* Evaluated by TÜV Rheinland (Report No. 968/FSP 1228.00/16 - 503) & (Report No. 968/V 1045.00/18 – 501/502)
in accordance with ISO 13849-1 and ISO 13849-2.
CAUTION
CAUTION symbol
indicates a possible hazard which may cause injury or equipment damage.
NOTE symbol indicates information useful to the user.
ATTENTION symbol indicates important information regarding installation and setup.
ZONED SAFETY MANIFOLD Technical Manual
Conditions for use of this product
(1) AVENTICS Manifold ("the PRODUCT") shall be used in conditions;
i) Where any problem, fault or failure occurring in the PRODUCT, if any, shall not lead to
any major or serious accident.
ii) Where the backup and fail-safe function are systematically or automatically provided
outside of the PRODUCT for the case of any problem, fault or failure occurring in the
PRODUCT.
(2) The PRODUCT has been designed and manufactured for the purpose of being used in general
industries.
ASCO L.P. shall have no responsibility or liability including but not limited to any and all
responsibility or liability based on contract, warranty, tort, product liability for any injury or death
to persons, loss or damage to property caused by the product that are operated or used in
application not intended or excluded by instructions, precautions or warnings contained in
AVENTICS Technical, User, Instruction, Safety Manuals, I&M Sheets or Bulletins.
Precautions
Before using this product, please read this manual and the relevant manuals in their entirety,
carefully and pay attention to safety and product application. The following symbols are used in
the manual to identify important safety, installation and application information.
NOTE!
!
TDG3ZSTM1-5EN 08/20
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CAUTION
ZONED SAFETY MANIFOLD Technical Manual
Electrical installation and operational guidelines
All AVENTICS communication nodes should be grounded during the installation process.
These grounding guidelines can be found in National Electrical code IEC 60204-1 or EN
60204-1.
All AVENTICS G3 Electronics Products to be installed or wired in accordance with AVENTICS
published instructions and applicable electrical codes. The following shall apply per UL, if
required.
To be connected to a Class 2 power source only.
Class 2 Device Wiring Only – Do Not Reclassify and Install as Class1, 3 or Power and
Lighting Wiring.
Wire connection shall be rated suitable for the wire size (lead and building wiring)
employed.
SYSTEM MAXIMUM MODULES: Up to a maximum 16 I/O modules (units) can be connected
to 1 Communication Module not including any Sub-Bus and Miscellaneous modules, or
equivalent.
CLASS 2 WIRING: All field wiring shall be suitable for Class 1, Electric Light and Power, or
Class 2, 3 wirings are routed separately and secured to maintain separation between
1) Class 2 wiring and all other class wiring, and
2) Limited energy circuit conductors from unlimited energy circuit conductors.
MULTIPLE CLASS 2 POWER SOURCES: When interconnected, class 2 sources shall be Listed
and rated suitable for parallel interconnection.
When using molded connector power cables, Do Not rely on wire colors for Pin-Out. Always
use pin number references.
TDG3ZSTM1-5EN 08/20
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ZONED SAFETY MANIFOLD Technical Manual
Safety Information
The Zoned Safety Manifold (501, 502 & 503) have been evaluated by TÜV Rheinland ® (Report No.
968/FSP 1228.00/16 – 503 and Report No. 986/V 1045.00/18 – 501/502 to satisfy the
requirements of ISO 13849-1 Type-B for use in pneumatic safety related applications. The Zoned
Safety Manifold is part of a Safety System as a Safety Related Part (SRP) and can be used in Safety
Systems up to Category 3 PLd; with appropriate external safety control functionality (e.g.
monitoring, timing, pulse test, etc.) and insuring that adherence to all related Safety Standards are
met. Per ISO 13849, the end user or third-party organization must evaluate and certify adherence
of the complete Control System (CS) including all SRPs. Reliability data of our pneumatic
components can be given upon request. More details on sample applications and technical
information can be found in our technical manual available on our website.
In accordance with ISO 13849-2 specifications, both safe and standard components must be
powered using an SELV/PELV DC power supplies.
In order to ensure that cross talk of internal 0 VDC & 24 VDC channels is not possible, each
external supply line (0 VDC & 24 VDC) to the component must be interrupted using a dual channel
safety relay or dual channel safety output device.
When used in certain environments that can have conductive dust, water or other media that can
cause internal conduction, an appropriate cabinet or enclosure shall be used.
When valves with Manual overrides are selected for the U-Wiring and X-Wiring manifold blocks,
adequate measures must be taken to prevent any hazardous situations that may occur (e.g. use
the diagnostic feedback of the DC elements as identification on a display).
Machinery Directive and Related Standards:
Machinery Directive (MD) 2006/42/EC
ISO 13849-1
ISO 13849-2
IEC 62061
EN ISO 12100-1
ISO 4414
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ZONED SAFETY MANIFOLD Technical Manual
Table of Contents
PAGE
1. Zoned Safety Manifold Introduction ......................................................................................................... 1-6
1.1 Overview ......................................................................................................................................... 1-6
1.2 ZONED SAFETY Manifold Features .................................................................................................... 1-6
2. Zoned Safety Manifold (SRP/CS) .............................................................................................................. 2-7
2.1 Zoned Safety Manifolds .................................................................................................................... 2-7
2.2 Zoned Safety - Zoned Power Manifold Base ("X" Wiring) ................................................................. 2-8
2.3 Zoned Safety – Pilot Valve Manifold Base ("U" Wiring) .................................................................... 2-8
2.4 Zoned Safety – Auxiliary Port 4 Sandwich Block .............................................................................. 2-9
2.5 Zoned Safety – Pilot Separation Sandwich Block ............................................................................. 2-9
2.6 Pilot Separation – Zoned and Individual ........................................................................................ 2-10
2.7 Zoned Safety Control System Connection Diagram ........................................................................ 2-11
3. G3 Protocol Support / Configuration ...................................................................................................... 3-12
3.1 Protocol Support ............................................................................................................................ 3-12
3.2 Zoning Safety Configuration – Display ........................................................................................... 3-13
3.3 Zoned Safety Configuration – Web Server ..................................................................................... 3-14
4. Zoned Safety Manifold Mapping ............................................................................................................. 4-16
4.1 Zoned Safety Manifold Mapping ..................................................................................................... 4-16
4.2 Zoned Safety Manifold Data Sizing Worksheet (EtherNet/IP DLR Example) .................................. 4-17
4.3 Zoned Safety Mapping Example #1 (EtherNet/IP DLR Node – 503) ............................................... 4-18
4.4 Zoned Safety Mapping Example #2 (EtherNet/IP DLR Node – 503) ............................................... 4-20
4.5 Zoned Safety Mapping Example #3 (EtherNet/IP DLR Node – 501) ............................................. 4-22
5. Zoned Safety Web Server ....................................................................................................................... 5-24
5.1 Node Configuration ........................................................................................................................ 5-24
5.2 Diagnostics .................................................................................................................................... 5-25
6. Zoned Safety Circuit Examples/Analysis ................................................................................................ 6-27
6.1 Example #1 Automated Assembly Machine .................................................................................... 6-27
6.2 Example #2 Automated Insertion Tool .......................................................................................... 6-32
6.3 Example #3 Clamping Weld Fixture ............................................................................................... 6-37
7. Appendix ................................................................................................................................................ 7-42
7.1 System Specifications .................................................................................................................... 7-42
7.2 Factory Default Settings ................................................................................................................ 7-42
7.3 Troubleshooting/Error Messaging ................................................................................................. 7-42
7.4 Glossary of Terms .......................................................................................................................... 7-43
7.5 Technical Support .......................................................................................................................... 7-43
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ZONED SAFETY MANIFOLD Technical Manual
1. Zoned Safety Manifold Introduction
1.1 Overview
The Zoned Safety Manifold is intended to be used in pneumatic circuits to provide functional safety in
accordance with the Machinery Directive 2006/42/CE and the ISO 13849 standards. This unit is an
integrated assembly that incorporates the required Output Devices (SRP/CS), necessary to satisfy up to
Category 3 of ISO 13849-1; see Category 3 architecture, below from ISO 13849-1. The Zoned Safety
Manifold must be connected to the G3 Platform of AVENTICS Fieldbus Electronics.
Unique components (in yellow) represent the Output Device in each channel identified above. The
complete Zoned Safety Manifold integrates these required functions into and easy to render pneumatic
system that allows for the required Safety adherence. See section 2 for further breakdown of the
complete Zoned Safety Manifold. Complete adherence up to Category 3 requires implementation of the
Input Device and Logic Element in addition to the Zoned Safety Manifold.
1.2 ZONED SAFETY Manifold Features
Features Description
G3 Support Functional with all ETHERNET based Fieldbus protocols (See Sec. 3.1)
Up to Category 3 PLd Evaluated against ISO 13849-1 & 2, by TÜV Rheinland
Multiple Zones One manifold supports up to 3 Safety Zones, up to 16 coils each
Integral Pilot Valve(s) Pilot valve support integral to manifold, can be external if required
Standard Valve Support Up to 32 coil capability, in one Standard area (in addition to Safety Zones)
Pilot Separation Optional Pilot Separation of power valves
Z
O
N
E
D
S
A
F
T
E
Y
501 Zoned Safety shown
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ZONED SAFETY MANIFOLD Technical Manual
2. Zoned Safety Manifold (SRP/CS)
2.1 Zoned Safety Manifolds
The Zoned Safety Manifold incorporates the required pneumatic SRP/CS (Safety Related Parts of a
Control System) into a single manifold assembly.
The following sub sections detail the various groupings and individual components that make up the
Safety Manifold Zone(s). The manifold example below only represents two of the possible three zones.
For complete detail of the Zoned Safety Manifold assembly and I/O mapping; refer to Section 4 of this
Technical Manual.
Power Valves
Zone #2
Power Valves
Zone #1
SAFETY MANIFOLD ZONE(s)
(SRP/CS)
PILOT
VALVES
SRP/CS
Pilot Valve
Zone #2
STANDARD
VALVES
Pilot Valve
Zone #1
G3 Electronics
NOTE!
502 and 503 represented above, 501 similar in capability but without the support of the Port
4 Sandwich block or the Pilot Separation Block.
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501 & 503
501 &
503
2.2 Zoned Safety - Zoned Power Manifold Base ("X" Wiring)
ZONED SAFETY MANIFOLD Technical Manual
The Zoned Power Manifold base with the M12 connector, supplies power to the integrated valve
solenoid drivers and routes the output signals to any additional manifold base(s) connected within a
zone. Up to (16) valve solenoid coils can be controlled in each zone. All connected valve solenoid coils
are controlled from the attached G3 node. The M12 connector must be externally supplied from a
Safety Relay or Safety Output via a Safety PLC. This becomes one of the redundant channels for a
Category 3 application.
The valve(s) mounted on the Zoned Power Manifold Base and subsequent valve manifold bases, are
referred to as "Power Valves". They drive the pneumatic actuators in a pneumatic safety circuit;
providing one of the pneumatic channels of a Category 3 circuit.
502 & 503
501
1
2
3
4
Pin #1 = No Connection
502
1
2
Pin #2 = No Connection
Pin #3 = 0 VDC
Pin #4 = + 24 VDC Safety Power
4
3
Connector orientation identified above
2.3 Zoned Safety – Pilot Valve Manifold Base ("U" Wiring)
The Pilot Valve Manifold Base controls the mounted pilot valves via the M12 connector, isolated from
the connected G3 node. Supply air, Exhaust and Pilot air are common with the other manifold blocks.
The M12 connector must be externally supplied by a Safety Relay or Safety Output via a Safety PLC.
This becomes one of the redundant channels for a Category 3 application.
The valve(s) is used to supply Pilot Operated (PO) Check Valves, Rod-Locks, Pilot Operated Spring
Return Valves, etc. The pilot valve(s) along with external pneumatic components provide one of the
pneumatic channels of a Category 3 circuit.
NOTE!
502 & 503
501
1
2
3
4
Pin #1 = No Connection
502
1
2
Pin #2 = No Connection
Pin #3 = 0 VDC
Pin #4 = + 24 VDC Safety Power
4
3
Connector orientation identified above
Test pulses from electronic safety output devices will cause the valve’s solenoid LED connected to
the "U" wiring manifold type to flicker at the same rate as the safety output pulse test and make it
appear dimmer than the other solenoid LEDs. This is normal and will not harm any of the
components including the solenoid valve. The "X" wiring manifold option does not exhibit this
dimming effect as it contains dedicated zone drivers which help to reduce this effect.
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Pin #1 = + 24 VDC
Fitting
– 502/503
port from Auxiliary Port
2.4 Zoned Safety – Auxiliary Port 4 Sandwich Block
ZONED SAFETY MANIFOLD Technical Manual
The Auxiliary Port 4 Sandwich Block assembly mounts beneath the Pilot Valve(s), incorporating the
AP10 pressure switch for indirect monitoring of the Pilot Valves, and providing Diagnostic Coverage.
This block also allows for the routing of air from port 4 of the Pilot Valve Manifold Base, to supply pilot
pressure to the Pilot Separation Sandwich Block (Zoned or Individual) of the manifold; see Sec 2.5 and
2.6. The Port 4 Sandwich assembly is available with or without pressure switch.
* Auxiliary Port 4 Sandwich
Block, not available for 501
Zoned Safety Manifolds
1
3
Pin #3 = 0 VDC
4
Pin #4 = Output
INB10-532-020 - Fitting – 502/503
129-100 – 1/8 Plug – 502/503
IN438-020-000 1/8 – 502
IN438-021-001 1/4 – 503
2.5 Zoned Safety – Pilot Separation Sandwich Block
A single Zoned Pilot Sandwich Block can be used in each zone to ensure complete disabling of pilot
pressure to all power valves within a zone. This ensures that the power valves cannot shift (manually
or electronically) unless pressure is supplied to this blocks supply port. Available with or without
fitting. Individual Pilot Sandwich Blocks are available for individual piloting of valves, see Sec 2.6. The
Pilot Separation Blocks are available with and without fittings.
* Pilot Separation Sandwich
Block, not available for 501
Zoned Safety Manifolds
INB10-532-020
Optional Pilot Supply
4 Sandwich
* Without pressure Sensor,
does not come with fitting
Port is either equipped with a plug (WITHOUT pilot zoning) or with a
Male Straight 5/32 (4mm) fitting (WITH pilot zoning).
The ports of the street T (WITH pressure switch) are NPT. For
applications that require the removal of the fitting or plug, and
BSPP/G ports, an adapter can be purchased, see catalog for details.
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X X
2.6 Pilot Separation – Zoned and Independent
ZONED SAFETY MANIFOLD Technical Manual
The option exists to provide pilot air to each zone or to individual valves in each zone, separate from
the Internal or External pilot supply that is provided from the endplates. Below represent some of the
different piloting options available.
Internally or Externally supplied from the Endplate(s)
Supplied from Port 4 Sandwich to Zoned Pilot Sandwich
X X
X
Supplied from Port 4 Sandwich to Individual Pilot Sandwich
X
X
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2.7 Zoned Safety Control System Connection Diagram
ZONED SAFETY MANIFOLD Technical Manual
This Diagram represents a typical application showing a
Safety PLC, Remote Safety I/O Module and a two zone,
Zoned Safety Manifold. This example represents one of
many control platform suppliers that can be utilized with a
Zoned Safety Manifold. The "X" and "U" manifold
connections require a safety output with monitoring and
diagnostics. Other safety output devices (e.g. Safety
Output Relays, etc.) can also be used to provide the
necessary safety output function to the "X" and "U"
manifold bases.
Pilot Zoning
Zone 2 Power
"X" Manifold Base
Connection Provides
Power for Zone 2 Valves
Zone 1 Power
"X" Manifold Base
Connection Provides
Power for Zone 1 Valves
EtherNet/IP
Safety I/O Module
Safety PLC
EtherNet/IP
Diagnostic
coverage of
Pilot Valves
Pilot Valve
"U" Manifold Base Connections
Provides Power and Control for
Pilot Valves
Allen Bradley is a
registered trademark of
Rockwell Automation
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ZONED SAFETY MANIFOLD Technical Manual
3. G3 Protocol Support / Configuration
3.1 Protocol Support
The Zoned Safety Manifolds must be connected to a G3 Electronics Node to operate. Not all G3
supported protocols will support the Zoned Safety Manifolds. Below is a list of the G3 protocols that
support the Zoned Safety Manifolds.
Zoned Safety Manifold Protocol Compatibility
Technical Manual No.
TDG3ENTM1-xEN 4.016
TDG3EDTM1-xEN 4.016
TDG3EMTM1-xEN 4.016
TDG3PNTM-xEN 4.016
TDG3PLTM1-xEN 4.016
TDG3ECTM1-xEN 4.016
Node Protocol
EtherNet/IP 240-181
EtherNet/IP DLR 240-325
Modbus TCP 240-292
PROFINET 240-240
POWERLINK 240-309
EtherCAT 240-310
G3 Technical Manuals can be downloaded from http://www.asco.com/en-us/Pages/fieldbus-technical-
document-search.aspx
The Zoned Safety Manifold can be configured to operate three separate and isolated zones. The
manifold will need to be configured to operate the connected zones; unless already configured from the
factory. Zone configuration for all protocols is the same. See section 3.2 and 3.3 for safety zone setting.
Nodes and Valve Driver assemblies with Firmware prior to the revisions listed are not
NOTE!
compatible with Zoned Safety. All information related to the G3 platform of electronics
and the specific protocol should be referenced in their respective Technical Manual. Each
Technical Manual can be found at www.asco.com.
Node
Part No.
Minimum Firmware
Revision
Rev. 1.01, Build 42389-2
Rev. 1.01, Build 42389-2
Rev. 1.01, Build 42389-2
Rev. 1.01, Build 42389-2
Rev. 1.01, Build 42391
Rev. 1.01, Build 42389-2
Minimum
Valve Driver
Firmware
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IP ADDRESS
192.168.3.120
3.2 Zoning Safety Configuration – Display
ZONED SAFETY MANIFOLD Technical Manual
The Safety Zone parameter can be set using the nodes integrated display. The menu system below
identifies the appropriate steps for setting the number of zones. This should match the number of safe
zones in the physical configuration of the Zoned Safety Manifold. If the manifold was assembled and
tested by ASCO, the correct number of zones will have already been configured prior to shipment.
IP ADDRESS
192.168.3.120
CONFIG MODE
STANDARD
SELECT COILS
32=STANDARD
SAFETY ZONES
NONE
SAFETY ZONES
NONE
SAFETY ZONES
1 SAFE ZONE
Pressing the SET button
for one of these screens
will initiate the
highlighted selection.
SAFETY ZONES
2 SAFE ZONES
SAFETY ZONES
3 SAFE ZONES
N O TE !
SAFETY ZONES
RETURN
RETURN TO
MAIN MENU
Pressing the SET button will
return the user to the next
root screen in the main menu.
WEB SERVER
ENABLED
Insure Firmware Revision and Valve Driver Part No. are compatible with Zoned Safety
Functionality; see Section 3.1.
Subject to change without notice
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Pressing the NEXT button will
return the user to the start of
the Config. Mode menu.
SELECT COILS
32=STANDARD
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3.3 Zoned Safety Configuration – Web Server
ZONED SAFETY MANIFOLD Technical Manual
Under the Node Configuration tab of the node's web server, there is the "Safety Zones" parameter. This
parameter allows the user the ability to change the supported number of Safe Zones to match the
physical configuration of the Zoned Safety Manifold. If the manifold was assembled and tested by
ASCO, the correct number of zones will have already been configured if manifold assembly is shipped
from the factory.
Number of Safety
Zones should only be
adjusted if an
additional Zone(s) has
been physically added.
As identified above,
the Safety Zone size
should have already
been selected prior to
test and ship. This
screen represents a
replacement node with
"Default" settings.
NOTE!
Web Page may vary slightly for each supported protocol. Refer to specific protocol's Technical
Manual for detail on commissioning. See Section 3.1 of this manual for supported protocols.
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ZONED SAFETY MANIFOLD Technical Manual
To adjust/set the appropriate number of zones, use the pull-down menu of the Safety Zones
parameter. As shown below, a maximum of (3) zones are available. If the number of zones chosen
does not match the physical configuration, error messaging will appear. Refer to section 7.3 for trouble
shooting/error messaging descriptions and correction.
Safety Zone
selection allows for
a Maximum of 3
Zones. Safety Zone
selection will not be
available unless the
Max Coils selection
is set to (32).
NOTE!
Web Page may vary slightly for each supported protocol. Refer to specific protocol's Technical
Manual for detail on commissioning. See Section 3.1 of this manual for supported protocols.
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The main power connection on the node only supplies valve power to the standard
Safe Zone
#2 (16)
503
502
50
1
ZONED SAFETY MANIFOLD Technical Manual
4. Zoned Safety Manifold Mapping
4.1 Zoned Safety Manifold Mapping
The Zoned Safety Manifold mapping section is meant to identify the mapping structure of the valve side
of the manifold. Example #2 incorporates one input module (240-205) for reference. Any additional
mapping structure related to the I/O side of the G3 electronics platform should be referenced in the
appropriate Technical Manual for that protocol; see Section 3.1 of this manual.
Below is a full rendering (sections) of a Zoned Safety Manifold. In addition to the 3 Safe Zone sections,
there are (32) additional standard coils that can be part of the assembly. These additional Non-Safe
coils, like the Safety Manifold section, are controlled from the attached G3 Node. Each Safe Zone is
identical in its functionality. They can be used to control separate adjacent cells or work stations and
can incorporate different Safety Functions.
Also, identified below are additional examples of Zoned Safety Manifold configurations with various
zones and Non-Safe sections.
!
Safe Zone #3 (16)
Valve Coil Capability
Valve Platform
coils. Up to 32 standard coils can be used for general purpose applications.
Valve Platform
Valve Coil Capability
Safe Zone #1 (16)
Valve Coil Capability
Pilot Valve
Section
Non-Safe (Standard use)
Zone (32) Coil Capability
Valve Platform
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4.2 Zoned Safety Manifold Data Sizing Worksheet (EtherNet/IP DLR Example)
ZONED SAFETY MANIFOLD Technical Manual
Step
: Choose appropriate value and place the corresponding Input and Output Size values in the boxes labeled, “Valve Byte
1
2
3
Valve Side
Step Zoned Safety Valve Side Description
Digital Modules Byte Sizes
Step Module No. Description
Analog Modules Byte Sizes
Step Module No. Description
Total Input (Status)/Output Size Calculation
Step Module Position Model Number Input (Status)Bytes Output Bytes
Requirements” at the bottom of the page. Non-Safe data is always present; Safe-Zone data is selectable.
: Choose up to sixteen modules to be included on the discrete I/O side of the manifold and place the sum of the corresponding
input bytes and output bytes in the boxes labeled, “Sub-Bus Byte Requirements” at the bottom of the page.
: Total the input byte and output byte values from the boxes labeled “Sub-Bus Byte Requirements” and “Valve Byte
Requirements” in the boxes labeled “Total Input and Output Bytes for Manifold. This is the total input and output byte values
required for the configured manifold.
Input Bytes
Status
Enabled
Up to 32 Solenoid Coils Standard Coil Area 4 0 4
1
2
2
2
1 Valve Side Byte Requirements:
2 I/O Byte Requirements:
3 Total Input and Output Bytes for Manifold
Up to 16 Solenoid Coils Safe Zone #1 2 0 2
Up to 16 Solenoid Coils Safe Zone #2 2 0 2
Up to 16 Solenoid Coils Safe Zone #3 2 0 2
Input Bytes
Status
Enabled
240-203/204 16 Inputs - Terminal Strip 3 2 0
240-205/209 16 Inputs - 8 x 12mm 3 2 0
240-206/210 8 Inputs - 8 x 12mm 2 1 0
240-207 16 Outputs - 8 x 12mm 2 0 2
240-208 8 Outputs - 8 x 12mm 1 0 1
240-211 8 Inputs / 8 Outputs - 8 x 12mm 3 1 1
240-241 Sub – Bus Valve Output 4 0 4
240-300 High Current 8 Outputs – 8 x 12mm 1 0 1
240-316 8 Inputs - Terminal Strip 2 1 0
240-323 16 Input – M23 Connector 3 2 0
240-330 16 Output - Terminal Strip 2 0 2
Input Bytes
Status
Enabled
240-212/214 4 Inputs 10 8 0
240-213/215/307 2 Inputs/ 2 Outputs 6 4 4
240-311 4 RTD Inputs 10 8 0
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
11th
12th
13th
14th
15th
16th
Optional Diagnostic Word:
Status
Disabled
Status
Disabled
Status
Disabled
2 0
Output Bytes
Output Bytes
Output Bytes
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↓ ↓ ↓ ↓ ↓ ↓
U
U
X
X
4.3 Zoned Safety Mapping Example #1 (EtherNet/IP DLR Node – 503)
ZONED SAFETY MANIFOLD Technical Manual
Manifold Settings:
- (2) Safe Zones
- All "Safe Zone" stations wired for Double Solenoid
- Pilot Valve section valves are single solenoid
- All status bits enabled
- Standard valves are not represented
* U-Wiring Manifold/Valves not represented in
Mapping Tables. Control of the Valves comes
from external Safety Output device.
15
13
11
9
7
5
3
1
15
13
11
9
7
5
3
1
14
12
10
8
6
4
2
0
14
12
10
8
6
4
2
0
Manifold I/O Configuration: How to Order:
Pos.
No.
1 NA NA NA NA NA
2 NA NA NA NA NA
3 NA NA NA NA NA
16 NA NA NA NA NA
Standard Valve Size (Data Always Mapped) 0 4 4
"X" and "U" Represent the location and type of manifold base
option (Zoned Power / Pilot Valve). Refer to Section 2.2 and
2.3, page 7 for detailed information.
Coil numbering represents the numbering in the mapping
tables on the next page. The recurring numbering and colorcoded boxes define the individual zones. The "U- wiring"
manifold bases are not controlled by the attached fieldbus
node. Therefore, they are not represented in the mapping
tables.
I/O
Module Type
(If Present)
Diagnostic Word 0 0 2
Safe Zone #1 0 2 2
Safe Zone #2 0 2 2
Safe Zone #3 NA NA NA
Part No.
In Out
Status
Bytes
Total: 0 8 10
STA Part Number
8503AV3R300VA45
Sta 1 R503A2B10M11MF1
K503AU516663006
Sta 2 R503A2B10M11MF1
K503AU516663010
8503AMS22UA0010
Sta 3 R503A2B60MA00F1
K503AP438300010
Sta 4 R503A2B60MA00F1
8503AMM22X83H10
Sta 5 R503A2B60MA00F1
Sta 6 R503A2B60MA00F1
8503AMM22MA0010
Sta 7 R503A2B60MA00F1
Sta 8 R503A2B60MA00F1
8503AMM22MA0010
Sta 9 R503A2B60MA00F1
Sta 10 R503A2B60MA00F1
8503AMM22MA0010
Sta 11 R503A2B60MA00F1
K503AP438300010
Sta 12 R503A2B60MA00F1
8503AMM22X83H10
Sta 13 R503A2B60MA00F1
Sta 14 R503A2B60MA00F1
8503AMM22MA0010
Sta 15 R503A2B60MA00F1
Sta 16 R503A2B60MA00F1
8503AMM22MA0010
Sta 17 R503A2B60MA00F1
Sta 18 R503A2B60MA00F1
8503AMM22MA0010
G3ED100R0STD
ASSEMBLED
Subject to change without notice
4-18
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
ZONED SAFETY MANIFOLD Technical Manual
I/O Table Mapping Example:
This example uses the RS Logix 5000 generic driver selection Data – "SINT – with status". The diagnostics and
status data are written to a separate status table. Output bytes 0 – 3 are reserved for the general purpose nonsafe valve section.
Example No. 1 Table Data: SINT – with status
Output Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
2
3
4
5
6
7
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 7
Zone No. 1
Coil No. 15
Zone No. 2
Coil No. 7
Zone No. 2
Coil No. 15
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 6
Zone No. 1
Coil No. 14
Zone No. 2
Coil No. 6
Zone No. 2
Coil No. 14
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 5
Zone No. 1
Coil No. 13
Zone No. 2
Coil No. 5
Zone No. 2
Coil No. 13
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 4
Zone No. 1
Coil No. 12
Zone No. 2
Coil No. 4
Zone No. 2
Coil No. 12
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 3
Zone No. 1
Coil No. 11
Zone No. 2
Coil No. 3
Zone No. 2
Coil No. 11
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 2
Zone No. 1
Coil No. 10
Zone No. 2
Coil No. 2
Zone No. 2
Coil No. 10
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 1
Zone No. 1
Coil No. 9
Zone No. 2
Coil No. 1
Zone No. 2
Coil No. 9
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 0
Zone No. 1
Coil No. 8
Zone No. 2
Coil No. 0
Zone No. 2
Coil No. 8
Input Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
No Discrete Inputs Attached to Manifold Example
Status Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
(Optional)
1
(Optional)
2
(Optional)
3
(Optional)
4
(Optional)
5
(Optional)
6
(Optional)
7
(Optional)
8
(Optional)
9
(Optional)
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 7
Status
Coil No. 15
Status
Coil No. 23
Status
Coil No. 31
Status
Coil No. 7
Status
Coil No. 15
Status
Coil No. 7
Status
Coil No. 15
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 6
Status
Coil No. 14
Status
Coil No. 22
Status
Coil No. 30
Status
Coil No. 6
Status
Coil No. 14
Status
Coil No. 6
Status
Coil No. 14
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 5
Status
Coil No. 13
Status
Coil No. 21
Status
Coil No. 29
Status
Coil No. 5
Status
Coil No. 13
Status
Coil No. 5
Status
Coil No. 13
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 4
Status
Coil No. 12
Status
Coil No. 20
Status
Coil No. 28
Status
Coil No. 4
Status
Coil No. 12
Status
Coil No. 4
Status
Coil No. 12
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 3
Status
Coil No. 11
Status
Coil No. 19
Status
Coil No. 27
Status
Coil No. 3
Status
Coil No. 11
Status
Coil No. 3
Status
Coil No. 11
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 2
Status
Coil No. 10
Status
Coil No. 18
Status
Coil No. 26
Status
Coil No. 2
Status
Coil No. 10
Status
Coil No. 2
Status
Coil No. 10
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 1
Status
Coil No. 9
Status
Coil No. 17
Status
Coil No. 25
Status
Coil No. 1
Status
Coil No. 9
Status
Coil Nog. 1
Status
Coil No. 9
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 0
Status
Coil No. 8
Status
Coil No. 16
Status
Coil No. 24
Status
Coil No. 0
Status
Coil No. 8
Status
Coil No. 0
Status
Coil No. 8
Status
Subject to change without notice
4-19
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TD
G3ZSTM1
-5EN
08
/20
↓ ↓ ↓ ↓ ↓ ↓
8503AV3J300VA00
Sta 1
R503A2B40MA00F1
G3ED10
1
R0STD
Pilot Valve
:
U
U
X
4.4 Zoned Safety Mapping Example #2 (EtherNet/IP DLR Node – 503)
ZONED SAFETY MANIFOLD Technical Manual
Manifold Settings:
- (1) Safe Zones
- All "Safe Zone" stations wired for Double Solenoid
- Pilot Valve section valves are single solenoid
- All status bits enabled
- Standard valves are represented
* U-Wiring Manifold/Valves not represented in
Mapping Tables. Control of the Valves comes
from external Safety Output device.
3
1
No Connection
with Node
2
0
Manifold I/O Configuration: How to Order:
Pos.
No.
"X" and "U" Represent the location and type of manifold base
option (Zoned Power / Pilot Valve). Refer to Section 2.2 and
2.3, page 7 for detailed information.
Coil numbering represents the numbering in the mapping
tables on the next page. The recurring numbering and colorcoded boxes define the individual zones. The "U- wiring"
manifold bases are not controlled by the attached fieldbus
node. Therefore, they are not represented in the mapping
tables.
I/O
Module Type
1 16I PNP 240-205 2 0 1
2 NA NA NA NA NA
3 NA NA NA NA NA
16 NA NA NA NA NA
Standard Valve Size (Data Always Mapped) 0 4 4
(If Present)
Diagnostic Word 0 0 2
Safe Zone #1 0 2 2
Safe Zone #2 NA NA NA
Safe Zone #3 NA NA NA
Part No.
In Out
Status
Bytes
Total: 2 6 9
Subject to change without notice
4-20
www.asco.com
STA Part Number
Sta 2 R503A2B40MA00F1
8503AMM22MA0010
Sta 3 R503A2B10M11MF1
8503AU516663005
Sta 4 P503AB428359001
8503AMS22UA0010
Sta 5 R503A2B60MA00F1
Sta 6 R503A2B60MA00F1
8503AMM22XA0010
Sta 7 R503A2B60MA00F1
Sta 8 R503A2B60MA00F1
8503AMM22MA0010
Sta 9 R503A2B60MA00F1
Sta 10 R503A2B60MA00F1
8503AMM22MA0010
ASSEMBLED
TD
G3ZSTM1
-5EN
08
/20
ZONED SAFETY MANIFOLD Technical Manual
I/O Table Mapping Example:
This example uses the RS Logix 5000 generic driver selection Data – "SINT – with status". The diagnostics and
status data are written to a separate status table. Output bytes 0 – 3 are reserved for the general purpose nonsafe valve section.
Example No. 2 Table Data: SINT – with status
Output Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
2
3
4
5
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 7
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 6
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 5
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 4
Allocated
and
Reserved
Non-Safe
Coil No. 3
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 3
Zone No. 1
Coil No. 11
Non-Safe
Coil No. 2
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 2
Zone No. 1
Coil No. 10
Non-Safe
Coil No. 1
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 1
Zone No. 1
Coil No. 9
Non-Safe
Coil No. 0
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 0
Zone No. 1
Coil No. 8
Input Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
Discrete
Input No. 7
Discrete
Input No. 15
Discrete
Input No. 6
Discrete
Input No. 14
Discrete
Input No. 5
Discrete
Input No. 13
Discrete
Input No. 4
Discrete
Input No. 12
Discrete
Input No. 3
Discrete
Input No. 11
Discrete
Input No. 2
Discrete
Input No. 10
Discrete
Input No. 1
Discrete
Input No. 9
Discrete
Input No. 0
Discrete
Input No. 8
Status Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
(Optional)
1
(Optional)
2
(Optional)
3
(Optional)
4
(Optional)
5
(Optional)
6
(Optional)
7
(Optional)
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 7
Status
Non-Safe
Coil No. 15
Status
Non-Safe
Coil No. 23
Status
Non-Safe
Coil No. 31
Status
Coil No. 7
Status
Coil No. 15
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 6
Status
Non-Safe
Coil No. 14
Status
Non-Safe
Coil No. 22
Status
Non-Safe
Coil No. 30
Status
Coil No. 6
Status
Coil No. 14
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 5
Status
Non-Safe
Coil No. 13
Status
Non-Safe
Coil No. 21
Status
Non-Safe
Coil No. 29
Status
Coil No. 5
Status
Coil No. 13
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 4
Status
Non-Safe
Coil No. 12
Status
Non-Safe
Coil No. 20
Status
Non-Safe
Coil No. 28
Status
Coil No. 4
Status
Coil No. 12
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 3
Status
Non-Safe
Coil No. 11
Status
Non-Safe
Coil No. 19
Status
Non-Safe
Coil No. 27
Status
Coil No. 3
Status
Coil No. 11
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 2
Status
Non-Safe
Coil No. 10
Status
Non-Safe
Coil No. 18
Status
Non-Safe
Coil No. 26
Status
Coil No. 2
Status
Coil No. 10
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 1
Status
Non-Safe
Coil No. 9
Status
Non-Safe
Coil No. 17
Status
Non-Safe
Coil No. 25
Status
Coil No. 1
Status
Coil No. 9
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Non-Safe
Coil No. 0
Status
Non-Safe
Coil No. 8
Status
Non-Safe
Coil No. 16
Status
Non-Safe
Coil No. 24
Status
Coil No. 0
Status
Coil No. 8
Status
Subject to change without notice
4-21
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
↓ ↓ ↓ ↓ ↓ ↓
K501AMM42
M
A0010
8503AMM22MA0010
8
13
U U
2
Pilot Valve
:
X
11
7
1
5
1
4
4.5 Zoned Safety Mapping Example #3 (EtherNet/IP DLR Node – 501)
ZONED SAFETY MANIFOLD Technical Manual
Manifold Settings:
- (1) Safe Zones
- All "Safe Zone" stations wired for Double Solenoid
- Pilot Valve section valves are single solenoid
- All status bits enabled
- Standard valves are not represented
1
3
9
1
5
3
* U-Wiring Manifold/Valves not represented in
Mapping Tables. Control of the Valves comes
from external Safety Output device.
No Connection
with Node
12
10
4
6
0
2
0
Manifold I/O Configuration: How to Order:
Pos.
No.
1 16I PNP 240-205 2 0 1
2 NA NA NA NA NA
3 NA NA NA NA NA
16 NA NA NA NA NA
Standard Valve Size (Data Always Mapped) 0 4 4
I/O
Module Type
(If Present)
Diagnostic Word 0 0 2
Safe Zone #1 0 2 2
Safe Zone #2 NA NA NA
Safe Zone #3 NA NA NA
Part No.
In Out
Status
Bytes
Total: 2 6 9
"X" and "U" Represent the location and type of manifold base
option (Zoned Power / Pilot Valve). Refer to Section 2.2 and
2.3, page 7 for detailed information.
Coil numbering represents the numbering in the mapping
tables on the next page. The recurring numbering and colorcoded boxes define the individual zones. The "U- wiring"
manifold bases are not controlled by the attached fieldbus
node. Therefore, they are not represented in the mapping
tables.
STA Part Number
K501AV3L200VMUF
Sta 1 R501A2B10M11MF1
Sta 2 P501AB429685001
Sta 3 R501A2B10M11MF1
Sta 4 P501AB429685001
K501AMS42UA0010
Sta 5 R501A2B60MA00F1
Sta 6 R501A2B60MA00F1
Sta 7 R501A2B60MA00F1
Sta 8 R501A2B60MA00F1
K501AMM42XA0010
Sta 9 R501A2B60MA00F1
Sta 10 R501A2B60MA00F1
Sta 11 R501A2B60MA00F1
Sta 12 R501A2B60MA00F1
G3ED101R0STD
240-205
ASSEMBLED
Subject to change without notice
4-22
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
ZONED SAFETY MANIFOLD Technical Manual
I/O Table Mapping Example:
This example uses the RS Logix 5000 generic driver selection Data – "SINT – with status". The diagnostics and
status data are written to a separate status table. Output bytes 0 – 3 are reserved for the general purpose nonsafe valve section.
Example No. 3 Table Data: SINT – with status
Output Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
2
3
4
5
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 7
Zone No. 1
Coil No. 15
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 6
Zone No. 1
Coil No. 14
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 5
Zone No. 1
Coil No. 13
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 4
Zone No. 1
Coil No. 12
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 3
Zone No. 1
Coil No. 11
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 2
Zone No. 1
Coil No. 10
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 1
Zone No. 1
Coil No. 9
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Allocated
and
Reserved
Zone No. 1
Coil No. 0
Zone No. 1
Coil No. 8
Input Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
1
Discrete
Input No. 7
Discrete
Input No. 15
Discrete
Input No. 6
Discrete
Input No. 14
Discrete
Input No. 5
Discrete
Input No. 13
Discrete
Input No. 4
Discrete
Input No. 12
Discrete
Input No. 3
Discrete
Input No. 11
Discrete
Input No. 2
Discrete
Input No. 10
Discrete
Input No. 1
Discrete
Input No. 9
Discrete
Input No. 0
Discrete
Input No. 8
Status Table
BYTE Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0
(Optional)
1
(Optional)
2
(Optional)
3
(Optional)
4
(Optional)
5
(Optional)
6
(Optional)
7
(Optional)
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 7
Status
Coil No. 15
Status
Coil No. 23
Status
Coil No. 31
Status
Coil No. 7
Status
Coil No. 15
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 6
Status
Coil No. 14
Status
Coil No. 22
Status
Coil No. 30
Status
Coil No. 6
Status
Coil No. 14
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 5
Status
Coil No. 13
Status
Coil No. 21
Status
Coil No. 29
Status
Coil No. 5
Status
Coil No. 13
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 4
Status
Coil No. 12
Status
Coil No. 20
Status
Coil No. 28
Status
Coil No. 4
Status
Coil No. 12
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 3
Status
Coil No. 11
Status
Coil No. 19
Status
Coil No. 27
Status
Coil No. 3
Status
Coil No. 11
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 2
Status
Coil No. 10
Status
Coil No. 18
Status
Coil No. 26
Status
Coil No. 2
Status
Coil No. 10
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 1
Status
Coil No. 9
Status
Coil No. 17
Status
Coil No. 25
Status
Coil No. 1
Status
Coil No. 9
Status
Comm.
Module
Diag. Bit
Sub-bus
Diag. Bit
Coil No. 0
Status
Coil No. 8
Status
Coil No. 16
Status
Coil No. 24
Status
Coil No. 0
Status
Coil No. 8
Status
Subject to change without notice
5-23
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
ZONED SAFETY MANIFOLD Technical Manual
5. Zoned Safety Web Server
The Web Server for all supported protocols (see Sec. 3.1), have been upgraded to support the Zoned Safety
Manifold functionality. The changes to each supported protocol web server, includes only two of the available
tabs; the Node Configuration and Diagnostics. This section will only detail the changes of these two
tabs, related to the Zoned Safety Manifold. For complete web server detail, refer to the Technical Manual for
the desired protocol. The example screen shots are based on an EtherNet/IP DLR node. Some of the identified
tabs will change per protocol. The Zoned Safety parameter on the Node Configuration tab will be the same for
all protocols,
and the feature set for the Diagnostics tab will be the same.
5.1 Node Configuration
The Node Configuration tab allows the user to configure and set the various parameters identified
below. Related to this topic is the Safety Zones tab that allows for the configuration and setting of the
specific number of Safe Zones connected to the node; for further detail refer to Section 3.3.
Subject to change without notice
5-24
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TD
G3ZSTM1
-5EN
08
/20
5.2 Diagnostics
ZONED SAFETY MANIFOLD Technical Manual
The Diagnostics tab allows the user to monitor all attached I/O connected to the Zoned Safety
Manifold; as well as "force on" all attached valves and Outputs. Additional features include the ability
to monitor different values like Firmware Revisions, Serial Number, Etc. The sample scree shot below
identifies "two" Zoned Power Manifold Bases are attached to the EtherNet/IP manifold; therefore,
there are "two" Safe Zones.
Subject to change without notice
5-25
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
Expanded
Expanded
ZONED SAFETY MANIFOLD Technical Manual
Zone #1
Zone #2
Safety Zones 1 and 2 have been expanded in the screen shot above to show web page representation. Coil data shown
is representative of the EtherNet/IP DLR manifold connected.
Subject to change without notice
5-26
www.asco.com
TD
G3ZSTM1
-5EN
08
/20
Safety PLC
CH 1
A1 A2 A3
A
4
1V1
3V1
1V0 2V1
4V1
1V2
1V3
2V2 2V3
3V2 3V3
4V2
4V3
1S0
4S1
4S2
3S1
3S2
2S1
2S2 1S1
1S2
used.
ZONED SAFETY MANIFOLD Technical Manual
6. Zoned Safety Circuit Examples/Analysis
6.1 Example #1 Automated Assembly Machine
The example is based on an automatic assembly machine, with manual loading and unloading of the
work piece. It has been determined, based on the Risk Assessment, that the loading/unloading station
requires Risk Reduction to make it safe. It has also been determined that the Safety Function requires
the motion (Actuators) to stop when the Safety Function is initiated. It has also been determined that
the required Category and PLr required, based on ISO 13849-1 is, Category 3 PLd.
The tooling in the load/unload area has four clamps that hold a work piece during the machine process.
The four clamps are represented by Actuators A1, A2, A3 and A4 in the pneumatic circuit.
This analysis only considers the pneumatic control, in the form of a sub-system. Additional SafetyRelated control components (e.g. protective devices, electrical logic elements, etc.) must be evaluated
in the form of a sub-system for a complete evaluation of the Safety Function.
Safety Function: Safety Related Stop and Unexpected Startup
I
1,2
The Safety Functions can be applied to each individual actuator (A1, A2, A3 and A4); however, they can
be considered a single Safety Function since they are implemented utilizing the same SRP/CS. Each
Actuators Safety Function is executed at the same time.
The Safety related block diagram identified below identifies the pneumatic SRP of the Zoned Safety
Manifold and how they are separated into Channels
1V1 / 2V1 / 3V1 / 4V1
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3 / 1V0+4V2+4V3
DC: 1S0, 1S1, 1S2, 2S1, 2S2, 3S1, 3S2, 4S1, 4S2
CH 2
!
Response times should
be considered when
multiple actuators are
connected and when
long tube lengths are
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The physical representation of the Zoned Safety Manifold is identified in the diagram below.
Included are the required external elements (e.g. Pilot Operated Spring Return Valves) to achieve a redundant
circuit(s). The colored boxes represent the channels identified in the Safety Block diagram shown on the
previous page.
ZONED SAFETY MANIFOLD Technical Manual
Air Operated
Valve
Air Operated
Valve
Air Operated
Valve
Air Operated
Valve
Air Operated
Valve
Air Operated
Valve
Air Operated
Valve
Channel 1
Channel 2
DC
!
When valves with Manual overrides are selected for the U-Wiring and X-Wiring
manifold blocks, adequate measures must be taken to prevent any hazardous
situations that may occur (e.g. use the diagnostic feedback of the DC elements as
identification on a display that a valve is manually overridden).
Air Operated
Valve
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Safety PLC
CH 2
The following evaluation of MTTFd, DC, CCF, etc. for Example #1 circuit, only includes the Pneumatic
portion (SRP) as a sub-system identified in the red box below. All other SRP (e.g. protective devices,
electrical logic elements) must be evaluated in the form of a sub-system for a complete evaluation of
the safety function.
ZONED SAFETY MANIFOLD Technical Manual
1V1 / 2V1 / 3V1 / 4V1
I
1,2
CH 1
DC: 1S0, 1S1, 1S2, 2S1, 2S2, 3S1, 3S2, 4S1, 4S2
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3 / 1V0+4V2+4V3
It had been identified previously that the required Category and PLr be Category 3 PLd. The following
example evaluation will determine if the identified circuit along with its components will adhere to the
required Category and PL rating.
Reliability Data for Pneumatic Valves:
(data supplied by manufacturer)
B
of 1V1 thru 4V1 = 20,000,000 cycles (R503A2B60MA00F1)
10d
B
of 1V0 = 20,000,000 cycles (R503A2B10M11MF1)
10d
B
of 1V2 thru 4V3 = 60,000,000 cycles (L12PA452O000000)
10d
Machine Parameters:
Working Hours h
Working Days dop = 240 days
Cycle Time t
MTTFd Calculations for each CHANNEL:
= 16 hours
op
= 10 seconds
cycle
(The elements in each channel are being evaluated together since their operation is simultaneous)
MTTFd =
B
10d
0,1 x nop
n
dop x hop x 3600 s/h
=
op
t
cycle
CHANNEL 1 (1V1 thru 4V1):
nop = (240 days x 16 hours x 3600 s/h) / 10 cycle = 1,382,400 cycles/year
MTTF
MTTF
= 20,000,000 cycles / 0.1 x 1382400 cycles/year = 145 years (value capped at 100 years)
d
= "HIGH"
d
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ZONED SAFETY MANIFOLD Technical Manual
CHANNEL 2 (1V0+1V2+1V2 thru 1V0+4V2+4V3):
nop = (240 days x 16 hours x 3600 s/h) / 10 cycle = 1,382,400 cycles/year
MTTF
MTTF
1 / MTTF
MTTF
Taking 108 years (capped at 100), yields an MTTF
DC (Diagnostic Coverage) / Calculations:
1V0: Pressure monitoring of the control signal for the Pilot Operated Two Position Valves: 90%
1V1 thru 4V1: Fault detection of the process: 60%
1V2 thru 8V2: Regular checking of the operation: 60%
DC = (0.9/108) + (0.6/108) + (0.6/145) / (1/108) + (1/108) + (1/145) = 71%
DC
Common Cause Failure Estimation:
Separation / Segregation: 15
Diversity: 20
Well Tried Components: 5
Environmental: 25+10
Total: 75 points (65 points required)
Mission Time Calculation:
= 20,000,000 cycles / 0.1 x 1382400 cycles/year = 145 years (value capped at 100 years)
d1
= 60,000,000 cycles / 0.1 x 1382400 cycles/year = 434 years (value capped at 100 years)
d2
avg
TM =
= 1 / Σ
d
= "HIGH"
d
= Low
B
10d
nop
MTTFd) = 108 years (value capped at 100 years)
1,2
value of "HIGH".
d
TM (R503A2B60MA00F1) = 20,000,000 cycles / 1,382,400 cycles/year = 14.5 years
TM (R503A2B10M11MF1) = 20,000,000 cycles / 1,382,400 cycles/year = 14.5 years
TM (L12PA452O000000) = 60,000,000 cycles / 1,382,400 cycles/year = 43 years
Because of Mission Time requirements (20 years) against PL adherence; 1V1 thru 4V1 and 1V0 will need
to be replaced after 14.5 years.
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ZONED SAFETY MANIFOLD Technical Manual
Determining Achieved PL:
The determination of category has already been satisfied based on the redundant pneumatic circuit
pertaining to motion of the clamps (cylinder A1, A2, A3 and A4). Therefore, considering the DC
MTTFd of each channel, we can conclude adherence to Category 3 PLd for this example.
DC
= LOW
avg
MTTFd = HIGH
avg
, the
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Safety PLC
CH 1
CH 2
DC
1V1
2V1
3V1
1V0
A3
A1
A2
3V3
3V2
2V3
2V2
1V3
1V2 1S0
3S2
3S1 2S2
2S1
1S2
1S1
1V4
6.2 Example #2 Automated Insertion Tool
ZONED SAFETY MANIFOLD Technical Manual
The example is based upon an automatic insertion tool, with manual loading and unloading of the work
piece. It has been determined, based on the Risk Assessment, that the loading/unloading station
requires Risk Reduction to make it safe. It has also been determined that the Safety Function requires
the motion (Insertion Actuators) to release all pneumatic energy when initiated. It has also been
determined that the required Category and PLr required, based on ISO 13849-1 is, Category 3 PLd.
The tooling in the load/unload area has three horizontally mounted insertion cylinders that each insert
a roll pin in the work piece during the tool process. The insertion cylinders are represented by
Actuators A1, A2 and A3 in the pneumatic circuit.
This analysis only considers the pneumatic control, in the form of a sub-system. Additional SafetyRelated control components (e.g. protective devices, electrical logic elements, etc.) must be evaluated
in the form of a sub-system for a complete evaluation of the Safety Function.
Safety Function: Safe Release of Air
1V1 / 2V1 / 3V1
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3
1S0, 1S1, 1S2, 2S1, 2S2, 3S1, 3S2
The Safety Functions can be applied to each individual actuator (A1, A2 and A4); however, they can be
considered a single Safety Function since they are implemented utilizing the SRP/CS. Each Actuators
Safety Function is executed at the same time.
The Safety related block diagram identified below identifies the pneumatic SRP of the Zoned Safety
Manifold and how they are separated into channels.
I
1,2
!
With this type of circuit,
Cylinder Volume, Pilot
Valve Flow and Response
Times should be
considered when multiple
actuators are connected.
To increase exhaust flow,
a quick exhaust valve can
be utilized in each
secondary exhaust path.
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The physical representation of the Zoned Safety Manifold is identified in the diagram below. Included
are the required external elements (Inline Check Valves) to achieve a redundant circuit(s). the colored
boxes represent the channels identified in the safety block diagram shown on the previous page.
!
ZONED SAFETY MANIFOLD Technical Manual
When valves with Manual overrides are selected for the U-Wiring and X-Wiring
manifold blocks, adequate measures must be taken to prevent any hazardous
situations that may occur (e.g. use the diagnostic feedback of the DC elements as
identification on a display that a valve is manually overridden).
If utilized in circuit
Channel 1
Channel 2
DC
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CH 1
DC
The following evaluation of MTTFd, DC, CCF, etc. for Example #2 circuit, only includes the Pneumatic
portion (SRP) as a sub-system identified in the red box below. All other SRP (e.g. protective devices,
electrical logic elements) must be evaluated in the form of a sub-system for a complete evaluation of
the safety function.
ZONED SAFETY MANIFOLD Technical Manual
1V1 / 2V1 / 3V1
I
1,2
Safety PLC
1S0, 1S1, 1S2, 2S1, 2S2, 3S1, 3S2
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3
It had been identified previously that the required Category and PLr be Category 3 PLd. The following
evaluation will determine if the identified circuit along with its components will adhere to the required
Category and PL.
Reliability Data for Pneumatic Valves:
(data supplied by manufacturer)
B
of 1V1 thru 3V1 = 20,000,000 cycles (R503A2B50MA00F1)
10d
B
of 1V0 = 20,000,000 cycles (R503A2B10M11MF1)
10d
B
(Value taken from ISO 13849-1, Table C.1)
of 1V0 = 20,000,000 cycles (CV2FN)
10d
B
(Value taken from ISO 13849-1, Table C.1)
of 1V0 = 20,000,000 cycles (SEV10BN)
10d
If utilized in circuit
Machine Parameters:
Working Hours h
Working Days dop = 220 days
Cycle Time t
= 16 hours
op
= 15 seconds
cycle
CH 2
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MTTFd Calculations for each CHANNEL:
ZONED SAFETY MANIFOLD Technical Manual
(The elements in each channel are being evaluated together since their operation is simultaneous)
MTTFd =
B
10d
0,1 x nop
n
dop x hop x 3600 s/h
=
op
t
cycle
CHANNEL 1 (1V1 thru 4V1):
nop = (220 days x 16 hours x 3600 s/h) / 15 cycle = 844,800 cycles/year
MTTF
MTTF
= 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
d
= "HIGH"
d
CHANNEL 2 (1V0+1V2+1V3 thru 1V0+3V2+3V3):
nop = (220 days x 16 hours x 3600 s/h) / 15 cycle = 844,800 cycles/year
MTTF
MTTFd2 = 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
MTTF
MTTF
1 / MTTFd = 1 / Σ
1 / MTTFd = 1 / Σ
MTTF
= 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
d1
= 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
d3
= 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
d4
(MTTFd) = 79 years (value capped at 100 years)
1,2,3,4
(MTTFd) = 59 years (value capped at 100 years)
1,2,3,4
= "HIGH" with or without Quick Exhaust Valve SEVxxBN
d
If utilized in circuit
If utilized in circuit
DC (Diagnostic Coverage) / Calculations:
1V0: Pressure monitoring of the control signal for the Inline Check Valves: 90%
1V1 thru 3V1: Fault detection of the process: 60%
DC = (0.9/237) + (0.6/237) / (1/237) + (1/237) = 75%
DC
Separation / Segregation: 15
Diversity: 20
Well Tried Components: 5
Environmental: 25+10
Total: 75 points (65 points required)
= Low
avg
Common Cause Failure Estimation:
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Mission Time Calculation:
TM =
ZONED SAFETY MANIFOLD Technical Manual
B
10d
nop
TM (R503A2B50MA00F1) = 20,000,000 cycles / 844,800 cycles/year = 23.6 years
TM (R503A2B10M11MF1) = 20,000,000 cycles / 844,800 cycles/year = 23.6 years
TM (CV2FN) = 20,000,000 cycles / 844,800 cycles/year = 23.6 years
TM (SEV10BN) = 20,000,000 cycles / 844,800 cycles/year = 23.6 years
A minimum of 20 years for Mission Time is met for this system.
If utilized in circuit
Determining Achieved PL:
The determination of category has already been satisfied based on the redundant pneumatic circuit
pertaining to motion of the clamps (cylinder A1, A2, A3 and A4). Therefore, considering the DC
MTTFd of each channel, we can conclude adherence to Category 3 PLd for this example.
DC
= LOW
avg
MTTFd = HIGH
avg
, the
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Safety PLC
CH 1
CH 2
DC
2V1
1V1 3V1 1V0
1V2
1V3
1S1
2V2 2V3
2S1
3V2
3V3
3S1
1S0
1S2 1S3 2S2 2S3
3S2 3S3
used.
6.3 Example #3 Clamping Weld Fixture
ZONED SAFETY MANIFOLD Technical Manual
The example is based upon an automated weld fixture, with manual loading and unloading of the work
piece. It has been determined, based on the Risk Assessment, that the loading/unloading station
requires Risk Reduction to make it safe. It has also been determined that the Safety Function requires
the motion (Clamping Cylinders) to move to a safe position. It has also been determined that the
required Category and PLr required, based on ISO 13849-1 is, Category 3 PLd.
The tooling in the load/unload area has three pneumatic clamp cylinders that each clamp an area of the
inserted sheet metal during the weld process. The clamping cylinders are represented by Actuators A1,
A2 and A3 in the pneumatic circuit.
This analysis only considers the pneumatic control, in the form of a sub-system. Additional SafetyRelated control components (e.g. protective devices, electrical logic elements, etc.) must be evaluated
in the form of a sub-system for a complete evaluation of the Safety Function.
Safety Function: Safe Return of Motion
The Safety Functions can be applied to each individual actuator (A1, A2 and A4); however, they can be
considered a single Safety Function since they are implemented utilizing the SRP/CS. Each Actuators
Safety Function is executed at the same time.
The Safety related block diagram identified below identifies the pneumatic SRP of the Zoned Safety
Manifold and how they are separated into channels.
1V1 / 2V1 / 3V1
I
1,2
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3
1S0, 1S1, 1S2, 1S3 2S1, 2S2, 2S3, 3S1, 3S2, 3S3
!
Response times should
be considered when
multiple actuators are
connected and when
long tube lengths are
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The physical representation of the Zoned Safety Manifold is identified in the diagram below. Included
are the required external elements (Pilot Actuated & Solenoid Pilot Actuated Valves) to achieve a
redundant circuit(s). The colored boxes represent the channels identified in the safety block diagram
shown on the previous page.
!
ZONED SAFETY MANIFOLD Technical Manual
When valves with Manual overrides are selected for the U-Wiring and X-Wiring
manifold blocks, adequate measures must be taken to prevent any hazardous
situations that may occur (e.g. use the diagnostic feedback of the DC elements as
identification on a display that a valve is manually overridden).
Channel 1
Channel 2
DC
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Safety PLC
CH 1
DC
The following evaluation of MTTFd, DC, CCF, etc. for Example #3 circuit, only includes the Pneumatic
portion (SRP) as a sub-system identified in the red box below. All other SRP (e.g. protective devices,
electrical logic elements) must be evaluated in the form of a sub-system for a complete evaluation of
the safety function.
ZONED SAFETY MANIFOLD Technical Manual
1V1 / 2V1 / 3V1
I
1,2
1S0, 1S1, 1S2, 1S3 2S1, 2S2, 2S3, 3S1, 3S2, 3S3
1V0+1V2+1V3 / 1V0+2V2+2V3 / 1V0+3V2+3V3
CH 2
It had been identified previously that the required Category and PLr be Category 3 PLd. The following
evaluation will determine if the identified circuit along with its components will adhere to the required
Category and PL.
Reliability Data for Pneumatic Valves:
(data supplied by manufacturer)
B
of 1V1 thru 3V1 = 20,000,000 cycles (R503A2B40MA00F1)
10d
B
of 1V0 = 20,000,000 cycles (R503A2B10M11MF1)
10d
B
(Value taken from ISO 13849-1, Table C.1)
B
(Value taken from ISO 13849-1, Table C.1)
of 1V2, 2V2, 3V2 = 20,000,000 cycles (153PA441O000000)
10d
of 1V3, 2V3, 3V3 = 20,000,000 cycles (153PA441O000000)
10d
Machine Parameters:
Working Hours h
Working days dop = 220 days
Cycle Time t
MTTFd Calculations for each CHANNEL:
= 8 hours
op
= 20 seconds
cycle
(The elements in each channel are being evaluated together since their operation is simultaneous)
MTTFd =
B
10d
0,1 x nop
n
dop x hop x 3600 s/h
=
op
t
cycle
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ZONED SAFETY MANIFOLD Technical Manual
CHANNEL 1 (1V1 thru 3V1):
nop = (220 days x 8 hours x 3600 s/h) / 20 cycle = 316,800 cycles/year
MTTF
MTTF
nop = (220 days x 16 hours x 3600 s/h) / 15 cycle = 844,800 cycles/year
MTTF
MTTFd2 = 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
1 / MTTF
MTTF
Taking 79 years, yields an MTTF
DC (Diagnostic Coverage) / Calculations:
1V1, 2V1 and 3V1: Pressure monitoring by 1S1, 2S1 and 3S1: 90%
1V0, 1V2, 1V3, 2V2, 2V3, 3V2 and 3V3: Position monitoring by 1S2, 2S2 and 3S2: 90%
DC = (0.9/631)+(0.9/237)+(0.9/237)+(0.9/237)/ (1/631)+(1/237)+ (1/237)+ (1/237) = 90%
DC
Separation / Segregation: 15
Diversity: 20
Well Tried Components: 5
Environmental: 25+10
Total: 75 points (65 points required)
Mission Time Calculation:
= 20,000,000 cycles / 0.1 x 316,800 cycles/year = 631 years (value capped at 100 years)
d
= "HIGH"
d
CHANNEL 2 (1V0+1V2+1V3 thru 1V0+3V2+3V3):
= 20,000,000 cycles / 0.1 x 844,800 cycles/year = 237 years (value capped at 100 years)
d1
= 1 / Σ
d
= "HIGH"
d
= MEDIUM
avg
(MTTFd) = 118 years
1,2,3
d
value of "HIGH".
Common Cause Failure Estimation:
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ZONED SAFETY MANIFOLD Technical Manual
TM =
B
10d
nop
TM (R503A2B40MA00F1) = 20,000,000 cycles / 316,800 cycles/year = 63.1 years
TM (R503A2B40MA00F1) = 20,000,000 cycles / 316,800 cycles/year = 63.1 years
TM (153PA441O000000) = 20,000,000 cycles / 316,800 cycles/year = 63.1 years
TM (153PA441O000000) = 20,000,000 cycles / 316,800 cycles/year = 63.1 years
A minimum of 20 years for Mission Time is met for this system.
Determining Achieved PL:
The determination of category has already been satisfied based on the redundant pneumatic circuit
pertaining to motion of the clamps (cylinder A1, A2, A3 and A4). Therefore, considering the DC
MTTFd of each channel, we can conclude adherence to Category 3 PLd for this example.
DC
= MEDIUM
avg
MTTFd = HIGH
avg
, the
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.
ZONED SAFETY MANIFOLD Technical Manual
7. Appendix
7.1 System Specifications
Supply Voltage
Current
Reverse Polarity Reverse polarity is protection is provided on both Node and Valve power.
Total current on the Power Connector (“Valves” and
“Node” Pins) must not exceed 4 Amps.
Electrical
Valves (501, 502, 503): 24 VDC ± 10% Node: 24 VDC ± 10%
Recommended
External Fuse
Spike Protection
Valve Solenoid
Coil Output Drivers
Operating Temperature for
Electronic Components
7.2 Factory Default Settings
External fuses should be chosen depending upon manifold configuration. Please
refer to power consumption chart in the specific Technical Manual of the used
protocol, for additional fuse sizing information.
Output spike protection is internally provided for valve and discrete outputs.
Additionally, all 500 Series valves have integrated spike suppression.
Maximum 0.5 Amps per output. All output points are short circuit protected and
have internal spike protection.
-10 to 115°F (-23 to 46°C)
Please refer to the Technical Manual related to the protocol used. The factory defaults identified
below are specific to the Zone Safety Manifold operability.
7.3 Troubleshooting/Error Messaging
Symptom Possible Cause Solution
Safety Zone Mismatch
See appropriate Technical Manual for protocol specific issue(s). Technical Manual reference can be
identified in Section 3.1, Page 10.
Description Default
Number of Safety Zones
FACTORY DEFAULT SETTINGS
Setting based on the number of "Zones" (number of
"X" wiring manifolds. See Section 4.0 for reference to
"X" wiring manifolds).
Zone setting Parameter of node
does not match physical manifold
Adjust Parameter to match; see section 3.3
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ZONED SAFETY MANIFOLD Technical Manual
7.4 Glossary of Terms
The following is a list and description of common terms and symbols used throughout this document:
Term Description
A, b, c, d, e Performance Level indication
B, 1, 2, 3, 4 Category indication
B
Number of Cycles that 10% of the components fail dangerously
10d
CCF Common cause failure
DC Diagnostic coverage
DC
Average diagnostic coverage
avg
dop Mean operation, in days per year
hop Mean operation, in hours per day
MTTFd Mean time to dangerous failure
nop Number of cycles/year of a SRP, based on dop, hop and t
PL Performance Level
PLr Performance Level required
Risk assessment Overall process that includes the risk analysis and risk evaluation
Risk analysis A combination of the specified limits of the machine, identified hazards and risk estimation
Risk evaluation Determination, based on the risk analysis, of whether the risk reduction objectives have been reached
Safety function Function of the machine whose failure can result in and immediate increase of the risk(s)
SRP/CS Safety Related Parts of a Control System
t
cycle
TM Period of time covering the intended use of an SRP/CS
501, 502, 503 Valve platforms that support Zoned Safety
The mean time between the beginning of two successive cycles of the component (e.g. switching of a valve)
in seconds per cycle
cycles
7.5 Technical Support
For technical support, contact your local AVENTICS distributor. If further information is required,
please call ASCO Technical Support Department at (248) 596-3337 or email
ASCONumatics.TechSupport@emerson.com.
Issues relating to network setup, PLC programming, sequencing, software related functions, etc.
should be handled with the appropriate product vendor.
Information on device files, technical manuals, local distributors, and other AVENTICS products
and support issues can be found on the ASCO website at www.asco.com.
Subject to change without notice
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