapter 12 Flexi Link Station A Flexi Link Station B controller Digital Digital Digital input output rem
73. differ on the earth connections If this is the case you must install an additional potential equalization Follow the relevant standards and regulations Table 50 Update rate for a Flexi Line System as a function of the maximum length of cable and the size of the process image ATTENTION Connecting devices Chapter 4 4 8 Flexi Line 4 8 1 Flexi Line overview Flexi Line enables you to reliably network up to 32 MELSEC WS stations Only WS0 CPU3 modules can be used in a Flexi Line system The connection of all the other CPU modules WSO CPUO WS0 CPU1 is not possible A uniform process image is defined for the entire Flexi Line system Each byte of this process image is either global i e in the entire system or local i e only for the related station and its neighboring stations Each Flexi Line station communicates with its neighboring stations via this process image The topology permits communication without addressing Features e Reliable connection of up to 32 MELSEC WS stations via the Flexi Line interface e Topology without addressing In case of a change in the order of the stations it is sufficient to confirm the new arrangement using a Teach pushbutton e The EFI interface remains available without limitation It is possible to connect EFI compatible sensors It is possible to connect a Flexi Link system e A global process image is defined for all stations e Within the process image global or loca
74. ding to the types of events Figure 59 Troubleshooting flowchart for safety output relay EWordesenpiian module When the PWR LED has turned off PWR LED has turned off YES K1 2 or K3 4 LED has turned off When the K1 2 or K3 4 LED has turned off 139 Annex Chapter 14 2 When the PWR LED has turned off Refer to the following flowchart when the PWR LED of the safety relay output module has turned off at power on or during operation of the MELSEC WS safety controller PWR LED has turned off Figure 60 Flowchart when the PWR LED has turned off Is power supplied to the CPU module Supply power How is the PWR LED Is the safety relay Connect the safety relay output module securely output module to module connected to the module on the left securely on the left How is the PWR LED Replace the safety relay Completed output module 140 Chapter 14 Annex 3 When the K1 2 or K3 4 LED has turned off Refer to the following flowchart when the K1 2 or K3 4 LED of the safety relay output module has turned off at power on or during operation of the MELSEC WS safety controller K1 2 or K3 4 LED has turned off Are the outputs Supply the outputs from the WSO XTIO input to the from the WSO XTIO B1 or B2 terminal of the to the B1 or B2 terminal WS0 4RO of the WSO 4RO Figure 61 Flowchart when the K1 2 or K3 4 LED has turned off How is the K1 2 or K3 4 LED
75. dule Other than on red Mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Mitsubishi service center or representative explaining a detailed description of the problem Other than on red Execute the system diagnostics and perform troubleshooting according to the diagnostics result The memory plug or the CPU module has been failed The module needs to be replaced Completed 128 Chapter 14 Figure 50 Flowchart when the MS LED is flashing red or flashing red and green 129 Annex 4 When the MS LED is flashing red or flashing red and green Refer to the following flowchart when the MS LED of the CPU module is flashing red or flashing red and green at power on or during operation of the MELSEC WS safety controller MS LED of the CPU module is flashing red or flashing red and green The configuration of the module whose Are there any modules whose MS LED is flashing red and green is MS LED is flashing red and green incorrect The configuration or system configuration needs to be reexamined Execute the system diagnostics using the Setting and Monitoring Tool and perform troubleshooting according to the diagnostics result Figure 51 Flowchart when the CPU module cannot communicate with Setting and Monitoring Tool Annex Chapter 14 5 Wh
76. e The CPU module WSO0 CPUO can only be operated together with the memory plug WSO MPLO Product description Chapter 3 3 5 2 Display elements and terminal description Figure 4 Display elements WSO CPUO Memory plug LED MS Module Status Reese interfaca LED CV Configuration Verified 28 Chapter 3 Table 6 Displays of the MS LED on WS0 CPUO Table 7 Displays of the CV LED on WS0 CPUO Table 8 Memory plug pin assignment 29 Product description MS LED Meaning Notes O Supply voltage is outside range Switch on the supply voltage and check it at the terminals A1 and A2 Red Green 1 Hz A self test is being carried out or the system is being initialized Please wait Green 1 Hz System is in Stop state Start the application in the Setting and Monitoring Tool Green 2 Hz Identify e g for Flexi Link Green System is in Run state Red 1 Hz Invalid configuration Check the module type and version of the CPU module and safety I O modules whose MS LED flashes Red green If appropriate adapt the configuration using the Setting and Monitoring Tool For detailed information refer to the Setting and Monitoring Tool Diagnostics view Red 2 Hz Critical error in the system Switch the supply voltage off and on possibly in this module again If the error is not eliminated after Application is stopp
77. e 0xC306 Follow on error of CPU module e Replace WSO XTDI WSO XTIO CPU module 0x0029C006 module in hardware installation 0x0029C006 WSO0 XTIO e Power supply at terminal A2 GND Check supply voltage at terminals WSO XTDI of WSO XTIO module interrupted A1 24 V and A2 0 V at the WSO 0xC307 Internal hardware failure of WSO XTIO module also under worst CPU module XTIO or WSO XTDI module case load conditions 0x0029C006 Follow on error of CPU module Toresetthe error power cycle the 0x0029C006 CPU module e If the error persists replace WSO XTDI WSO XTIO module in hardware installation WSO0 XTIO Short circuit to 24V or cross circuit Check wiring of effected output OxC30A in wiring of safe output Q1 Q4 Check capacitive load CPU module ee flashing Check inductive load 0x0029C006 e Capacitive load exceeded the allowed maximum value e g by capacitor for spark quenching Inductive load exceeded the maximum value allowed Internal hardware failure of WSO XTIO module Follow on error of CPU module 0x0029C006 To reset the error power cycle the CPU module If the error persists replace WSO XTIO module in hardware installation 85 Diagnostics Chapter 10 LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures WSO0 CPUO WS0 WS0 XTIO or codes CPU1 or WSO CPU3 WS0 XTDI MS 6 Green All
78. e 56 Flowchart when the MS LED is flashing red firmware V2 00 0 or later MS LED of the safety I O module is flashing red 1Hz What is the flash rate The configuration of the safety I O module whose MS LED is flashing red is invalid The configuration needs to be re examined using Setting and Power off the MELSEC WS Monitoring Tool safety controller and then on Are there any other safety I O modules whose MS LED is flashing red Other than flashing red 2 Hz How is the MS LED Flashing red 2 Hz Please consult your local Completed Mitsubishi service center or representative explaining a detailed description of the problem 136 Chapter 14 Figure 57 Flowchart when the MS LED is flashing red and green firmware V1 xx 0 137 Annex 5 When the MS LED is flashing red and green Refer to the following flowchart when the MS LED of the safety I O module is flashing red and green at power on or during operation of the MELSEC WS safety controller a For safety I O modules firmware V1 xx 0 MS LED of the safety I O module is flashing red and green The configuration of the safety I O module whose MS LED is flashing red and green is invalid The configuration needs to be re examined using Setting and Monitoring Tool Are there any other safety I O modules whose MS LED is flashing red and gre
79. e ensures that any changes on the machine or manipulations of the protective device are detected before use re use Each safety application must be checked at an interval specified by you The effectiveness of the protective device must be checked by authorized commissioned persons If any modifications have been made to the machine or the protective device or if the MELSEC WS safety controller has been changed or repaired the system must be checked again as specified in the checklist in Chapter 14 Carry out regular or daily inspections in order to keep the MELSEC WS modules in an optimal operating mode Check whether the implementation of the MELSEC WS modules fulfills all the technical data of the device Check the mounting conditions and whether the wiring of the MELSEC WS modules is still correct Regularly verify that the safety functions fulfill the requirements of the application as well as all relevant regulations and standards e g regular checking in order to ensure the reliability of the safety functions Note Maintenance Chapter 11 11 2 Device replacement A critical fault in a MELSEC WS module impairs the complete network Devices that have critical faults must therefore be repaired or replaced rapidly We recommend keeping spare devices of the MELSEC WS modules at hand so that network operation can be re established as fast as possible Safety measures for replacing devices Observe the following safety measures wh
80. e input to local output 79 5 ms Table 56 Example for the calculation of the response time of a remote input in a MELSEC WS safety controller 96 Chapter 12 97 Technical data 12 1 2 Min switch off time The minimum switch off time e g of connected sensors is the minimum time for which a switch off condition must be present in order to be detected so that error free switching is possible The min switch off time must be greater than the logic execution time 1 ms and greater than the test gap Long gap if the input is connected to test output X1 X8 and the test gap is gt 1 ms and greater than the test period i e the higher value of the two test outputs used the max Off on delay if safety mats or bumpers are used 1 Take the values from the Setting and Monitoring Tool report Table 57 Data sheet WSO CPUO WS0 CPU1 and WS0 CPU3 Technical data 12 2 Data sheet 12 2 1 Safety related parameters Chapter 12 CPU modules WS0 CPUO WS0 CPU1 and WS0 CPU3 This information relates to an ambient temperature of 40 C which is normally used for the statistical calculation of the values Tm mission time WS0 CPU0 WS0 CPU1 3 Safety Integrity Level SIL3 IEC 61508 SIL claim limit SILCL3 IEC 62061 Category Category 4 EN ISO 13849 1 Performance Level PLe EN ISO 13849 1 PFHd mean probability of a 1 07 x 10 1 69 x 10 dangerous failure per hour
81. e safe inputs are set to zero Critical fault The system will be in state Critical fault MS LED of the module which detected the critical fault Red 2 Hz MS LED of the modules which are unclear about the error origin 6 Red Applications in all modules are in operating state Stop All safe outputs in the system are switched off All safety process data is set to zero Typically also not safety related process data is set to zero Diagnostics Chapter 10 How to place the device back in operation Rectify the cause of the malfunction in accordance with the display of the MS and CV LEDs gt In the case of critical faults switch the voltage supply of the MELSEC WS safety controller off for at least 3 seconds and back on again The MELSEC WS safety controller may restart when it detects a recoverable error caused by noise The MELSEC WS safety controller is ready for operation again if the error cause has been eliminated after the restart Create an interlock program using a reset button to prevent the MELSEC WS safety controller from restarting automatically after the safety function is activated and the safety controller turns off the outputs 80 Chapter 10 Note Diagnostics 10 2 Error displays of the status LEDs error messages and rectification measures This section lists and describes the most important error codes possible causes and potential rectification measures These error messages can be
82. e switch 1 of 2 connected to 24 V NO NO Channel 1 Contact between 24 V and 11 Channel 2 Contact between 24 V and I2 Mode switch 1 of 2 connected to test output Channel 1 Contact between X1 and 11 Channel 2 Contact between X1 and I3 Function Notes Testing Possible User mode switches without test pulses allow 2 to 8 operating modes user mode switches with test pulses allow 2 to 4 operating modes When wiring the tested user mode switches it should be noted that odd numbered inputs I1 I3 I5 I7 have to be used if an odd numbered test output X1 X3 X5 XT is used and even numbered inputs 12 I4 I6 18 have to be used if an even numbered test output X2 X4 X6 X8 is used Further information is available in the manual of the user mode switch 4 1 7 Potential free contacts The Setting and Monitoring Tool makes a series of potential free contacts available for free configuration of contact elements This allows different NC NO contact combinations with and without testing to be implemented In addition elements are available for the start and stop button reset button and external device monitoring EDM Function Notes Testing Possible Series connection Possible Discrepancy time See Setting and Monitoring Tool Note Table 34 Connection of magnetic safety switches with equivalent inputs Table 35 Connection of magne
83. echnical data General Data Protection class Ill IEC 61140 Enclosure rating Terminals IP 20 IEC 60529 Housing IP 40 IEC 60529 Ambient temperature in operation 25 55 C Storage temperature 25 70 C Humidity 10 95 non condensing Climatic conditions 55 C 95 relative humidity IEC 61131 2 No corrosive gases Vibration resistance 5 150 Hz 1 g EN 60068 2 6 10 500 Hz 3 g RMS EN 60068 2 64 Shock resistance Continuous shock Single shock 10 g 16 ms IEC 60068 2 27 30 g 11 ms IEC 60068 2 27 Electromagnetic compatibility Class A IEC 61000 6 2 EN 55011 System connection Dual level spring clamp terminals Power input via FLEXBUS without currents to X1 X8 Max 2W Cross section of connecting wires Single core or finely stranded 0 2 1 5 mm AWG 24 15 Finely stranded with ferrules 0 25 1 5 mm AWG 24 15 Dimensions W x H x D 22 5 x 106 5 x 120 8 mm Weight Safe inputs I1 18 139 g 5 Input voltage High 13 30 V DC Input voltage Low 5 5 V DC Input current High 2 4 3 8 mA Input current Low 2 5 2 1 mA Input reverse current in case of ground interruption Hardware version lt V1 10 0 Max 20 mA Hardware version 2 V1 10 0 1 5 KQ effective reverse resistance to power supply Max 2 mA Switching current with mechanical contacts
84. ed All multiple repetition replace this module outputs are switched off For detailed diagnostics information refer to the Setting and Monitoring Tool Red Critical error in the system Switch the supply voltage off and on possibly in another module again Application is stopped All If the error is not eliminated after outputs are switched off multiple repetition replace the module which displays Red 2 Hz If this is not the case use the diagnostic functions of the Setting and Monitoring Tool to narrow down the respective module CV LED Meaning Note O Configuration in progress Yellow 2 Hz Storing of configuration data in the non volatile memory Supply voltage may not be interrupted until the storage process has been completed Yellow 1 Hz Unverified configuration Verify configuration with the Setting and Monitoring Tool 9 Yellow Verified configuration Pin Assignment A1 24 V voltage supply for all the modules with the exception of the outputs Q1 Q4 A2 GND of the voltage supply Table 9 Pin assignment of the RS 232 interfacee on WSO CPUO Note Note Product description Chapter 3 RS 232 interface The CPU module furthermore has an RS 232 interface with the following functions Transferring the configuration from the Setting and Monitoring Tool to the memory plug Uploading the configuration from the memory plug to the Setting and
85. ed green firmware version as selected in the e Safety I O modules are missing project file MS LED of all other modules is flashing red or red green MS Green 1 Hz MS Green 1 Hz System is in Stop state ready to run Start application in Setting and CV Monitoring Tool Hz For automatic start after power up a verification of the project is necessary with Setting and Monitoring Tool MS Green 1 Hz MS Green 1 Hz System is in Stop state ready to run Start application in Setting and CV 0 Yellow a Monitoring Tool MS Green MS Green System is in operation No error detected One or more safety I O WSO XTIO Module power supply of WSO XTIO is Check supply voltage at terminals A1 modules 0x4804 too low or missing 24 V and A2 0 V at the WSO XTIO MS Red green 0x4806 module also under worst case load 0x4807 conditions 1 Hz firmware V2 00 0 or MS Red 1 Hz firmware V1 xx 0 and Q1 Q2 Q3 Q4 Green 1 Hz Error is reset automatically after approx 8 seconds if the error reason no longer exists 82 Chapter 10 Diagnostics LED indication on module CPU module Safety I O module Possible error Possible reasons Possible measures WS0 CPUO WSO WSO0 XTIO or codes CPU1 or WS0 CPU3 WS0 XTDI MS 6 Green One or more safety WSO0 XTIO Short circuit to 24 V or cross circuit in Chec
86. ed off Is power supplied to Supply power to the the A1 and A2 terminals of A1 and A2 terminals the CPU module of the CPU module On or flashing How is the MS LED Check the power supply status with a circuit tester Is the power supply voltage within specifications Supply power within the rated voltage On or flashing How is the MS LED Is the safety I O module Connect the safety securely connected to the I O module to module module on the leit on the left securely On or flashing How is the MS LED Replace the safety I O module Completed 133 Annex Chapter 14 3 When the MS LED has turned on red Refer to the following flowchart when the MS LED of the safety I O module has turned on red at power on or during operation of the MELSEC WS safety controller Figure 54 Flowchart when the MS LED has turned on red MS LED of the safety I O module has turned on red Decrease the total number of safety l O modules to 12 or less Is the total number of safety l O modules 12 or less On or flashing How is the MS LED Power off the MELSEC WS safety controller and then on Other than on red How is the MS LED On red Power off and then on repeatedly Other than on red How is the MS LED On red Narrow down the troubled module using the Setting and Monitoring Tool and replace the module C
87. ed to frame potential Use suitable components or devices that fulfill all the applicable regulations and standards Actuators at the outputs can be wired single channeled In order to maintain the respective Safety Integrity Level the lines have to be routed in such a manner that cross circuits to other live signals can be excluded for example by routing them within protected areas such as in a control cabinet or in separate sheathed cables NCAUTION e Before performing online operations Force mode for the running MELSEC WS safety controller from the PC read the relevant manuals carefully and ensure the safety The online operations must be performed by qualified personnel following the operating procedure determined at designing Fully understand the precautions described in the Safety Controller Setting and Monitoring Tool Operating Manual before use e Do not disassemble or modify the modules Doing so may cause failure malfunction injury or a fire Mitsubishi does not warrant any products repaired or modified by persons other than Mitsubishi or FA Center authorized by Mitsubishi e Shut off the external power supply all phases used for the MELSEC WS safety controller before mounting or removing the module Failure to do so may cause the module to fail or malfunction e After the first use of the product do not mount remove the module from to the DIN mounting rail and the terminal block to from the module more than 50
88. ee the flowchart When the MS LED has turned off On green Can the CPU module communicate with Setting and Monitoring Tool Configure the system only with the CPU C module and the memory plug ompleted Then mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Mitsubishi service center or representative explaining a detailed description of the problem 131 Figure 52 Troubleshooting flowchart for safety I O module Annex 14 4 3 Troubleshooting flowchart for safety I O module Chapter 14 This section describes how to identify errors and measures to eliminate the errors 1 Troubleshooting flowchart The following shows the error description according to the types of events MS LED has turned off NO MS LED has turned on red NO MS LED is flashing red NO MS LED is flashing red and green When the MS LED has turned off When the MS LED has turned on red YES When the MS LED is flashing red When the MS LED is flashing red and green 132 Chapter 14 Annex 2 When the MS LED has turned off Refer to the following flowchart when the MS LED of the safety I O module has turned off at power on or during operation of the MELSEC WS safety controller Figure 53 Flowchart when the MS LED has turned off The MS LED of the safety I O module has turn
89. een 24 V and 24V i M 13 24V BS l4 M y Channel 4 Right side NC contact between 24 V and l4 Type IIIA At Type IIIA two equivalent inputs NO contacts of the two two hand buttons are monitored A valid input signal is only generated if the ON state High level exists at both inputs within a period of 0 5 s synchronous change both two hand buttons pressed and if both were in the OFF state Low level beforehand Function Notes Tested Possible Series connection Not possible cascading Discrepancy time Fixed Value 500 ms See Two hand control type IIIA function block in the logic in the CPU module with which these inputs are to be evaluated Table 28 Functions with two hand control unit typelllC Note Note Table 29 Connection of safety mats Table 30 Function of safety mats ATTENTION Note Connecting devices Chapter 4 Type IIIC At Type IIIC two pairs of antivalent inputs NO NC contact pairs of the two two hand buttons are monitored A valid input signal is only generated if the ON state High Low level exists at both inputs within a period of 0 5 s synchronous change both two hand buttons pressed and if both were in the OFF state Low High level beforehand Function Notes Tested Possible Series connection Not possible cascading Discrepancy time Possible 0 500 ms See Two hand control type IIIC function block in the logic in the CPU module with whic
90. efully and follow the instructions for action ATTENTION An ATTENTION indicates concrete or potential dangers It is intended to protect you from harm and help avoid damage to devices and systems Read warnings carefully and follow them Otherwise the safety function may be impaired and a dangerous state may occur The term dangerous state The dangerous state standard term of the machine is always shown in the drawings and diagrams of this document as a movement of a machine part In practical operation there may be a number of different dangerous states 16 Chapter 1 About this document e machine movements e electrical conductors e visible or invisible radiation e acombination of several risks and hazards 17 On safety Chapter 2 On safety This chapter deals with your own safety and the safety of the equipment operators Please read this chapter carefully before working with the MELSEC WS safety controller or with the machine protected by the MELSEC WS safety controller 2 1 Qualified safety personnel The MELSEC WS safety controller must be mounted commissioned and serviced only by qualified safety personnel Qualified safety personnel are defined as persons who have undergone the appropriate technical training and have been instructed by the responsible machine owner in the operation of the machine and the current valid safety guidelines and are sufficiently familiar with the appli
91. el 1 Contact E31 between X1 and I3 connected to test eu OE Channel 2 Contact E41 between X2 and 14 output 3 positions Channel 1 Contact E13 between 24 V and 15 connectedto24 V 2 V Channel 2 Contact E23 between 24 V and I6 pid za 1 Channel 3 Contact E31 between 24 V and I7 Channel 4 Contact E41 between 24 V and l8 3 positions Channel 1 Contact E13 between 24 V and 11 connected to test 24V n x mt c x2 d M 2L Channel 4 Contact E41 between X2 and 14 Function Notes Testing Possible Series connection Not possible Discrepancy times See Setting and Monitoring Tool Note Further information is available in the manual of the enabling switch SICK E100 or in the manuals of devices used 50 Chapter 4 Note Table 26 Connection of two hand control Table 27 Functions with two hand control unit type IIIA 51 Connecting devices 4 1 4 Two hand control The contact symbols in this chapter show the switching status while both two hand buttons are not pressed Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Type IIIA zv g Channel 1 Contact between 24 V and 11 connected to 24 V E 5 Channel 2 Contact between 24 V and I2 Type IIIC m Channel 1 Left side NO contact between 24 V and 11 us av gg onov Channel 2 Left side NC contact between 24 V and I2 connected to 24 V nus v E Channel3 Right side NO contact betw
92. en Completed Annex b For safety I O modules firmware V2 00 0 or later Figure 58 KAS LED of the safety I O module Flowchart when the MS is flashing red and green LED is flashing red and green firmware V2 00 0 or later Is power supplied to the A1 and A2 terminals of the safety 1 0 module Supply power to the A1 and A2 terminals of the safety I O module Flashing red and green Check the input and output How is the MS LED lines connected to the safety I O module whose MS LED is flashing red and green Check the power supply status with a circuit tester On green or off How is the MS LED Is the power supply voltage within specifications Supply power within the rated voltage Flashing red and green YES Flashing red and green How is the MS LED Replace the safety I O module Please consult your local Mitsubishi service center or representative explaining a detailed description of the problem Chapter 14 On green or flashing green On green or flashing green Completed 138 Chapter 14 Annex 14 4 4 Troubleshooting flowchart for safety relay output module This section describes how to identify errors and measures to eliminate the errors 1 Troubleshooting flowchart The following shows the error description accor
93. en replacing MELSEC WS modules Do not try to dismantle or repair the MELSEC WS modules Not only does Mitsubishi accept no claims for liability but it is also dangerous as it makes verifying the original safety functions impossible Reset the device into a state in which safety is ensured gt Carry out replacement only when the voltage supply is switched off in order to avoid an electric shock or unexpected device behavior n order to continue using the system configuration check s the new module of the same type same material number and is there no error at the new module after the replacement s the new module plugged in at the same position as the replaced module Have all connectors been re connected to the correct terminals Otherwise you have to completely reconfigure and commission the new system including all the necessary tests see Chapter 9 After the replacement ensure that no errors arise with the new MELSEC WS modules Always carry out a function test before commissioning a replacement module e SICK EFl compatible devices do not have to be reconfigured after the replacement of a MELSEC WS module f you send in MELSEC WS modules for repair generate a report on your project and carry out diagnostics with the Setting and Monitoring Tool enclose a detailed description of the problem with the device and send the MELSEC WS modules with all available information to your local Mitsubishi
94. en the CPU module cannot communicate with Setting and Monitoring Tool Refer to the following flowchart when communication with a peripheral device is disabled when connecting the CPU module with Setting and Monitoring Tool The CPU module cannot communicate with Setting and Monitoring Tool Is the connection cable Connect the connection properly connected cable properly Can the CPU module ommunicate with Setting and Monitoring Tool YES Can the CPU module communicate with Setting and Monitoring Tool after replacing the connection cable Can the CPU module Communicate with Setting and Monitoring Tool after replacing with another CPU module To the next page Is the USB to RS 232 conversion cable used Is the USB driver installed into the PC Install the USB driver into the PC Can the CPU module communicate with Setting and Monitoring Tool Please consult your local Mitsubishi service center or representative Completed explaining a detailed description of the problem 130 Chapter 14 Annex From the previous page Reconnect Setting and Monitoring Tool to the old CPU module and check that the CPU module runs normally How is the MS LED of the CPU module Flashing red See the flowchart When the MS LED is flashing red See the flowchart When the MS LED has turned on red S
95. er Paper cardboard recycling 22 Chapter 3 Figure 1 MELSEC WS safety controller 23 Product description Product description This chapter provides information on the features and properties of the MELSEC WS safety controller and describes the structure and operating principle 3 1 System properties The MELSEC WS safety controller is characterized by the following system properties modular structure 1 CPU module up to 12 safety I O modules up to 4 safety relay output modules and up to 2 different network modules each with 22 5 mm compact width 8 to 96 inputs and 4 to 48 safe outputs programmable use of up to 255 standard and application specific logic blocks standard logic blocks e g AND OR NOT XNOR XOR application specific logic blocks e g emergency stop two hand muting press ramp down operating mode selector switch reset restart integration in different networks via network modules possible Ethernet and CC Link 2 EFI interfaces on the WSO0 CPU1 and WSO CPUS modules see Section 3 6 The Setting and Monitoring Tool is available for configuring the control tasks For the acquisition of Setting and Monitoring Tool please contact your local Mitsubishi representative Product description Chapter 3 3 2 System configuration A MELSEC WS safety controller consists of the following modules amemory plug CPU module up to 2 network modules up to 12 additio
96. er must be powered down The MELSEC WS safety controller must be powered up All safety functions of the connected safety sensors must be verified 110 Chapter 12 Figure 34 Dimensional drawing WS0 CPUx mm Figure 35 Dimensional drawing WSO0 XTIO WSO XTDI WSO 4RO mm 111 Technical data 12 3 Dimensional drawings 12 3 1 WSO0 CPUx module with memory plug 96 5 93 3 22 5 93 7 gt It 120 8 j 114 4 je gt los vot i 2 o o Y F A EE Y MITSUBISHI 9 MEO aU 9 9 RE Bo Bags Foo Y Y o o pes 937 22 5 I 120 8 lt i 12 3 2 WSO0 XTIO module WSO XTDI module and WS0 4RO module 114 4 96 5 IEEE EEEN eee Ordering information Chapter 13 Ordering information 13 1 Available modules and accessories Table 62 Device types of MELSEC Device type pant WS series WS0 MPL000201 Memory plug for WSO0 CPUO or WSO CPU1 WS0 MPL100201 Memory plug for WS0 CPU3 wso cPuooo200 CPU module l Dual level spring clamp terminals WS0 CPU130202 CPU module 2 EFI connections dual level spring clamp terminals WS0 CPU320202 CP
97. esponse time remote input to local output 70 5ms Evaluation2 1 Inputs Response time of the considered input in In1 6 5ms the signal path 2 Logic 2 x logic execution time 8 0ms Response time of the logic NX Delay through logic application 3 Outputs Response time of the Flexi Line output Out2 Oms Total response time Response time of the Flexi Line output 14 5ms 142 Chapter 14 Annex Flexi Line Station E Logic execution time 8ms Occurrence Input Input from Flexi Line Occurrence Out Digital outputs Flexi Line connections Response time in the 14 5ms General Response time of the 40 0ms through 4 stations station with the remote actuator Robot response input time 4x 10ms 7 2x2ms 56 0ms General Output processing time 4 5ms Total Input 70 5ms Total Out1 44 5ms Evaluation 1 Inputs Response time of the considered input in Input 70 5ms remote input 2 Logic d 2 x logic execution time 16 0ms Response time of the logic ES Delay through logic application 3 Outputs Response time of the considered output in Out1 44 5ms path 2 Total response time remote input to local output 131 0ms Table 67 Example for the calculation of the response time of a remote input in a MELSEC WS safety controller 143 Annex 14 6 SICK contact Chapter 14 More representatives and agencies in all major industrial nations at www sick com Australia Phone
98. ety controller to ensure that the entire system operates safely Before operating the MELSEC WS safety controller read the relevant manuals carefully and determine the operating procedure so that the safety can be ensured Furthermore before performing online operations for the MELSEC WS safety controller from the PC determine corrective actions to be taken for communication errors caused by failure such as a poor contact e Create an interlock program using a reset button to prevent the MELSEC WS safety controller from restarting automatically after the safety function is activated and the safety controller turns off the outputs NCAUTION e Ensure that an entire system using the MELSEC WS safety controller meets the requirements for the corresponding safety category The life of safety relays in the safety relay output module depends on the switching condition and or load Configure a system satisfying the number of switching times of the safety relays in the module e Do not install the communication cables together with the main circuit lines or power cables Keep a distance of 100 mm or more between them Failure to do so may result in malfunction due to noise e If a mechanical switch such as a relay is connected to an input terminal of a safety I O module consider contact bounce e Observe the protective notes and measures Observe the following items in order to ensure proper use of the MELSEC WS safety controller e W
99. evision 2 xx must be selected in the Setting and Monitoring Tool hardware configuration Function package Revision 2 xx is available with Setting and Monitoring Tool 1 3 0 and higher n order to use function package Revision 2 xx the respective module must have at least firmware version V2 00 0 Otherwise you will receive an error message when you try to upload a configuration using Revision 2 xx to a module with a lower firmware version Newer modules are downward compatible so that any module can be replaced by a module with a higher firmware version The same firmware version and function package revision as those of the module used must be set to the new project after a project stored in the memory plug is modified You will find the device s date of manufacture at the bottom of the type label in the format yywwnnnn yy year ww calendar week nnnn continuos serial number in the calendar week 26 Chapter 3 Table 5 Variants of the memory plug 27 Note Note Product description 3 4 Memory plug On each CPU module there is a memory plug The system configuration for the entire MELSEC WS safety controller is only saved in the memory plug On the replacement of modules this situation has the advantage that it is not necessary to re configure that the MELSEC WS safety controller There are two different variants of the memory plug that can only be used with specific CPU modules Memory plug Comp
100. f On filters V3 10 i ei V1 7 0 on the inputs 11 to 18 on the Revision 3 xx WSO XTIO XTDI Product description Chapter 3 Minimum required firmware or software version WS0 XTIO Setting and Device WS0 CPU WSO0 XTDI Monitoring Tool Ethernet interface module S EOM 7 V1 2 0 Revision 1 xx CC Link interface module M 11 B V1 24 es Reisontx 0 0 8 51 0 7 0 ROHS conformity WSO XTIO M Hardware version V1 01 or higher 1 means any or not applicable 2 All other modules from product launch onwards Note You can find the firmware version on the type label of the MELSEC WS modules in the field firmware version To be able to use modules with a new firmware version you will need a new version of the Setting and Monitoring Tool For WS CPUO 1 2 V2 01 as well as WS0 XTIO XTDI 2 V2 00 the Designer with at least V1 3 0 is required This aspect is to be taken into account on the replacement of devices in existing systems You will find the hardware version of the MELSEC WS modules in the hardware configuration of the Setting and Monitoring Tool in the Online state or in the report if the system was online previously The version of the Setting and Monitoring Tool can be found in the Extras menu under About Forthe acquisition of the newest version of the Setting and Monitoring Tool please contact your local Mitsubishi representative e The function package Revision 1 xx or R
101. g functions monitoring of the connected sensor equipment also refer to Chapter 4 passing the input information to the CPU module The WSO XTDI module cannot be used alone and always requires a main CPU module The simultaneous use of several WSO XTIO modules is possible see Section 3 2 Voltage for the internal logic and the test outputs is supplied from the memory plug via the FLEXBUS backplane bus Limited short circuit recognition A WSO XTDI has two test signal generators One test signal generator is responsible for the odd numbered test outputs X1 X3 X5 and X7 the other for the even numbered test outputs X2 X4 X6 and X8 Short circuits between test signal generators on module are detected also between test signal generators on different modules provided the test gaps are lt 4 ms and the test periods are 2 200ms for the relevant test outputs Short circuits to 24 V DC stuck at high at inputs connected to test outputs are detected independently of the test gap time Please be aware that at the WSO XTDI the odd numbered test outputs X1 X3 X5 and X7 are connected to one common test signal generator and that the even numbered test outputs X2 X4 X6 and X8 are connected to another common test signal generator Therefore short circuits between test outputs X1 X3 X5 and X7 cannot be detected The same applies respectively for test outputs X2 X4 X6 and X8 Take this into consideration during the wiring e g sepa
102. g the left mouse button Deactivate the option Enable test pulses of this output The test pulses of this output are switched off A notice will be displayed in the hardware configuration area under the respective WSO XTIO module Table 15 Maximum extended fault detection times for cross circuits on WSO XTIO ATTENTION Product description Chapter 3 3 8 5 Extended fault detection time for cross circuits on the outputs Q1 to Q4 on the WSO0 XTIO for switching loads with high capacitance From firmware version V3 10 it is possible to configure an extended fault detection time for cross circuits for the outputs Q1 to Q4 on WSO XTIO modules This configuration can be necessary for switching loads on which there is a cross circuit fault immediately after switching off change from high to low with a normal fault detection time because the voltage at the load does not drop to the low level as quickly as expected Examples of such cases are Loads with higher capacitance than permitted as standard for the output e g the supply voltage for programmable controller output cards for safety related Switching For this application the test pulse for the output must also be deactivated see section 3 8 4 Inductive loads that cause an overshoot in the positive voltage range after the induction voltage has decayed WS0 XTIO s NUES Maximum time to low level S 3 5 V gt Option for switching loads Ae firmware MARIA ERU RE allo
103. gnal paths and the correct inclusion in higher level controllers Check the correct data transfer from and to the MELSEC WS safety controller Check the logic program of the safety controller Perform a complete validation of the safety functions of the system in each operating mode and an error simulation Observe the response times of the individual applications in particular Completely document the configuration of the system the individual devices and the result of the safety check n order to prevent unintentional overwriting of the configuration activate the write protection of the configuration parameters of the MELSEC WS safety controller Modifications are only possible if the write protection has been deactivated Commissioning Chapter 9 9 2 Tests before the initial commissioning A report that provides the configuration can be created with the Setting and Monitoring Tool The purpose of the initial commissioning tests is to confirm the safety requirements specified in the national international rules and regulations especially in the Machine and Work Equipment Directive EC Conformity gt Check the effectiveness of the protective device at the machine using all the selectable operating modes and functions Ensure that the operating personnel of the machine fitted with the safety controller become instructed by the qualified personnel of the machine owner before beginning work Arranging the instruct
104. h these inputs are to be evaluated Synchronization time Fixed Value 500 ms See Two hand control type IIIC function block in the logic in the CPU module with which these inputs are to be evaluated Further information is available in the manual of the two hand control 4 1 5 Safety mats and bumpers The contact symbols in this chapter show the switching status while the safety mat or bumper is not pressed Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Pressure sensitive short Channel 1 Contact between X1 and 11 circuiting switching mats in 3 3 ap Channel 2 Contact between X2 and I2 amp ra 4 wire technology connected B a to test output Function Notes Parallel connection Possible Ensure that the switch off condition is sufficient The duration of the switch off condition of safety mats and bumpers must be at least as long as the greatest value for the test period of both used test outputs to ensure that the switch off condition is detected and that no sequence error occurs Further information is available in the manual of the safety mats 52 Chapter 4 Table 31 Connection of user mode Switches Table 32 Function of user mode Switches Note Table 33 Functions of potential free contacts 53 Connecting devices 4 1 6 User mode switches Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Mod
105. he initial commissioning They are dependent on the application whose requirement must be checked by the manufacturer installer This checklist should be retained stored with the machine documentation so that you can use it as a reference for periodical tests 1 Have the safety rules and regulations been observed in compliance with the directives standards applicable to the machine Are the applied directives and standards listed in the declaration of conformity Does the protective device comply with the required category Are the required protective measures against electric shock in effect protection class Has the protective function been checked in compliance with the test notes in this documentation Especially Functional check of the command devices sensors and actuators connected to the safety controller Test of all switch off paths Are you sure that the safety controller was tested fully for safety functionality after each configuration change Yes Yes Yes Yes Yes Yes No No No No No No This checklist does not replace initial commissioning and regular tests by qualified safety personnel Figure 37 Wiring example of emergency stop pushbuttons Annex Chapter 14 14 3 Wiring examples 1 Wiring of the emergency stop pushbuttons start switches stop switche
106. he MELSEC WS safety controller fulfills the requirements of Class A industrial applications in accordance with the Interference emission basic specifications The MELSEC WS safety controller is therefore only suitable for use in an industrial environment and not for private use The MELSEC WS safety controller may only be used within specific operating limits voltage temperature etc refer to the technical data in Chapter 12 in the sense of Section 2 2 and Section 7 1 It may only be used by specialist personnel and only at the machine at which it was mounted and initially commissioned by qualified personnel in accordance with the MELSEC WS manuals All warranty claims against Mitsubishi Electric Corporation are forfeited in the case of any other use or alterations being made to the software or to devices even as part of their mounting or installation Pay attention to the safety notes and protective measures of the user s manuals hardware and Safety Controller Setting and Monitoring Tool Operating Manual gt Make sure that on the implementation of safety related functional logic the regulations in the national and international standards are met in particular the control strategies and the measures for risk reduction that are stipulated for your application The external voltage supply of the device must be capable of buffering brief mains voltage failures of 20 ms as specified in IEC 60204 The MELSEC WS safety co
107. hen mounting installing and using the MELSEC WS safety controller observe the standards and directives applicable in your country e The national international rules and regulations apply to the installation use and periodic technical inspection of the MELSEC WS safety controller in particular e Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Provision and Use of Work Equipment Directive 89 655 EC Low Voltage Directive 2006 95 EC The work safety regulations safety rules e Manufacturers and owners of the machine on which a MELSEC WS safety controller is used are responsible for obtaining and observing all applicable safety regulations and rules e The notices in particular the test notices of this manual e g on use mounting installation or integration into the existing machine controller must be observed e The test must be carried out by specialized personnel or specially qualified and authorized personnel and must be recorded and documented and retraced at any time by third parties e The external voltage supply of the device must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204 e The modules of the MELSEC WS safety controller conform to Class A Group 1 in accordance with EN 55011 Group 1 encompasses all the ISM devices in which intentionally generated and or used conductor bound RF energy that is required for the inner function of the device itself occurs e The MELSEC WS s
108. hing current A 108 Chapter 12 109 Technical data Output circuit Y14 Y24 Type of output N O contact connected to internal 24 V DC positively guided current limited Number of N O contacts Y 14 24 2 Output voltage 24 V DC 16 30 V DC Output current Max 75 mA Load capacity 200 nF General data Electrical isolation Supply circuit input circuit No Supply circuit output circuit Yes Input circuit output circuit Yes Weight without packaging 186 g 5 Operating data Ambient operating temperature 25 C 55 C Storage temperature 25 C 70 C Air humidity Climatic conditions 10 to 95 96 non condensing IEC 61131 2 No corrosive gases Mechanical strength Vibration IEC 61131 2 Vibration resistance 5 500 Hz 3 grms EN 60068 2 64 Electrical safety IEC 61131 2 Impulse voltage withstand level Uimp Overvoltage category 4 kV Contamination level 2 inside 3 outside Rated voltage Enclosure rating housing terminals 300 V AC IP 40 IP 20 IEC 60529 Electromagnetic compatibility Terminal and connection data IEC 61131 2 IEC 61000 6 2 EN 55011 class A Single or fine stranded wire 0 2 1 5 mm Fine stranded wire with terminal 0 25 1 5 mm2 crimps Insulation stripping length 8 mm Maximum break away torque 0 6 Nm 3 The total output current
109. ion is the responsibility of the machine owner 78 Chapter 10 79 Diagnostics Diagnostics ATTENTION 10 1 Inthe event of faults or errors Cease operation if the cause of the malfunction has not been clearly identified Stop the machine if you cannot clearly identify or allocate the error and if you cannot safely remedy the malfunction Complete functional test after remedying malfunction Carry out a full functional test after a malfunction has been remedied 10 1 1 ERROR operating states With certain malfunctions or a faulty configuration the MELSEC WS safety controller enters the safe status The LEDs of the individual modules of the safety controller indicate the corresponding error level Depending on the error there are different error levels Configuration error The system will be in state Configuration required MS LED Red 1Hz Applications in all modules are in operating state Stop All safe outputs in the system are switched off All safety process data is set to zero Typically also not safety related process data is set to zero Recoverable error Applications in all modules remain in operating state Run MS LED of the effected modules Red green alternating 1 Hz MS LED of not effected modules 6 Green e If safe outputs on the system are effected then as a minimum these outputs are switched off e f safe inputs are effected then at least the process data for thes
110. k wiring of all output 1 0 modules 0x4701 wiring of safe output Q1 Q4 whose e Check capacitive load MS Red green 0x4702 LED is flashing Check inductive load 1 Hz firmware 0x4704 Capacitive load exceeded the V2 00 0 0x4705 allowed maximum value e g by Replace XTIO module or capacitor for spark quenching To reset the error all outputs of the MS X Red 1 Hz ee ic cse MIS effected module have to be turned off firmware V1 xx 0 and maximum value allowed from Heals of By tuningot related input 1 or Q2 or Q3 or Q4 signals e g E stop Error reset can ae ececaues Internal Hardware failure of WSO take up to 8 seconds Alternatively mE 1 Hz XTIO module power cycle the CPU module e Short circuit to 0 V in wiring of safety output Q1 Q4 whose LED is flashing e Power supply on the XTIO module interrupted briefly One or more safety WSO0 XTIO For inputs which are connected to test Check wiring of effected input 1 0 modules WSO XTDI output e Replace testable sensor MS Red green 0x4601 e Short circuit to 24 V or cross circuit 1 Hz firmware V2 00 0 or MS Red 1 Hz firmware V1 xx 0 and 11 or I2 or I3 or 14 or 15 or l6 or I7 or 18 Green 1 Hz in wiring for tested sensors a Short circuit to 24 V or cross circuit in wiring from X1 X2 or X8 to tactile switch or test input of testable input b Short circuit to 24 V or cross circuit in wiring from t
111. l Stop switch or the like T efeje n efe WS0 CPUO WS0 XTIO WSO XTDI Reset switch and start switch or the like single channel NO contact FH E Connect a stop switch with single channel NC contact for direct operation and a reset switch or a start switch with single channel NO contact between the 11 to 18 input terminals and the A1 24 V terminal Stop switch or the like single channel NC contact Q Reset switch and start switch or the like single channel NO contact Annex Chapter 14 2 Wiring of safety switches Connect a safety switch to the MELSEC WS safety controller as shown below Figure 39 Wiring example of safety Safety switch switches dual channel equivalent Switching contacts Connect a safety switch with dual channel equivalent Switching contacts for direct operation between the 11 to I8 input terminals and the X1 and X2 test output terminals 24 V DC dep m mm o TEE A1 A2 RE A1 A2 X1 X2 X3 X4 11 WSO0 CPUO WS0 XTIO WSO XTDI Connect a safety switch with interlock with dual channel equivalent switching contacts for direct operation between the 11 to 18 input terminals and the X1 and X8 output terminals TN Door switch with spring lock dual channel equivalent switching contacts 24V
112. l bytes can be defined e The process image can contain up to 12 bytes or 96 bits e The maximum cable length between 2 stations is 1000 meters The possible total length of a system with 32 stations is therefore 31 kilometers e The overall system has a fixed update rate This rate is dependent on the maximum length of cable between two stations and the size of the process image Max cable length 32 bits 64 bits 96 bits 125m 2 ms 2ms 4 ms 250m 2ms 4ms 8 ms 500 m 4 ms 8 ms 12ms 1000 m 8 ms 12 ms 20 ms 4 8 2 Connection of a Flexi Line system Do not use buffering elements in a Flexi Line system It is not allowed to use buffering elements such as e g CAN bridges CAN repeaters or CAN optical light barriers in a Flexi Line system As a general rule no components other than Flexi Line stations are allowed Otherwise the operator of the machine will be in danger The stations in a Flexi Line system are connected together as follows gt Connect the Next connection of each station with the Prev connection of the next station Connect together the identically labeled terminals that is A to A and B to B 64 Chapter 4 Connecting devices Figure 20 Bev Connection of a Flexi Line system LA1_A2J A1 A2 A A2 AT A2 MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI ue 12 pre B AnextB A ena B A era B ABAB Notes Anexternal terminator is not required for the Flexi Line connections
113. le devices see Section 5 1 have extended functions in connection with the WSO CPU1 or WSO CPUS module Error displays and error elimination are described in the manuals of the corresponding devices 10 4 Mitsubishi support If you cannot remedy a malfunction using the information in this chapter please contact your local Mitsubishi representative When you send in a WSO MPLO or WSO MPL1 memory plug for repair or analysis it is returned in the state of delivery i e with an empty configuration Therefore save your configuration s to project files with the Setting and Monitoring Tool 10 5 Extended diagnostics The Setting and Monitoring Tool contains extended diagnostic possibilities If you cannot identify what kind of error is occurring or if you have serviceability problems it allows you to locate the error more accurately For detailed information refer to the Safety Controller Setting and Monitoring Tool Operating Manual 88 Chapter 11 Maintenance Maintenance 89 The following sections inform about regular tests and the exchange of MELSEC WS modules Do not try to dismantle repair or modify the MELSEC WS modules This can lead to a loss of the safety function s In addition Mitsubishi accepts no claims for liability 11 1 Regular inspection of the protective device by qualified safety personnel gt Check the system at the inspection intervals specified in the national rules and regulations This procedur
114. luated by UL The approval is accomplished according to UL 508 general use applications 20 Chapter 2 21 ATTENTION Note On safety 2 4 General protective notes and protective measures Observe the protective notes and measures Please observe the following items in order to ensure proper use of the MELSEC WS safety controller When mounting installing and using the MELSEC WS safety controller observe the standards and directives applicable in your country The national international rules and regulations apply to the installation use and periodic technical inspection of the MELSEC WS safety controller in particular Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Provision and Use of Work Equipment Directive 2009 104 EC Low Voltage Directive 2006 95 EC the work safety regulations safety rules Manufacturers and owners of the machine on which a MELSEC WS safety 1 controller is used are responsible for obtaining and observing all applicable safety regulations and rules The notices in particular the test notices see Chapter 9 of this manual e g on use mounting installation or integration into the existing machine controller must be observed The tests must be carried out by specialized personnel or specially qualified and authorized personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time by third pa
115. luence fthe senders are only mounted on one side the light beams may not overlap on the receiver side so that the light beam of one sender does not reach two receivers fthe senders and receivers are mounted alternatively ensure that the light beam of Sender S1 cannot be received by Receiver R3 and that the light beam of Sender S3 cannot be received by Receiver R1 58 Chapter 4 Table 45 Connection of ESPE 59 Note ATTENTION Note Connecting devices 4 4 Electro sensitive protective equipment ESPE Electrical connection Example from Setting and Monitoring Tool with WSO XTIO SICK C2000 C4000 M2000 M4000 ie PN OSSD1 receiver at 11 S300 S3000 V300 MiniTwin 24v El 2 2 OSSD2 receiver at I2 Further information is available in the manual of the corresponding SICK ESPE or in the manuals of devices used 4 5 Safe outputs Q1 to Q4 Safety oriented devices must be suitable for safety related signals A function interruption of safe outputs results in a loss of the safety functions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the outputs Q1 to Q4 Connect the GND wires of the power supply to earth so that the devices do not Switch on when the output line is applied to frame potential 4 6 EFI devices If your MELSEC WS safety controller contains a WSO CPU1 or a WS0
116. n these applications 1 power plants 2 trains railway systems airplanes airline operations other transportation systems 3 hospitals medical care dialysis and life support facilities or equipment 4 amusement equipments 6 handling of nuclear or hazardous materials or chemicals 5 incineration and fuel devices 7 mining and drilling 8 and other applications where the level of risk to human life health or property are elevated REVISIONS The manual number is given on the bottom left of the back cover Print date Manual number Revision September 2009 SH NA 080855ENG A First edition March 2010 SH NA 080855ENG B A new module CC Link interface module was added July 2011 December 2011 SH NA 080855ENG C SH NA 080855ENG D Description on Flexi Link system was added Correction of errors in writing August 2012 SH NA 080855ENG E A new function was added to WSO XTIO modules June 2013 SH NA 080855ENG F Correction of errors in writing August 2014 SH NA 080855ENG G A new module WSO CPUS3 module was added A new function was added to WSO XTIO and WSO XTDI modules Description on Flexi Line system was added Japanese manual version SH 080852 G This manual confers no industrial property rights or any rights of any other kind nor does it confer any patent licenses Mitsubishi Electri
117. nactive Low transition fa single channel input is used and an unexpected pulse or a delayed falling edge at this input may lead to a dangerous situation the following measures have to be taken Protected cabling of the related signal to exclude cross circuits to other signals No cross circuit detection i e no connection to test output See the Safety Controller Setting and Monitoring Tool Operating Manual This needs especially to be considered for the following inputs Reset input on the Reset function block Restart input on the Restart function block Restart input on the Press function blocks Eccentric Press Contact Universal Press Contact N break Press Setup Press Single Stroke Press Automatic Override input on a Muting function block Reset input on a Valve function block Reset to zero input and Reload input on a Counter function block After the configuration you obtain the following documentation in the Setting and Monitoring Tool under Report Logic report e Parts list Wiring diagrams 46 Chapter 4 Connecting devices Figure 15 Example extract of the documentation in the Setting uen Basic components Station and Monitoring Tool Software component for CPUO and CPU1 main modules Software component for 4RO relay module Software component for GCC1 Network Modules Software component for GMOD Software component for XTDI extension module Software component for XTIO extension module
118. nal safety I O modules in addition up to 4 WSO 4RO safety relay output modules meaning a max of 16 safe relay outputs Figure 2 Examples for the minimum configuration of a MELSEC WS safety controller with 1 WSO0 CPUO and WSO XTDI 0000 oom or WS0 CPU1 and WSO X1 X2 X3 X4 X1 X2 A1 A2 XTIO H 2 3M H 2 B3 AY A xi x x x M A2 Xt 32 Ar A2 MITSUBISHI nono MITSUBISHI hese us MS m3 ov sone QI Q2 Q3 Q4 5 6 7 6B Q1 Q2 Q3 04 Figure 3 Maximum configuration of e the MELSEC WS safety ux controller without safety relay output module ecu of the modules Type Kind Inputs Outputs oe EE WS0 CPUO WS0 CPU1 CPU module 4 255 1x WSO0 CPU3 4 WSO0 XTIO Safety I O combined module 8 4 ids WSO XTDI Safety input module 8 WS0 4RO Safety relay output module 4 4x WS0 GETH Ethernet interface module 2x WS0 GCC1 CC Link interface module 1 EFI terminals 2 Max of 16 safe relay outputs 24 Chapter 3 Table 4 Required firmware and software versions 25 Product description 3 3 Version compatibility and features For the MELSEC WS series several firmware versions and function packages exist that allow different functions This section gives an overview which firmware version which function package and or which version of the Setting and Monitoring Tool is required to use a certain function or device
119. nd other applications where the level of risk to human life health or property are elevated d MELCO SHALL NOT BE LIABLE FOR SPECIAL INCIDENTAL CONSEQUENTIAL INDIRECT OR PUNITIVE DAMAGES FOR LOSS OF PROFITS SALES OR REVENUE FOR INCREASED LABOR OR OVERHEAD COSTS FOR DOWNTIME OR LOSS OF PRODUCTION FOR COST OVERRUNS OR FOR ENVIRONMENTAL OR POLLUTION DAMAGES OR CLEAN UP COSTS WHETHER THE LOSS IS BASED ON CLAIMS FOR BREACH OF CONTRACT OR WARRANTY VIOLATION OF STATUTE NEGLIGENCE OR OTHER TORT STRICT LIABILITY OR OTHERWISE e In the event that any damages which are asserted against MELCO arising out of or relating to the Products or defects in them consist of personal injury wrongful death and or physical property damages as well as damages of a pecuniary nature the disclaimers and limitations contained in these terms shall apply to all three types of damages to the fullest extent permitted by law If however the personal injury wrongful death and or physical property damages cannot be disclaimed or limited by law or public policy to the extent provided by these terms then in any such event the disclaimer of and limitations on pecuniary or economic consequential and incidental damages shall nevertheless be enforceable to the fullest extent allowed by law f In no event shall any cause of action arising out of breach of warranty or otherwise concerning the Products be brought by Customer more than one year after the cause
120. nected to test o i x Channel 2 Contact between X2 and l6 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO output Single channel wow n Contact between 24 V and 11 connected to 24 V V om Coil at Q1 Single channel 4 9 Contact between X1 and 11 connected to test a LA qi Coil at Q1 Dual channel connected to 24 V 24V Ho M 24V Fy 2 2E Channel 1 Contact between 24 V and l1 Channel 2 Contact between 24 V and I2 Coil at Q1 Dual channel a te Channel 1 Contact between X1 and 11 J mE connected to test 2 E i Channel 2 Contact between X2 and I2 a pupul Coil at Q1 Function Notes Testing Possible Series connection cascading If safety switches are connected in series the max line resistance shall not exceed 100 O see Chapter 12 Discrepancy times See Setting and Monitoring Tool Further information is available in the manuals of the electro mechanical safety switches or in the manuals for devices used Table 24 Connection of enabling switches Table 25 Functions of enabling switches Connecting devices 4 1 3 Enabling switch e g SICK E100 Chapter 4 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO 2 positions Channel 1 Contact E31 between 24 V and l1 connected to 24 V Av e Channel 2 Contact E41 between 24 V and 12 2 positions Chann
121. nected using only EFI1 or using both EFI1 and EFI2 The overall number of status bits per station that can be made available to the other stations in the Flexi Link system depends on the connection method Connection method Available status bits per station EFI1 26 EFI1 2 52 You can not use Flexi Link and EFI communication at the same time i e it is not possible to connect other EFI compatible devices on the EFI2 connection while EFI1 is used for Flexi Link The process data sent by any station are received almost simultaneously by all other stations The processing logic in the individual stations is however not necessarily simultaneous as the stations are not synchronized The data on EFI1 and on EFI2 are consistent The data on EFI1 and EFI2 can however be inconsistent for a short time as they are transferred separately 4 7 3 Connection of a Flexi Link system Do not use buffering elements in a Flexi Link system It is not allowed to use buffering elements such as e g CAN bridges CAN repeaters or CAN optical light barriers in a Flexi Link system As a general rule no components other than Flexi Link stations are allowed Otherwise the operator of the machine will be in danger There are two possibilities for wiring a Flexi Link system connection via EFI1 26 bits connection via EFI1 and EFI2 52 bits Either way always the identically named terminals have to be connected e g EFI1 A on sta
122. ng the module onto the DIN mounting rail Figure 23 Installing end clips 71 Mounting Dismantling Make sure that the voltage supply of the MELSEC WS safety controller is switched off Hang the device onto the DIN mounting rail 1 Ensure that the earthing spring contact is positioned correctly 2 The earthing spring contact of the module must contact the DIN mounting rail securely to allow electrical conductivity Snap the module onto the DIN mounting rail by pressing it lightly in the direction of the arrow 3 gt If there are several modules slide the modules together individually in the direction of the arrow until the side plug connection latches in Install end clips on the left and right The following steps are necessary after mounting completing the electrical connections configuration See the Safety Controller Setting and Monitoring Tool Operating Manual checking the installation Mounting Dismantling Chapter 6 6 2 Steps for dismantling the modules Figure 24 Removing the plug in terminals Remove plug in terminals with the wiring and the end clips Figure 25 Disconnecting the plug connections If there are several modules slide the modules away from each other individually in the direction of the arrow until the side plug connection is separated Figure 26 Removing modules from the DIN mounting rail
123. ntroller may not start up normally when power is restored immediately after the external power supply has been shut off within 5 seconds To restore the power wait for 5 or more seconds after power off The modules of the MELSEC WS safety controller conform to Class A Group 1 in accordance with EN 55011 Group 1 encompasses all ISM devices in which intentionally generated and or used conductor bound RF energy that is required for the inner function of the device itself occurs Note On safety Chapter 2 UL CSA applications Only use the following cables for spring clamp terminals AWG 24 16 copper suitable for temperatures of 60 to 75 C for plug in terminals AWG 30 12 copper suitable for temperatures of 60 to 75 C gt The plug in terminal tightening torque must be 4 4 to 5 3 Ib in v Use the devices only in an environment with a pollution degree of 2 gt The modules shall be supplied by an isolating power source protected by an UL248 fuse rated max 100 V where V is the DC supply voltage with the maximum value of 42 4 V DC such that the limited voltage current requirements of UL508 are met gt Max WSO XTIO Q1 Q4 total current lsum 3 2 A gt Network modules WS0 GETH and WS0 GCC1 are intended to be used with Class 2 Therefore the CPU module must be supplied in this case with a Class 2 power source or Class 2 transformer in accordance with UL 1310 or UL 1585 The safety functions are not eva
124. ntroller through a relay terminal block Wiring and replacement of an external power supply must be performed by maintenance personnel who is familiar with protection against electric shock For wiring methods refer to Chapter 7 e Place the cables in a duct or clamp them If not dangling cable may swing or inadvertently be pulled resulting in damage to the module or cables or malfunction due to poor contact Startup and Maintenance Precautions WARNING e Do not touch any terminal while power is on Doing so will cause electric shock e Shut off the external power supply all phases used in the system before cleaning the module or retightening the terminal screws Failure to do so may result in electric shock Tighten the terminal screw within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction e Safety oriented devices must be suitable for safety related signals A function interruption of safety outputs results in a loss of the safety functions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the safety outputs Wire the MELSEC WS safety controller so that 24 V DC signals cannot unintentionally contact safety outputs Connect the GND wires of the power supply to earth so that the devices do not switch on when the safety output line is appli
125. obal tag name Teaching simulates the presence of temporarily suspended switched off stations Any station can be used as access point to address and configure the entire system with the Setting and Monitoring Tool The configuration of the entire Flexi Link system is stored in a single project file The Flexi Link system can be connected using only EFI1 or using both EFI1 and EFI2 The overall number of process data bits per station that can be made available to the other stations in the Flexi Link system depends on the connection method Connection method Available process data bits per station EFI1 26 EFI EFI2 52 You can not use Flexi Link and EFI communication at the same time i e it is not possible to connect other SICK EFI compatible devices on the EFI2 connection while EFI1 is used for Flexi Link 60 Chapter 4 Table 47 System requirements for Flexi Link Table 48 Available status bits depending on the connection method 61 Notes ATTENTION Connecting devices 4 7 2 System requirements and restrictions for Flexi Link For Flexi Link the following system requirements must be met as a minimum System component Version Hardware WS0 CPU1 with firmware version V2 01 0 or higher or WSO CPU3 Software WSO0 CPU1 Setting and Monitoring Tool version 1 3 0 or higher WSO0 CPU3 Setting and Monitoring Tool version 1 7 0 or higher The Flexi Link system can be con
126. of the shield to FE should be close to the cable inlet of the control cabinet The FE terminal of the MELSEC WS safety controller is located at the bottom of the housing and connects automatically to the DIN mounting rail when the module is mounted To avoid further interferences the functional earth of the SICK sensors e g M4000 3000 must be connected to the EFI shield as well e f other cables are present within the same cable duct where the EFI cable is routed and these cables emit a high degree of EMC interference drives or motor related this can lead to availability problems in the application In this case it is recommended to install the EFI cable in a separate duct 4 7 Flexi Link 4 7 1 Flexi Link overview Flexi Link allows you to combine up to four Flexi Link stations via EFI for safe data communication Only modules from WS0 CPU1 or WS0 CPU3 can be used in a Flexi Link system The connection of WSO0 CPUO modules is not possible The process data of each station inputs and outputs logic results etc can be made available to all other stations in the Flexi Link system The Teach function allows to temporarily deactivate single stations without impairing the function of the overall system Features safe connection of up to four Flexi Link stations via EFI connection via EFI1 or EFI1 and EFI2 transfer receive up to 52 bit of information per station 26 bit per EFI channel Each bit can be assigned a gl
127. offers repair services for Products that are out of warranty or not covered by MELCO s limited warranty may vary Subject to availability of spare parts MELCO will offer Product repair services for 4 years after each Product model or line is discontinued at MELCO s or its FA Centers rates and charges and standard terms in effect at the time of repair MELCO usually produces and retains sufficient spare parts for repairs of its Products for a period of four 4 years after production is discontinued MELCO generally announces discontinuation of Products through MELCO s Technical Bulletins Products discontinued and repair parts for them may not be available after their production is discontinued the materials construction criteria functionality use properties or other characteristics of the equipment Systems or production lines into which the Products may be incorporated including any safety fail safe and shut down systems using the Products MELCO is not responsible for determining the suitability of the Products for their intended purpose and use including determining if the Products provide appropriate safety margins and redundancies for the applications equipment or systems into which they are incorporated c Customer acknowledges that qualified and experienced personnel are required to determine the suitability application design construction and proper installation and integration of the Products MEL
128. oltage is outside range Switch on the supply voltage and check it at the Red green With firmware V1 xx 0 Invalid configuration terminals A1 and A2 1 Hz With firmware 2 V2 00 0 Recoverable external Check the wiring of the flashing inputs and outputs error If all output LEDs flash check the supply voltage at terminals A1 and A2 of this module Green System is in Stop state Start the application in the Setting and Monitoring 1 Hz Tool 6 Green System is in Run state Red With firmware V1 xx 0 Recoverable external error Check the wiring of the flashing inputs and outputs 1 Hz If all output LEDs flash check the supply voltage at terminals A1 and A2 of this module With firmware 2 V2 00 0 Invalid configuration Red With firmware 2 V2 00 0 Critical error in the Switch the supply voltage off and on again 2 Hz system possibly in this module Application is If the error is not eliminated after multiple repetition stopped All outputs are switched off replace the module For detailed diagnostics information refer to the Setting and Monitoring Tool Diagnostics view Red With firmware V1 xx 0 Critical error in the system Switch the supply voltage off and on again possibly in this module or another module Application is stopped All outputs are switched off With firmware 2 V2 00 0 Critical error in the system possibly in another module Application is stopped All outputs are switched off
129. ompleted 134 Chapter 14 Figure 55 Flowchart when the MS LED is flashing red firmware V1 xx 0 135 Annex 4 When the MS LED is flashing red Refer to the following flowchart when the MS LED of the safety I O module is flashing red at power on or during operation of the MELSEC WS safety controller a For safety I O modules firmware V1 xx 0 MS LED of the safety I O module is flashing red Are all the LEDs for Q1 to Q4 of the safety I O modules within the system flashing Is power Supplied to the A1 and A2 terminals of the safety l O module Supply power to the A1 and A2 terminals of the safetyl O module On green or flashing green Check the input and output Flashing red lines connected to the safety I O module whose MS LED is flashing red How is the MS LED Check the power supply status with a circuit tester On green or off How is the MS LED Is the power supply voltage within Specifications Supply power within the rated voltage Flashing red On green or flashing green Flashing red How is the MS LED Replace the safety 1 O module Please consult your local Mitsubishi service center or representative explaining a detailed description of the problem Completed Annex Chapter 14 b For safety I O modules firmware V2 00 0 or later Figur
130. on protection diode How to activate the option for switching loads with high capacitance on output Q1 to Q4 on the WSO XTIO Connect an output element to the WS0 XTIO module Connect an output element to the WSO XTIO module Double click the output element using the left mouse button gt Select the Enable switching extended capacitive loads with this output option 38 Chapter 3 Product description 3 8 6 Single channel usage of WSO0 XTIO outputs Take into account possible brief switching to high on signal channel outputs In the case of an internal hardware fault outputs Q1 to Q4 which would normally be ATTENTION low may briefly switch to high until the fault is detected and there is a response to the fault The fault detection time plus the fault reaction time is dependent on the configuration selected for the output WSO0 XTIO firmware Activation of the switching of Error detection time version loads with high capacitance error response time lt V2 xx Not possible lt 10 ms 2 V3 10 Deactivated lt 10 ms Activated lt 50 ms Take into account this aspect in your risk analysis and risk reduction strategy above all for single channel outputs Otherwise the operator of the machine will be in danger 39 ATTENTION Product description Chapter 3 3 9 WSO XTDI safety input module 3 9 1 Description The WSO XTDI module is the input extension with 8 safe inputs It offers the followin
131. on the CPU module Stub lines or star shaped wiring are not permitted Unused conductors must be connected to FE on both ends The max permitted voltage at Flexi Line inputs is 30V to terminal A220VDC Flexi Line cable The Flexi Line stations can be connected using CAN cables shielded twisted pair Table 51 Possible cable lengths and Cable length Type types Tor Flexi Line Up to 125 m 2 x 0 34 mm AWG 22 connections Up to 1000 m 2 x 0 75 mm AWG 18 For recommended cables see Section 13 2 EMC measures Please observe the notes in section 4 9 Equipotential bonding gt Always connect the cable screen on both sides to earth potential If this is not possible then earth the side that is connected to the PRE terminals gt Be aware that the earth potential may differ on the earth connections If this is the case you must install an additional equipotential bonding Follow the relevant standards and regulations 65 Figure 21 Connection of the cable Note Connecting devices Chapter 4 4 9 EMC measures for Flexi Link and Flexi Line Flexi Link or Flexi Line cables are used to transmit communication signals Electromagnetic influences may disturb the signal transfer and interrupt the communication In order to minimize electromagnetical interference the following measures are required Connect all inactive metallic parts control cabinet doors and housing DIN mounting rails etc to the s
132. osal e reto traer et tee tute oe dan rd 22 2 5 2 Material separation sssssssssssssssese eene 22 Prod ct description iiii iere Ete e ipei bate ho ce Ede eiie d 23 3 4 System properties ee etin ae dte D TOEIC Reid 23 3 2 System configuration soren a e a nennen 24 3 3 Version compatibility and features 25 3 4 Memory plug titor bete eti oap Lote e Ober teet a boa prd Mog 27 3 5 CPU module WSO CPUO ssssssssssseseeseeeeeeerener ene n nennen nnn 27 9 944 Descriptlons 62 nee epo nM eR 27 3 5 2 Display elements and terminal description ssssessussss 28 3 60 CPU module WSO0 GBUM s eint etn pe De Ee dee rti 30 3 6 1 Descriptio ree o d eme 30 3 6 2 Display elements and terminal description 31 3 7 CPUmodule WSO CPU LLL Heute ee tinet tacet folet Heat edb a rette Daun 32 3 7 1 Desctiptlol orki reete t rite eei deans dut a ete oes 32 3 7 2 Display elements and terminal description 33 3 8 WSO XTIO safety I O combined module eee 34 3 9 T Description ie oet ene a take 34 3 8 2 Display elements and terminal description 35 3 9 3 Irnitemal circuits een ee ee ee et e d uera agde 36 3 8 4 Disabling the test pulses of WSO XTIO outputs Q1 to Q4 37 3 8 5 Extended fault detection time for cross circuits on the outputs Q1 to Q4 on the WSO XTIO for switching loads with high capacitance 38 3 8 6 Single channel usage of
133. ote input local input Flexi Link Station A Logic execution time 4 ms Occurrence In1 Digital inputs Occurrence Out2 Output to EFI device General Tactile sensor 0 ms If EFI functions are Response time of the used via SICK EFI message receiver see table compatible devices below for Flexi Link station B General Input processing time 6 5 ms Constant Flexi Link 4ms When On Off 8 0 ms filter When X1 X8 is connected at the test output Total In1 6 5 ms Total Out2 4ms Evaluation 1 Inputs jr e time of the considered input in the signal In1 6 5 ms 2 Logic Response time of the logic ex logic execution tme goms Delay through logic application 3 Outputs ie ad time of the considered output in the signal Out2 4 0 ms Total response time 18 5 ms Flexi Link Station B Logic execution time 8 ms Occurrence In2 Input from EFI device Occurrence Out1 Digital outputs If EFI functions Response time of the EFI 18 5 ms General Response time of the 40 0 ms are used via data source see table actuator Robot response SICK EFI above for Flexi Link station time compatible A devices Constant Flexi Link 0 5 ms General Output processing time 4 5 ms Total In2 19 0 ms Total Out1 44 5 ms Evaluation 1 Inputs Ar a time of the considered input in the signal In2 19 0 ms 2 Logic Response time of the logic SR eames aos Delay through logic application 3 Outputs Response time of the considered output in path 2 Out1 44 5 ms Total response time remot
134. ounting of the modules of the MELSEC WS safety controller 6 1 Steps for mounting the modules The MELSEC WS safety controller must be mounted in a control cabinet with at least IP 54 enclosure rating In a MELSEC WS safety controller the WSO0 CPUO WSO CPU1 or WSO CPUS is positioned at the far left The two optional network modules follow directly to the right of the CPU module Connect further MELSEC WS safety I O modules e g WSO XTIO or WSO XTDI on the right side of the network modules or on the right side of the CPU module if no network module is used The I O modules can be mounted in any order Connect an additional safety relay output module WS0 4RO on the far right of the entire MELSEC WS safety controller The modules are located in a 22 5 mm wide modular system for 35 mm DIN mounting rails to IEC EN 60715 The modules are connected to each other via the FLEXBUS plug connection integrated in the housing Take into account that when replacing a module the MELSEC WS modules have to be pushed approx 10 mm apart before the corresponding module can be removed from the DIN mounting rail Mount the modules in accordance with EN 50274 Ensure that suitable ESD protective measures are taken during mounting Otherwise the FLEXBUS backplane bus may be damaged Take suitable measures to ensure that foreign matter does not enter the connector openings in particular that of the memory plug 70 Chapter 6 Figure 22 Mounti
135. r other improper environment or 11 damaged or malfunctioning due to Acts of God fires acts of vandals criminals or terrorists communication or power failures or any other cause or failure that results from circumstances beyond MELCO s control All Product information and specifications contained on MELCO s website and in catalogs manuals or technical information materials provided by MELCO are subject to change without prior notice g The Product information and statements contained on MEL CO s website and in catalogs manuals technical bulletins or other materials provided by MELCO are provided as a guide for Customer s use They do not constitute warranties and are not incorporated in the contract of sale for the Products h These terms and conditions constitute the entire agreement between Customer and MELCO with respect to warranties remedies and damages and supersede any other understandings whether written or oral between the parties Customer expressly acknowledges that any representations or statements made by MELCO or others concerning the Products outside these terms are not part of the basis of the bargain between the parties and are not factored into the pricing of the Products i THE WARRANTIES AND REMEDIES SET FORTH IN THESE TERMS ARE THE EXCLUSIVE AND ONLY WARRANTIES AND REMEDIES THAT APPLY TO THE PRODUCTS j MELCO DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PU
136. rate routing sheathed cables 40 Chapter 3 Product description 3 9 2 Display elements and terminal description The displays of the MS LED as well as the input LEDs 11 18 are identical with those of the WSO XTIO see Section 3 7 2 Figure 10 Display elements WSO XTDI LED MS Module Status 8 input LEDs Table 16 Terminal Assignment Terminal assignment WSO0 XTDI X1 X3 Test output 1 test signal generator 1 X2 X4 Test output 2 test signal generator 2 11 14 Safe inputs 1 to 4 15 18 Safe inputs 5 to 8 X5 X7 Test output 1 test signal generator 1 X6 X8 Test output 2 test signal generator 2 3 9 3 Internal circuits Figure 11 Internal circuits WSO XTDI FLEXBUS safe inputs and test outputs Application 41 Figure 12 Example of the inclusion of a relay output module in the MELSEC WS safety controller ATTENTION Note Product description Chapter 3 3 10 WSO0 4RO safety relay output module 3 10 4 Description The WSO 4RO safety relay output module provides dual channel contact based outputs with positively guided relay contacts The WSO 4RO safety relay output module cannot be used independently but need to be switched via a WSO XTIO module To this purpose a control output of the WS0 XTIO module Q1 Q4 has to be jumpered to a control input of the relay output module B1 B2 see the following figure
137. rk without regard to conflicts of laws To the extent any action or dispute is not arbitrated the parties consent to the exclusive jurisdiction and venue of the federal and state courts located in the Southern District of the State of New York Any judgment there obtained may be enforced in any court of competent jurisdiction 6 Arbitration Any controversy or claim arising out of or relating to or in connection with the Products their sale or use or these terms shall be settled by arbitration conducted in accordance with the Center for Public Resources CPR Rules for Non Administered Arbitration of International Disputes by a sole arbitrator chosen from the CPR s panels of distinguished neutrals Judgment upon the award rendered by the Arbitrator shall be final and binding and may be entered by any court having jurisdiction thereof The place of the arbitration shall be New York City New York The language of the arbitration shall be English The neutral organization designated to perform the functions specified in Rule 6 and Rules 7 7 b 7 8 and 7 9 shall be the CPR Microsoft Windows Windows Vista Windows NT Windows XP Windows Server Visio Excel PowerPoint Visual Basic Visual C and Access are either registered trademarks or trademarks of Microsoft Corporation in the United States Japan and other countries Ethernet is a registered trademark of Xerox Corp All other company names and product names used in this manu
138. rocess data exchange between CPU module and SICK EFI compatible devices e Connection of up to four WSO0 CPU1 modules as a Flexi Link system see Section 4 T For further information about EFI interfaces refer to Section 5 1 30 Chapter 3 Figure 5 Display elements WSO0 CPU1 Table 10 Displays of the EFI LEDs on WSO0 CPU1 31 Product description 3 6 2 Display elements and terminal description The displays of the MS and CV LEDs as well as the pin assignment of the RS 232 interface are identical with those of the WSO CPUJO see Section 3 5 2 Memory plug RS 232 interface LED EFI1 LED EFI2 EFI1 A E EFI2 B EFI B EFI2 A LED MS Module Status LED CV Configuration Verified EFI LED EFM or EFI2 Meaning Note O OK Red Red 1 Hz Waiting for integration of any SICK EFl compatible device or Flexi Link station after power up Error e g Any expected SICK EFI compatible device or Flexi Link station not found within 3 minutes Integration check failed Communication interruption e SICK EFl compatible device address conflict Flexi Link ID conflict Check the wiring Later integration is still possible 2 Hz alternating Red Identify e g for Flexi Link Note Product description Chapter 3 3 7 CPU module WS0 CPU3 3 7 1 Description The CPU module WSO0 CPUS has the same functions as the CPU module WSO CPU1 Please obser
139. rties This manual must be made available to the user of the machine where the MELSEC WS safety controller is used The machine operator is to be instructed in the use of the device by qualified personnel and must be instructed to read the manual WS0 4RO only ATTENTION Table 2 Overview of disposal by component On safety Chapter 2 25 Environmental protection The MELSEC WS safety controller has been designed to minimize environmental impact It uses only a minimum of power and natural resources gt At work always act in an environmentally responsible manner 2 5 1 Disposal Disposal of unusable or irreparable devices should always occur in accordance with the applicable country specific waste disposal regulations e g European Waste Code 16 02 14 2 5 2 Material separation Material separation may only be performed by qualified safety personnel Exercise care when disassembling the devices The danger of injury is present Before you can turn over the devices for environmental friendly recycling you must separate the different materials of the MELSEC WS module from one another Separate the housing from the remaining components especially the PCB Send the separated components to the corresponding recycling centers see the following table Component Disposal Product Housing Plastic recycling PCBs cables plugs and electrical connection Electronics recycling pieces Packaging Cardboard pap
140. s and reset switches a Dual channel wiring with test pulse outputs Connect emergency stop pushbuttons to the MELSEC WS safety controller as shown below 24 V DC Connect an emergency stop pushbutton with dual channel equivalent switching contacts for direct operation between the 11 to 18 input terminals and the X1 and X2 test pulse output terminals Emergency stop pushbutton dual channel equivalent switching contacts WSO CPUO WSO XTIO WSO XTDI Connect an emergency stop pushbutton with dual channel equivalent switching contacts for direct operation between the I1 to 18 input terminals and the X1 and X2 test pulse output terminals Emergency stop pushbutton dual channel equivalent switching contacts Use the following terminal combinations for dual channel input wiring WSO XTIO I1 and X1 I2 and X2 I3 and X1 I4 and X2 I5 and X1 I6 and X2 I7 and X1 I8 and X2 WSO XTDI I1 and X1 I2 and X2 I3 and X3 I4 and X4 to I7 and X7 I8 and X8 116 Chapter 14 Figure 38 Wiring example of start Switches stop switches and reset switches 117 Annex b Single channel wiring without test pulse outputs Connect start switches stop switches and reset switches to the MELSEC WS safety controller as shown below 24 V DC single channel NC contact HH sul
141. s so that this reverse current does not lead to an unintended High level at the parallel connected inputs 74 Chapter 7 Figure 27 Safety controller power supply internal circuit 75 7 2 Electrical installation Internal circuit power supply 24V DC J A1 A1 Test outputs 24V X1 X8 A1 Test outputs A1 24V X1 X8 Test outputs 24V X1 X8 24V Memory plug FLEXBUS Application FLEXBUS FLEXBUS Application Q Safety 1 0 Q Safety VO FLEXBUS FLEXBUS Application Safety l O FLEXBUS 24V DC Network Network CPU module f module 1 module 2 module 1 module 2 module n H 1 i ae H A2 Outputs A2 Outputs A2 Outputs 0 V Q1 04 0V Q1 04 0 V Q1 04 Load Load Load Configuration Chapter 8 Configuration ATTENTION Note Check the safety function before commissioning and after every change If you change the configuration you must check the effectiveness of the safety function Please observe the test notes in the manuals of the connected protective devices The Setting and Monitoring Tool and the WSO MPLO or WSO MPL1 memory plug are
142. safety I O modules CPU module Function block error with dual channel e Check the wiring of the effected MS Green 0x000A001 1 input evaluation e g Emergency stop input and check switching capability Magnetic switch Discrepancy error at of both contacts outputs of the pair 1 of function block connected sensor e Cable interruption or short circuit to e Check mechanical dependency of 0 V at one of both input signals of both switches the input pair Replace switch sensor in hardware Hardware failure of sensor e g one installation of both contacts outputs is To reset the error the effected input permanently closed High or pair has to change within the opened Low configured discrepancy time from Defect sensor one of both signals ow Low to High High for equivalent does not change to the dual channel inputs from Low High to corresponding state to the other High Low for complementary dual input within the configured channel inputs discrepancy time Opening or closing of safety door was too slow so that the 2 contacts Switches e g reed contacts did not Switch within the configured discrepancy time CPU module e Function block error EDM or Valve Increase Max feedback delay time 0x00100011 monitor Feedback signal did not of the function block if acceptable follow the control signal within the for the application max feedback delay time Replace relay valve in the hardware Hardware failure of connected in
143. stallation relay valve or failure in the wiring Used relay valve has greater Switching delay for monitor contact All LEDs temporarily All LEDs temporarily CPU module e Power supply of CPU module had Ensure that power supply is off and then LED test off and then LED test 0x002D4006 short voltage dip to almost O V capable to buffer power interruption sequence sequence Power supply of CPU module had a up to 20 ms voltage drop approx down to 6 Ensure that power supply is V 16 V and increased back to capable to drive the load so that operating range Switching of loads does not cause a drop of the supply voltage e Check power supply wiring of CPU module Use separate wires to other heavy loads to avoid voltage drops on the supply cable by other load currents CPU module The system has performed a restart e Check installation for EMC aspects 0x003E4006 because interferences have been FE connection of DIN mounting rail detected in the FLEXBUS communication e FLEXBUS communication backplane communication to I O modules and to network modules disturbed due to EMC disturbance FLEXBUS communication backplane communication to I O modules and to network modules disturbed due to critical fault in any safety I O module I O modules or network module In this case this is a follow on error and there will be also other critical faults with almost the same time stamp 1 s in the diagnosis history
144. test pulses on the outputs If safe outputs are used without test pulses at least once per year either all safe outputs without test pulses have to be switched off at the same time for at least 1 second or alternatively a power reset has to be performed If safe outputs are used without test pulses Use protected or separate cabling for the safe outputs without test pulses because a short circuit to 24 V can not be detected if the safe output is High This could inhibit the switch off capability for the other safe outputs in case of an internal detected hardware failure due to reverse powering Make sure to limit the individual line core resistance to the downstream controller to this value to ensure that a short circuit between the outputs is safely detected Also note IEC 60204 Electrical Machine Equipment Part 1 General Requirements Examples for resulting max coil inductivity HW V1 00 0 1760 mH 0 5A 440 mH 1A 110 mH 2A HW V1 01 0 2960 mH 0 5A 740 mH 1A 185 mH 2A 12 2 3 WS0 XTDI safety input module Safety related parameters This information relates to an ambient temperature of 40 C which is normally used for the statistical calculation of the values Safety Integrity Level SIL3 IEC 61508 SIL claim limit SIL CL3 IEC 62061 Category Category 4 EN ISO 13849 1 Performance Level PLe EN ISO 13849 1 eee c Tw mission time 20 years EN ISO 13849 104 Chapter 12 105 T
145. thin specifications the rated voltage On or flashing How is the MS LED of the CPU module Is the memory plug properly Properly plug the memory plugged into the CPU module plug into the CPU module fow is the MS LED On or flashing ofthe CPU module Configure the system only with the CPU module and the memory plug The memory plug or the CPU module has been failed The module needs to be replaced How is the MS LED of the CPU module On or flashing Mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Completed Mitsubishi service center or representative explaining a detailed description of the problem 127 Annex Chapter 14 3 When the MS LED has turned on red Refer to the following flowchart when the MS LED of the CPU module has turned on red at power on or during operation of the MELSEC WS safety controller Figure 49 Flowchart when the MS LED has turned on red MS LED of the CPU module has turned on red Power off the MELSEC WS safety controller and then on How is the MS LED of the CPU module On red Can the CPU module communicate with the Setting and Monitoring Tool YES NO Configure the system only with the CPU module and the memory plug How is the MS LED of On red the CPU mo
146. tic safety switches with complementary inputs Table 36 Functions of magnetic safety switches Note Table 37 Connection of inductive safety switches Table 38 Functions of inductive safety switches Note Connecting devices 4 2 4 2 1 Chapter 4 Non contact safety sensors Magnetic safety switches e g SICK RE The contact symbols in this chapter show the switching status while the switch is actuated e g while the door is closed Magnetic safety switches with equivalent inputs e g SICK RE13 RE27 Electrical connection Example from Setting and Monitoring Tool with WSO XTIO Connected to test output Channel 1 Contact between X1 and 11 x yu n Ney Channel 2 Contact between X2 and 12 x2 2 2 Magnetic safety switches with complementary inputs e g SICK RE11 RE24 RE31 RE300 Connected to test output Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO xi NC contact between X1 and I3 peu 3 DE e B CT NO contact between X2 and 14 Function Notes Testing Possible Series connection cascading Possible observe the max line resistance of 100 O and the correct setting of the test impulse time Discrepancy time Default 1 5 s See Setting and Monitoring Tool Further information is available in the manuals of the SICK magnetic safety switches or in the manuals of devices used 4 2 2 Inductive safe
147. times IEC 61131 2 compliant respectively Exceeding the limit of 50 times may cause malfunction e Before handling the module touch a grounded metal object to discharge the static electricity from the human body Failure to do so may cause the module to fail or malfunction Disposal Precautions NCAUTION e When disposing of this product treat it as industrial waste Disposal of the product should always occur in accordance with the applicable country specific waste disposal regulations e g European Waste Code 16 02 14 e CONDITIONS OF USE FOR THE PRODUCT e 1 Although MELCO has obtained the certification for Product s compliance to the international safety standards IEC61508 EN954 1 ISO13849 1 from TUV Rheinland this fact does not guarantee that Product will be free from any malfunction or failure The user of this Product shall comply with any and all applicable safety standard regulation or law and take appropriate safety measures for the system in which the Product is installed or used and shall take the second or third safety measures other than the Product MELCO is not liable for damages that could have been prevented by compliance with any applicable safety standard regulation or law 2 MELCO prohibits the use of Products with or in any application involving and MELCO shall not be liable for a default a liability for defect warranty a quality assurance negligence or other tort and a product liability i
148. tion A with EFI1 A on station B etc Figure 19 Connection of Flexi Link stations via EFI1 and EFI2 Note Connecting devices Chapter 4 0VDC 1 A2 Al A2J AT A2 AT A2 MITSUBISHI MITSUBISHI MITSUBISHI occo ATA foco JT Max 100 m No external termination resistor is required for EFI connections on the CPU Stub lines or star shaped wiring are not permitted The max permitted overall cable length all stations for EFI1 and EFI2 is 100 m each Unused conductors must be connected to FE on both ends All connected Flexi Link stations must have the same 0 V DC of the power supply terminal A2 of memory plug The max permitted voltage at EFI inputs is 30 V to terminal A2 0 V DC 62 Chapter 4 Table 49 Possible cable lengths and types for Flexi Link connections 63 Connecting devices Flexi Link cable The Flexi Link stations can be connected using CAN cables shielded twisted pair Cable length Type Up to 40 m 2x2x0 25 mm AWG 23 Up to 100 m 2x2x 0 34 mm AWG 22 SICK offers a suitable cable for connection lengths up to 100 m Please also see Section 13 2 For cables please contact your local SICK representative see Section 14 5 http www sens control com EMC measures Please observe the notes in section4 9 Potential equalization Always connect the cable screen on both sides to earth potential Be aware that the earth potential may
149. tions The MELSEC WS safety controller supports applications up to Performance Level PL e in accordance with EN ISO 13849 1 and up to Safety Integrity Level SILCL3 in accordance with IEC 62061 The degree of safety actually attained depends on the external circuitry the realization of the wiring the parameter configuration the choice of the safety sensors and how they are mounted on the machine Take and evaluate these using e g a failure analysis FMEA For further information that has to be taken into consideration during the electrical installation see Chapter 7 Loss of the safety function through an incorrect configuration Plan and carry out configuration carefully The configuration of safety applications must be carried out with the greatest accuracy and must match the status and the condition of the machine or system to be monitored Check whether the configured safety application monitors the machine or system as planned and whether the safety of a configured application is ensured at all times This must be ensured in each operating mode and partial application Document the result of this check n each case observe the instructions for commissioning and daily checking in the manuals of the protective devices integrated into the safety application Note the warnings and function descriptions of protective devices connected to the MELSEC WS safety controller Contact the respective manufacturer of the protec
150. tive device if in doubt Take into account that the minimum switch off time of the connected sensors must be greater than the execution time of the logic see the chapter about the logic editor in the Safety Controller Setting and Monitoring Tool Operating Manual and the logic editor in the Setting and Monitoring Tool so that it is ensured that the MELSEC WS safety controller can detect the switching of the sensors The minimum switch off time of sensors is usually specified in the technical data of the sensors f an odd numbered test output is used odd numbered inputs have to be used If an even numbered test output is used even numbered inputs have to be used You have to use the test outputs of the module to which the device to be tested is connected ATTENTION Connecting devices Chapter 4 Protect single channel inputs against short circuits and cross circuits If a stuck at high error occurs on a single channel input with test pulses that was previously inactive the logic may see a pulse for this signal The stuck at high first causes the signal to become Active High and then after the error detection time back to Inactive Low again Due to the error detection a pulse may be generated Therefore single channel signals with test pulses need special attention e If the stuck at high occurs on a single channel signal input with test pulses that was previously Active High the logic will see a delayed Active High to I
151. tlonzzc ei IMBRE 67 5 1 2 Properties eiae eri rie belied JR rere d Pond eerie 67 5 71 93 UNCUONS A mte Mt po oM Eddie 68 5 1 4 Benefits oerte te mte e e dese ep te e t rivet toi esate 68 9 2 MULING m 69 6 Mounting Dismantling e Teeraa A emen 70 6 1 Steps for mounting the modules sssee eme 70 6 2 Steps for dismantling the modules ee 72 T Electrical installation ciii reden eic entree ae dod Fa dee dd oe Ya rada 73 7 1 Electrical installation requirements eccececceceeeeeeeeecaeceeeeeeeseesneneneeeeeeess 73 7 2 Internal circuit power supply sssssssssesseseemeee eene 75 8 Configuration iid ege ee desde delta eed te dea Pede el ce d cadens ue dd nd 76 9 GommlissSiOniriQ e iioii Apte iet e gr tn e ES Age E adt atem RUN 77 9 1 Full approval of the application sssssssssseeem 77 9 2 Tests before the initial commissioning essee em 78 JUSSI c 79 10 1 In the event of faults or errors sssssssssssseeeemeee eene 79 10 1 1 ERROR operating states sssssssseee eee 79 10 2 Error displays of the status LEDs error messages and rectificationvmeasWures 4 i deed ah ei digi pend 81 10 3 Additional error displays of SICK EFl compatible devices 88 10 4 Mitsubishi support sss e ener 88 10
152. ts are not as warranted and iv in any event the notice must given within the warranty period 2 Customer shall cooperate with MELCO and MELCO s representatives in MELCO s investigation of the warranty claim including preserving evidence ofthe claim and its causes meaningfully responding to MELCO s questions and investigation of the problem grant MELCO access to witnesses personnel documents physical evidence and records concerning the warranty problem and allow MELCO to examine and test the Products in question offsite or at the premises where they are installed or used and 3 If MELCO requests Customer shall remove Products it claims are defective and ship them to MELCO or MELCO s authorized representative for examination and if found defective for repair or replacement The costs of removal shipment to and from MELCO s designated examination point and reinstallation of repaired or replaced Products shall be at Customer s expense 4 If Customer requests and MELCO agrees to effect repairs onsite at any domestic or overseas location the Customer will pay for the costs of sending repair personnel and shipping parts MELCO is not responsible for any re commissioning maintenance or testing on site that involves repairs or replacing of the Products Repairs of Products located outside of Japan are accepted by MELCO s local authorized service facility centers FA Centers Terms and conditions on which each FA Center
153. ts with regard to EFI are available in the corresponding manuals of SICK products 5 1 1 Definition An EFI interface is a safe communication interface between SICK devices With it information from the sensor equipment can be read out as well as commands transferred to the sensor equipment 5 1 2 Properties Upto 4 SICK devices are possible per EFI line in as far as the SICK EFI compatible devices support this number Connection of the devices using a 2 wire cable Various device combination possibilities Sensor with sensor within the same product family Sensor with safety controllers and network modules Connection of up to four WSO0 CPU1 or WS0 CPU3 modules in a Flexi Link system see Section 4 7 Transferring of status information process data between SICK devices using an EFI interface Transferring the configuration from the Setting and Monitoring Tool to the SICK EFl compatible devices Uploading the configuration from the SICK EFI compatible devices to the Setting and Monitoring Tool Activation utilization of sensor functions 67 Special functions Chapter 5 5 1 3 Functions In addition to the product specific functions of the respective SICK EFI compatible devices the following functions are available General functions Status information process data of the SICK EFI compatible devices are available in the MELSEC WS safety controller and at the sensor Diagnostics information of all the S
154. ty switches e g SICK IN4000 and IN4000 Direct Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO IN4000 Test input TE IN4000 at X1 x1 Output A IN4000 at 11 IN4000 Direct pes OSSD1 IN4000 at I3 with OSSD OSSD2 IN4000 at 14 Function Notes Testing Necessary on IN4000 Series connection cascading IN4000 direct cannot be cascaded IN4000 up to 6 sensors per input Max off on delay of the cascade 10 ms otherwise the test gap will lead to switching off Observe the max line resistance of 100 Q and the correct setting of the test pulse time Further information is available in the manuals of the SICK inductive safety switches or in the manuals of devices used 54 Chapter 4 Table 39 Connection of transponders Table 40 Functions of transponders Note Table 41 Connection of testable Type 2 single beam photoelectric safety switches Note 55 Connecting devices 4 2 3 Transponder e g SICK T4000 Compact and T4000 Direct Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO T4000 Compact 24 V at LA 11 at LA 24V n Ney connected to 24 V 24v 3 0 X 24 V at LB I2 at LB T4000 Compact X1 at LA I3 at LA x1 s NC connected to test output x2 3 n 2 X2 at LB IM at LB T4000 Direct with OSSD E de Oe 24 V at UB T4000 I5 at OA zE ud p s 24 V at UB T4000 I6 at OB
155. ule Table 60 Data sheet WSO 4RO Supply circuit via WS0 CPUx Power consumption Max 3 2 W Input circuit B1 B2 Input voltage ON 18 V DC 30 V DC Output circuit 13 14 23 24 33 34 43 44 Y1 Y2 Y3 Y4 Number of N O contacts 4 13 14 23 24 33 34 43 44 Number of N C contacts 2 Y1 Y2 Y3 Y4 Switching voltage 230 V AC 5 253 V AC 230 V DC 5 253 V DC Switching current 10mA 6A Mechanical endurance Min 10 x 10 Electrical endurance See Figure 32 Minimum contact load with U 24 V 50 mW DC Total current 8A Response time 30 ms Type of output Potential free N O contacts positively guided Contact material AgSnO Output circuit fusing 6 A gG per current path Usage category AC 15 Ue 250 V le 3A DC 13 Ue 24 V le 3A 1 SeeFigure 32 or Figure 33 2 Time from LOW on B1 B2 to relay drop out 107 Figure 32 DC load breaking capacity safety relay output module WS0 4RO Figure 33 Electrical endurance safety relay output module WSO 4RO Technical data Chapter 12 Max DC load breaking capacity 30 20 eo Resistive load DC voltage V DC 01 02 0 5 2 5 10 20 DC current A Electrical endurance Operation 250 V AC resistive load on 1 N O contact 0 1 2 3 4 5 6 7 8 Switc
156. ummaryPage Page 1 255 Total a F z BEN OSSD CPUT TOL 5 e f C400 XTIOL1 516 Robot xmonjasos of AB Configuration Logic Digital inputs WS0 XTIO 1 1516 C4000 One C4000 safety light curtain Digital outputs Input from EFI device WS0 XTIO 1 Q3Q4 Robot Robot dual channel WS0 CPU1 0 EFI1 1 0SSD OSSD one C4000 receiver stand alone safety light curtain with high resolution for hazardous point hazardous area and access protection at machines 2 paths have to be considered and calculated separately 94 Chapter 12 Figure 30 Response times within a MELSEC WS safety Technical data controller Digital Digital input output Input from EFI device C4000 stand alone receiver Occurrence In1 Digital inputs Out Digital outputs General C4000 response time 14 0 ms Robot response time 40 0 ms General Input processing time 6 5 ms Output processing time 4 5 ms When On Off filter 8 0 ms When X1 X8 is connected at the test output a Safety mats and bumpers b Testable sensors Type 4 e g L41 c All other sensors Total In1 20 5 ms Total Out1 44 5 ms Evaluation Response time of the considered input in the In1 20 5 ms 1 Inputs signal path path 1 D iest Besronselime ot thel dit 2 x logic execution time 8 0 ms edu P g Delay through logic application Response time of the considere
157. unting in the manual of the respective sensors and in particular the following points Single beam photoelectric safety switches may only be used as access protection in accordance with EN ISO 13855 Usage as finger and hand protection is not permissible Observe the minimum distance to reflective surfaces e tis imperative that the safety distance between the light beam and hazardous point be observed at access protection 2 4 3 S Sender 1 Limit to hazardous area R Receiver 2 Reflective surface D Distance between sender and 3 Direction of access to hazardous receiver area a Minimum distance from reflective 4 Optical axis surfaces Figure 17 Minimum distance a as a factor of the distance D for testable single beam photoelectric safety switches with a field of view of 10 e g SICK Wx12 18 24 27 Vx18 Note Figure 18 Mounting to avoid mutual optical influence Connecting devices Chapter 4 a mm 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 260 D m Diagrams for SICK L21 and L41 are available in the respective manual Avoiding mutual influence at single beam photoelectric safety switches and between cascades f several single beam photoelectric safety switch pairs are used the field of view of the sensors has to be observed in order to prevent mutual inf
158. ve the notes in Section 3 7 In addition this module has a Flexi Line interface that permits the safe networking of up to 32 MELSEC WS stations see Section 4 8 The CPU module WS0 CPU3 can only be operated together with the memory plug WSO MPL1 32 Chapter 3 Figure 6 Display elements WS0 CPU3 Table 11 Displays of the EFI LEDs on WS0 CPU3 33 Product description 3 7 2 Display elements and terminal description The indications on the MS and CV LEDs as well as the terminal assignment for the RS 232 interface are identical to the CPU module WSO0 CPUS see section 3 5 2 The indications on the EFI1 and EFI2 LEDs are identical to the CPU module WSO CPU1 see section 3 6 2 Memory plug AL A2 MITSUBISHI i e LED EFI1 USB interface 48 xii tol LED Eri Line predececcor B Line predececcor A LINE APREB ANEXIB A erm B A rro RI Line Successor A Line Successor B LINE LED Meaning Flexi Line not configured and not in operation Green Flexi Line in operation Green 1 Hz Flexi Line started waiting for neighboring stations Green 2 Hz Teaching required Red Green 2 Hz Flexi Line configuration required Red 1 Hz Error on the Flexi Line bus e g communication interrupted Red Critical fault Flexi Line stopped USB interface WS CPU3 module furthermore has a USB interface
159. wed after switching off the output Version 2 Q1 to Q4 V2 xx Not possible 3 ms 2 V3 10 Deactivated 3 ms Activated 43 ms The capacitance beyond the value that is permitted for the output as standard must be discharged to the low level in the customer s installation after switching off the output If this condition is not met within the maximum time allowed there will be a cross circuit fault on the output independent of whether the test pulses on this output are activated or deactivated Pay attention to the suitability of the programmable controller output card for the safety related shut down of the outputs by switching the supply voltage The safety related shut down capability can be affected or even lost as a result of the following faults Undetected cross circuit on an output on the programmable controller output card that can result in the reverse supply of the programmable controller output card In some circumstances this fault can be excluded by laying wiring in an adequately protected area Undetected fault on the programmable controller output card that can result in the external supply of the programmable controller output card by another live signal Extension of the response time by a buffer capacitor in the supply for the programmable controller output card Please note that the outputs on the WSO XTIO modules cannot discharge this buffer capacitor as it is normally behind a reverse polarizati
160. witching contacts Corresponding elements for implementing dual channel complementary switching contacts are available in the element window under the group named Potential free contacts and restart Function Notes Testing Possible Series connection cascading If emergency stop pushbuttons are connected in series the max line resistance shall not exceed 100 O see Chapter 12 Discrepancy times See Setting and Monitoring Tool Further information is available in the manual for the emergency stop pushbutton SICK ES21 or in the manuals for devices used 48 Chapter 4 Note Table 21 Connection of electro mechanical safety switches Table 22 Connection of interlocks Table 23 Functions of electro mechanical safety switches and interlocks Note 49 Connecting devices 4 1 2 Electro mechanical safety switches with and without interlock The contact symbols in this chapter show the switching status while the door is closed Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Single channel 24V F n Contact between 24 V and l1 output connected to 24 V E Single channel Contact between X2 and I2 connected to test x2 Fe 2 amp output Dual channel Channel 1 Contact between 24 V and I3 ay xd I3 T connected to 24 V i 4 Channel 2 Contact between 24 V and 14 Dual channel Channel 1 Contact between X1 and 15 con
161. with the following functions Transferring the configuration from the Setting and Monitoring Tool to the memory plug Uploading the configuration from the memory plug to the Setting and Monitoring Tool Diagnostics of the MELSEC WS safety controller with the Setting and Monitoring Tool Note Product description Chapter 3 3 8 WSO0 XTIO safety I O combined module 3 8 1 Description The WSO XTIO module is an input output extension with 8 safe inputs and 4 safe outputs It has two test signal generators One for test output X1 and one for test output X2 The WSO XTIO module offers the following functions Monitoring of the connected safety devices also refer to Chapter 4 Passing on the input information to the CPU module Receiving the control signals from the CPU module and corresponding switching of the outputs Fast shut off Direct shut down of the actuators connected to the module possible from firmware version V1 11 0 on the CPU module CPUO or CPU1 as well as with all firmware versions on the CPU module CPUS Version V1 2 0 or later of the Setting and Monitoring Tool required for this purpose This feature significantly reduces the response time of the overall system For Switching off outputs only 8 ms have to be added to the response times of the devices connected to the inputs and outputs The response time on the FLEXBUS backplane bus as well as the logic execution time are irrelevant in this case

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