INSTRUCTION MANUAL AS-Interface Safety at Work VAA-2E
Contents
1. Strobe A gt Fig 4 1 Code generation Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 7 8 VAA 2E G4 SE Operating Principles of the input channels The safety monitor goes into the safe state without reporting a malfunction as soon as the code word 0000 is received If one bit of a 4 bit code word differs from the ex pected code word the safety monitor actuates the safe state for the equipment and indicates a fault The two input channels are independent The safety monitor evaluates the synchro nicity of two input signals depending on its configuration Shield OSSD1 OSSD2 OV Receiver ransmitter Shield ov 24V Functional ground FG Ground connection via cage clamp terminal Fig 4 2 example a light curtain with 2 outputs uses both channels of the module 2005 09 07 Date of Issue Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 VAA 2E G4 SE Co2. 1 Declaration of conformity 2 The AS Interface Safety Module VAA 2E G4 SE offering 2 safety inputs designed for two channel ESPE electro sensitive protective equipment for instance safety light curtains and light grids was developed and manufactured in observance of applica ble European standards and regulations O A declaration of conformity can be obtained from the manufacturer Il Note The manufacturer of this product Pepperl Fuchs GmbH in D 68307 Mannheim re tains a certified quality system in accordance with ISO 9001 ISO9001 CE Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Symbols used in this document 2 Symbols used in this document This symbol warns of danger STOP In the event the warning is ignored the consequences may range from personal injury to death of persons or from damage to destruction of Warning equipment This symbol warns of a possible fault Failure to observe may result in damage to the device or systems and installations connected to it up to and including compete lack of proper Attention functionality O This symbol brings important information to your attention lIl Note Subject to reasonable modification
3. 24V DC Functional ground FG Ground connection via cage clamp terminal Fig 6 1 A connected device with two short circuit monitored inputs It is necessary for the safety monitor to verify synchronous deactivation of input chan nels SE1 and SE2 This can be achieved by defining the devices as two channel forced or two channel dependent inputs in the configuration of the safety monitor Safety classification The module offers two independent and redundant input channels When both inputs channels are used a safety application up to category 4 according to EN 954 1 and or SIL 3 according to EN IEC 61508 and or Type 4 according to EN IEC 61496 1 can be implemented Channel short circuit monitoring ESPE usually monitor their outputs by applying appropriate test signals These test signals are designed to determine short circuits between channels and between a channel and the supply power Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Implementation 7 Implementation 7 1 Configuration requirements for the safety monitor Organizational measures necessary for the configuration of the safety monitor are given in the safety monitor docum
4. generate test pulses on the module inputs The width and fre quency of these test pulses are typically listed in the user manual or data sheet of the safety device 07 Positive test pulses must stay within the limits listed in the data sheet Warning 6 3 Shielding Terminals marked as Shield can be used as a feed through for ground connections and shields In order to be used as a shield one terminal must be connected to a ma chine ground or other suitable ground Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 1 1 VAA 2E G4 SE Interface properties 6 4 6 4 1 6 4 2 6 4 3 12 Inputs General For a Type 4 application according to EN 61496 the ESPE must provide two safe out put signals The device must be able to check for a short circuit between output sig nals as well as a short circuit to the supply voltage In this case safety systems can achieve SIL 3 according to EN 61508 or category 4 according to EN 954 1 7 Supply Supply ov 24V DC Shield OSSD1 OSSD2 Receiver 6 5 SE2 oll m m 3 p Coed jog ge 2 1 Supply Supply 24vDC 0v 8 9 Supply Supply Shield OV
5. management has the responsibility to comply with the require l ments of local regulations Note 3 3 Transfer time of safety relevant information The module shuts down in less than 10 ms The overall shut down time can be deter mined by summing up the shut down times of all peripheral devices connected to the safety system i e ESPE safety monitor expansion relays and any additional sec ondary switches Refer to the appropriate user documentations Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 5 VAA 2E G4 SE Safety 3 4 6 PFD Calculation In order to calculate the PFD probability of dangerous failure on demand of a safety related function it is crucial to consider the PFD values of all components used in this function At low demand rates the average PFD depends on the average environmental tem perature Ta 40 C Ta 55 C PFD 25 10 47 105 Ata high demand rate for the safety function the average probability of dangerous fail ure per hour PFH of the safety function is Ta 40 C Ta 55 C PFH 1 54 1091 n 3 10 94 h These values apply to equipment use for up to 10 years PFD and or PFH values of other components especially the safety monitor are found in their respective documentations S
6. FACTORY AUTOMATION AS Interface Safety at Work VAA 2E G4 SE Version 1 0 CE FJ PEPPERL FUCHS With regard to the supply of products the current issue of the following document is applicable The General Terms of Delivery for Products and Services of the Electrical Industry published by the Central Association of the Elektrotechnik und Elektroindustrie ZVEI e V in their most recent version as well as the supplementary clause Extended reservation of title We at Pepperl Fuchs recognise a duty to make a contribution to the future For this reason this printed matter is produced on paper bleached without the use of chlorine Date of Issue 2005 09 07 VAA 2E G4 SE Table of contents 1 Declaration of conformity 00 00 eee eee eee ees 2 2 Symbols used in this document 0 000 cece eee eee eee 3 3 Safety co cc beceee did teed ae dd wheel dine a aa aae es 4 3 1 Intended USG 2 26 cca sees cece ete eee dae eae Ra teas Bee lee ed 4 3 1 1 Safety Monitor requirements 00 cect eee 4 3 1 2 Wiring requirements c0c cs cece eee eke be dew ceeded eee eee eee eee eae 4 3 1 3 Light grids and light curtains 0 0 eee 5 3 2 General safety instructions 0 0 eects 5 3 3 Transfer time of safety relevant information 20 020e eee eeees 5 3 4 PFD Calculation 2 02000 cece eee nee eee eee eee eee 6 4 Operating Principles of the input channels 0200005 7 5 Connecti
7. ated parts of the machine control __ If a fault occurs it may system and or their components must be result in a loss of the safety designed constructed selected put together function and combined to meet the requirements of the corresponding standards in such a manner as to By selection of be able to withstand anticipated effects components 1 The requirements of B must be met As described for Category Use of components and principles with proven B but with higher safety safety related effectiveness related reliability of the safety function 2 The requirements of B and the use of compo e The occurrence of a fault nents and principles with proven safety related may result in a loss of the effectiveness must be satisfied The safety func safety function between tion s must be tested at appropriate intervals of testing intervals time by the machine control system e Loss of the safety function NOTE will be detected by the What is suitable depends on the application and test the type of machine 3 The requirements of B and the use of compo e If the individual fault nents and principles with proven safety related occurs the safety function effectiveness must be satisfied still remains intact The control systems must be designed in such a Some but not all faults are manner that detected e an individual fault in the control system does e An accumulation of not result in a loss of the safety function and unkn
8. entation 7 2 Installation Connecting the G4 series module to AS Interface is accomplished by using the ap propriate mounting base sold separately When using yellow AS Interface flat cables VAZ FK S YE and black Uay flat cable VAZ FK S Bk the module is connected using either a U G1FF or U G1FFA mount ing base Alternatively the mounting base U G1PP can be used with either round or flat cable To obtain IP67 protection the mounting screws on the module must be tightened such that the support points on the module bottom side make even contact with the mounting base Attention During the installation the unit must to be kept free of dirt and humidity Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 1 3 VAA 2E G4 SE Implementation 7 3 7 4 14 Cable bended ca 5 cm r TT ca 6 mm Connect the den insulated sensor actuator cable in sequence 3 4 2 1 Transmitter receiver and ground connections are connected via cage clamp termi nals Refer to chapter 5 1 for more information Module addressing The module can be addressed by using a handheld addressing device or the AS In terface master When using the handheld addressing device the AS Interface slave is simply inserted into it
9. ilding 18 Ayer Rajah Crescent Singapore 139942 Company Registration No 199003130E Tel 65 67799091 Fax 65 68731637 E mail sales sg pepperl fuchs com Subject to reasonable modifications due to technical advances Copyright PEPPERL FUCHS e Printed in Germany Singapore FJ PEPPERL FUCHS TDOCT 0862AENG Partno 182362 09 2005
10. nnections and LED indications 5 Connections and LED indications 5 1 Connections Terminal Function Description 1 Supply 24V power supply 1 receiver 2 Supply OV power supply 1 receiver 3 SE1 input signal 1 4 n c 5 SE2 input signal 2 6 Supply OV power supply 2 receiver 7 Supply 24V power supply 2 receiver 8 Supply 24V power supply 3 transmitter 9 Supply OV power supply 3 transmitter 10 Shield functional ground for transmitter 11 Shield functional ground for the module 12 Shield functional ground for receiver 13 n c 14 n c AS Interface yellow flat cable and auxiliary power U aux black flat cable are con nected using an appropriate mounting base sold separately Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 9 VAA 2E G4 SE Connections and LED indications 5 2 LED indication Function Description FAULT fault indication LED red AS Interface communication error and or module address is 0 PWR AS Interface power on LED green AUX auxiliary power Uayy present LED green SE1 input channel 1 indicating run mode LED yellow SE2 input channel 2 indicating run mode LED yellow Subject to
11. ons and LED indications 0e cece eee 9 5 1 Connections 2 6 esc ecer ieee eee ten ed eee eee ieee edad ae 9 5 2 LED indication aii eis ee asccsicice pd orsoni irist imni ee Reda E NEDE mia 10 6 Interface properties 0 cece eee eee eee 11 6 1 AS Interface auxiliary power 0 0 eee eee eee eee 11 6 2 Transmitter and receiver 0 0c eects 11 6 3 Shileldingiensenigeeiseaneeecterseoncedeaw newman EAEE 11 6 4 INPUTS 26S etre es teens eet eee tee eee ek meee Eee ates 12 6 4 T General es aieeaa ee ree ee ee aea EE 12 6 4 2 Safety classification uus eee eee 12 6 4 3 Channel short circuit monitoring 00 0 e eee 12 7 Implementation 0 00 cee eee 13 7 1 Configuration requirements for the safety monitor 020e0eeeee 13 7 2 Installation 6 oc cece cece scrie niiata ee Ce eee ee ee ee 13 7 3 Module addressing 0 00 e cece eee eee eee eee eee eee 14 7 4 Functionality Test 0 cc cece eee eee eee 14 8 AS Interface safety module 0 00 cece eee eee eee 15 9 Certificates srescerad r ids birai eaaa ea E aaa a 15 A Summary of the requirements for categories 0 055 16 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 1 VAA 2E G4 SE Declaration of conformity
12. ons in the user documentation must be followed The AS Interface monitor must fulfill the require ments of the system specifications version 2 01 dated 12 05 2000 Spezifikation der sicheren AS Interface Uebertragung or higher In order to evaluate a safety related function based on a safety standard all compo nents of the function have to be evaluated according to the same safety standard The correct execution of a desired safety function also depends on the proper con nection and configuration of the AS Interface safety monitor This also applies to the desired reaction when safety codes are corrupted or the unit exhibits a hardware fault refer to the documentation of the AS Interface safety monitor The safety function including all attached safety devices must be tested before the first startup The minimal requirement for the safety classification of the safety monitor needs to match the safety classification required by the application Wiring requirements The demands of the EN IEC 60204 1 or similar standard must always be consid ered The requirements for the external wiring and the selection of connected safety devices depend on the desired functionality as well as on the required safety classifi cations EN 954 1 or EN IEC 61508 Wires have to be safeguarded against simultaneous short circuit connections of the inputs SE1 and SE2 to the positive supply Subject to reasonable modifications due to technical advances Cop
13. own faults may result by the structure e the individual fault is detected whenever it is in a loss of the safety practical to do so in a reasonable manner function 4 The requirements of B and the use of compo If errors occur the safety nents and principles with proven safety related effectiveness must be satisfied The control systems must be designed in such a manner that e an individual fault in the control system does not result in a loss of the safety function and e the individual fault is detected during or before the next requirement for the safety function If this is not possible then it must not be possible for an accumulation of faults to result in loss of the safety function function still remains intact The fault is detected with sufficient time to prevent a loss of the safety function 1 The risk evaluation indicates whether the complete or partial loss of safety function s resulting from 16 the occurrence of faults is acceptable Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 With regard to the supply of products the current issue of the following document is applicable The General Terms of Delivery for Products and Services of the Electrical Industry p
14. reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany 1 0 Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Interface properties 6 Interface properties 6 1 AS Interface auxiliary power AS Interface and auxiliary power U aux are connected by using an appropriate mount ing base The AS Interface connection is reverse polarity protected and the maximum available current is internally limited The auxiliary power connection is also protected against reverse polarity The module is protected against overloads on its ouputs by a self healing fuse 6 2 Transmitter and receiver Transmitter and receiver are connected by spring terminals Every lead of the cable from the safety device must be connected to a terminal on the connection block This is necessary to prevent the occurrence of internal short circuits The power supply terminals may be used arbitrarily The two supply power connections on the terminal block inside the module are at the same potential and overload protected with respect to auxiliary power When auxilia ry power is reversed the auxiliary power on the terminal block of the module is also reversed The inputs are designed to be power limiting and operate according to EN IEC 61496 1 and EN 61131 2 ESPE are permitted to
15. s head and then addressed The module is preset to address 0 and can be set to addresses 1 through 31 Functionality Test Functionality tests must be performed as a part of the installation Because the con nected ESPE employ short circuit monitoring between channels additional short cir cuit testing of the cabling is not necessary Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Certificates 8 AS Interface safety module The safety function of the module depends on the proper configuration of the safety monitor refer to the documentation of the AS Interface safety monitor 9 Certificates Certified according to EN 954 1 EN IEC 61496 1 and EN IEC 61508 Subject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 1 5 VAA 2E G4 SE Summary of the requirements for categories A Summary of the requirements for categories to EN 954 1 ISO 13849 1 1 gt Summary of requirements System behaviour Important prin 9 ciple for 2 achieving Oo safety B The safety rel
16. s due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http www pepperl fuchs com 3 VAA 2E G4 SE Safety 3 Safety 3 1 Intended use 3 1 1 4 The AS Interface safety module permits the connection of one two channel ESPE to safeguard danger zones or areas in a system utilizing AS Interface Safety at Work It must be used as intended with a properly configured AS Interface safety monitor and a suitable ESPE safety light curtain or light grid with electronic OSSDs This allows the implementation of safety applications up to Category 4 according to EN 954 1 and or SIL 3 according to EN IEC 61508 as well as Type 4 based on EN IEC 61496 1 The safety requirements for the application are determined by either a risk analysis i e based on EN 1050 or derived from a C standard In addition to the instructions included in this user manual all applicable safety re quirements standards and regulations as well as operating instructions for the con nected peripheral devices must be considered Protection of operating personnel and equipment is not ensured if the module is not used in accordance with its intended use Warning Safety Monitor requirements The module shall only be used as a safty slave in an AS Interface network and must be connected to a suitable AS Interface safety monitor All instructi
17. ubject to reasonable modifications due to technical advances Copyright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Operating Principles of the input channels 4 Operating Principles of the input channels The safety module generates a code sequence of 4 bit code words A safety monitor evaluates the correctness of the code sequence As soon as the connected periph eral device reports an undisturbed operation of the application to the module the code sequence is transmitted through the AS Interface network If the safety monitor determines a code sequence as being incorrect it starts the tran sition to a safe system state based on its configuration If the peripheral device sig nals the activation of the safety function the transmission of the code sequence is terminated The module has two inputs for two separate and independently operating input chan nels Each channel operates on two of the 4 bit code words Both channels are required when connecting a safety device If the safe state is initi ated 4 bit code words with the value 0000 will be transmitted SE1 SE2 Pulse filter AS Interface P O 1 B amp Th Chip Diag 2mA 5 i 5V aa e lt La amp STL o O Code 5 N Generator E p Diag 2 mA
18. ublished by the Central Association of the Elektrotechnik und Elektroindustrie ZVEI e V in their most recent version as well as the supplementary clause Extended reservation of title We at Pepperl Fuchs recognise a duty to make a contribution to the future For this reason this printed matter is produced on paper bleached without the use of chlorine te N y F SIGNALS FOR THE WORLD OF AUTOMATION For half a century Pepperl Fuchs has been continually providing new impetus to the world of automation We develop manufacture and market electronic sensors and interface modules through our worldwide network Our global presence and highly flexible production and service organisations enable us to offer you complete individual solutions right where you need us We know what we are talking about because today Pepperl Fuchs is the company with the largest selection of industrial sensor technology in the world serving an exceptionally broad spectrum of applications Our signals move the World Twinsburg Mannheim Worldwide Headquarters Pepperl Fuchs GmbH K nigsberger Allee 87 68307 Mannheim Germany Tel 49 621 776 0 Fax 49 621 776 1000 E mail info de pepperl fuchs com USA Headquarters Pepperl Fuchs Inc 1600 Enterprise Parkway Twinsburg Ohio 44087 USA Tel 1 330 4253555 Fax 1 330 4254607 E mail sales us pepperl fuchs com Asia Pacific Headquarters Pepperl Fuchs Pte Ltd P F Bu
19. yright Pepperl Fuchs Printed in Germany Pepperl Fuchs Group Tel Germany 49 621 776 0 USA 1 330 4253555 Singapore 65 67799091 Internet http Avww pepperl fuchs com Date of Issue 2005 09 07 Date of Issue 2005 09 07 VAA 2E G4 SE Safety 3 1 3 Light grids and light curtains Safety systems must use ESPEs that satisfy EN IEC 61496 1 and offer short circuit protection between channels Type SLC and SLPCM light curtains devices with an integrated controller are recommended For application details refer to the user man uals of the connected safety devices The time limits for positive test pulses given in the data sheets must be observed 3 2 General safety instructions Any operation differing from what is described in this user manual may STOP compromise the safety and functionality of the connected system Warning The module should only be used by trained operators according to these instructions Installation and maintenance of the module under power shall only be performed by trained electricians If malfunction of the module cannot be corrected it must be taken out of operation and safeguarded against being inadvertently put back into operation Repair work shall only be performed by the manufacturer Alterations of or on the device are prohibited and void any warranty claims The requirements for the installations of a housing in IP67 applications need to be checked before operating the device Plant
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