* 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!
!
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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.
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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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