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80001217/00 06/2013
Original Installation Instructions
Safety Standstill Monitor
DA102S
UK
For hardware version 1.0
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Contents
1 Preliminary note ................................................................................................... 4
1.1 Symbols used ................................................................................................4
2 Safety instructions ...............................................................................................5
3 Items supplied......................................................................................................6
4 Functions and features ........................................................................................6
4.1 Requirements for the hardware configuration ...............................................7
4.1.1 Product-independent requirements ......................................................7
4.1.2 Product-dependent requirements .........................................................7
5 Function ............................................................................................................... 8
5.1 Block diagram ................................................................................................ 8
5.2 Operating principle ........................................................................................8
5.3 Switching function .......................................................................................... 9
5.4 Switch point setting ........................................................................................ 9
5.5 Switching outputs 14-23 and 24-24 ...............................................................9
5.6 Y7 transistor output ......................................................................................10
5.7 Pulse pick-ups (sensors) .............................................................................10
5.8 Sensor monitoring .......................................................................................10
5.8.1 Pulse comparison input 1 and 2 .........................................................10
5.8.2 Mechanical requirements on damping cams and gaps ......................10
5.9 Error message ............................................................................................. 11
5.10 Feedback contact ...................................................................................... 11
6 Installation..........................................................................................................12
6.1 Installation of the device ..............................................................................12
6.2 Installation of the pulse pick-ups (sensors) .................................................12
6.3 Arrangement of the damping cams ..............................................................12
6.3.1 Example rack ...................................................................................... 12
6.3.2 Example cam disc ..............................................................................13
7 Electrical connection .......................................................................................... 14
7.1 Connections (overview) ...............................................................................14
7.2 Supply voltage .............................................................................................15
7.3 Switch point setting ...................................................................................... 15
7.4 Pulse pick-ups (sensors) .............................................................................16
7.5 Feedback contact ........................................................................................16
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7.6 Switching outputs 14-23 and 24-24 .............................................................17
7.7 Y7 transistor output ......................................................................................17
8 Set-up ................................................................................................................18
9 Display elements ...............................................................................................18
9.1 LED indications and switching characteristics ............................................. 19
9.1.1 General ............................................................................................... 19
9.1.2 External errors ....................................................................................19
9.1.3 Internal faults ......................................................................................20
10 Maintenance, repair and disposal .................................................................... 20
11 Technical data ..................................................................................................21
12 Tests / approvals .............................................................................................. 23
13 Terms and abbreviations ..................................................................................24
14 EC Declaration of Conformity ..........................................................................25
This document is the original instructions.
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1 Preliminary note
The instructions are part of the unit. They are intended for authorised persons
according to the EMC and Low Voltage Directives and safety regulations.
The instructions contain information about the correct handling of the product.
Read the instructions before use to familiarise yourself with operating conditions,
installation and operation.
Follow the safety instructions.
1.1 Symbols used
► Instructions
> Reaction, result
→ Cross-reference
Important note
Non-compliance can result in malfunction or interference.
Information
Supplementary note.
LED off
LED on
LED flashes
LED flashes quickly
2 LEDs flash alternately
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2 Safety instructions
• Follow the operating instructions.
• Improper use may result in malfunctions of the unit. This can lead to personal
injury and/or damage to property during operation of the machine. For this
reason note all remarks on installation and handling given in this document.
Also adhere to the safety instructions for the operation of the whole installation.
• In case of non-observance of notes or standards, especially when tampering
with and/or modifying the unit, any liability and warranty is excluded.
• The unit must be installed, connected and put into operation by a qualified
electrician trained in safety technology.
• The applicable technical standards for the corresponding application must be
complied with.
• For installation the requirements according to EN 60204 must be observed.
• Connect and lay all cables according to EN ISO 13849-2 D.5.2 (Safety of
machinery - Safety-related parts of control systems).
• In case of malfunction of the unit please contact the manufacturer. Tampering
with the unit is not allowed.
• Disconnect the unit externally before handling it. Also disconnect any
independently supplied relay load circuits.
• After installation of the system perform a complete function check.
• Usetheunitonlyinspecifiedenvironmentalconditions(→11Technicaldata).
In case of special operating conditions please contact the manufacturer.
• Useonlyasdescribedbelow(→4Functionsandfeatures).
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3 Items supplied
• 1 safe standstill monitor DA102S including 5 Combicon connectors with screw
terminals
• 1 original operating instructions "Safe standstill monitor" reference no.
80001217.
If one of the above-mentioned components is missing or damaged, please contact
one of the ifm branch offices.
4 Functions and features
The device is a 2-channel pulse evaluation system for the safe detection of
underspeed or standstill of an object.
For evaluation, the device requires 2 pulse pick-ups (pnp-switching sensors
with "normally open" function).
The safe state is when the output contacts (13-14 and 23-24) of the device
are open.
ifm electronic gmbh does not assume any liability for the function and the
interaction of the device with devices from other manufacturers.
Suitability of the device for a certain application cannot be assured and
must be ensured by the user.
The device can be used in applications up to
• PL e according to ISO 13849-1
• SIL 3 according to IEC 61508
• SIL
CL
3 according to EN 62061
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4.1 Requirements for the hardware configuration
The following requirements must be met when using the device:
4.1.1 Product-independent requirements
It must be ensured that the safety requirements of the respective application
correspond to the requirements stated in these instructions.
The specified technical data indicated in these instructions must be complied with.
The principle of normally closed operation must be applied to all external safety
circuits connected to the system.
The following points have to be ensured in the application by taking administrative
measures:
• The devices of type "safe standstill monitor", DA102S, in operation must be
subjected to a self-test (switching on) within a period of maximum 6 months
(intermittent operation).
The self-test starts when the supply voltage is applied.
(→7.2Supplyvoltage)
• The safety-relevant relay contacts have to be protected by respective fuses of
3.6 A as short-circuit/overload protection.
(→7.6Switchingoutputs14-23and24-24)
4.1.2 Product-dependent requirements
In case of faults within the device which result in the defined safe state, the device
must be replaced.
Any faulty unit should be returned to the manufacturer.
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5 Function
5.1 Block diagram
Y7 14 24
L+ L-
S34 S43
E124 V DC E2
S33
inputs switchpoint
DC
DC
power
controller 1
fault
S44
Y4 Y5 13 23Y4 Y5Y2 Y6
K1
controller 2
K2
1: Supply voltage
2: Inputs
3: Switch point setting (bridging)
4: Feedback contact
5: "Standstill" switching outputs
6: "Fault" transistor output
5.2 Operating principle
The device is a 2-channel pulse evaluation system for the safe detection of
underspeed or standstill. In this respect the device picks up the pulse sequences
of 2 connected pulse pick-ups.
The microprocessors calculate the resulting frequency. The device detects
underspeed as compared to the set switch point by constantly comparing the
frequency of the actual and the preset values.
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5.3 Switching function
In accordance with a "safe standstill message", the output relays are energised
when the switch point is not reached or with standstill.
The output relays K1/K2 switch (are energised) when the set switch point is 5%
below the set level. They switch back (are de-energised) when the set switch point
is exceeded by 5%.
[Hz]
1,00
1,05
0,95
f
− 5 %
+ 5 %
t
Switching function
e.g. switch point setting 1 Hz
1: Switching outputs close
"Standstill" message
2: Switching outputs open
"No standstill" message
5.4 Switch point setting
Via an external circuit the switch point can be selected from 4 preset values (0.2 /
0.5 / 1 / 2 Hz).
(→7.3Switchpointsetting)
5.5 Switching outputs 14-23 and 24-24
Each input channel has an effect on the output relay.
The NO contacts of the output relays K1/K2 are connected in series. The
switching outputs are closed when both output relays have switched.
By means of the switching outputs a door guard locking system can, for example,
be controlled.
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5.6 Y7 transistor output
The Y7 transistor output provides a non-safety related signal for communication to
a PLC.
Status Y7 transistor output
Normal operation (no error) HIGH (ON)
Error LOW (OFF)
The output data is compatible with the input data of the current-sinking inputs of
type 1, 2, 3 to EN 61131-2.
5.7 Pulse pick-ups (sensors)
2 pnp-switching sensors with the "normally open" output function are connected to
the device as pulse pick-ups.
The position of the sensors and the mechanical design of the cams are not
arbitrary since one sensor must always be damped.
(→6.3Arrangementofthedampingcams)
5.8 Sensor monitoring
In order to prevent faulty standstill signalling, the sensors are permanently
monitored during operation of the installation.
5.8.1 Pulse comparison input 1 and 2
By permanently comparing the pulses it is evaluated whether the pulse sequences
of both sensors differ from each other.
If during operation a mechanical or electrical error causes one sensor to fail, there
willbeaninterruptionoftheotherwiseidenticalpulsesequence(f1≠f2).
In accordance with "safe" standstill monitoring this is not considered as
underspeed.
The output relays K1/K2 do not switch, there is an error message.
5.8.2 Mechanical requirements on damping cams and gaps
The arrangement of the mark-to-space ratio of the damping cams and gaps
ensure that at least one sensor is damped all the time.
Therefore the gap between the damping cams must not be of a size that both
sensors face a gap at the same time and are not damped.
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The device monitors continuously if this condition is met.
If this regulation is violated, there is an error and the device goes into the safe
state.
(→6.3Arrangementofthedampingcams)
5.9 Error message
If the device detects an error, the switching outputs are kept in the safe state.
The "Fault" LED is lit and the transistor output Y7 opens ("LOW" status).
Definition "safe state":
• Output relays K1/K2 are de-energised
• Switching outputs 13-14 and 23-24 open
• No standstill message
The error message is reset by interrupting the voltage supply.
5.10 Feedback contact
The device monitors the position of the guard locking by means of a feedback
contact.
• When a movement starts, the output relays K1/K2 are de-energised.
The switching outputs open.
The output LEDs K1/K2 flash when the feedback contact is open.
• If the input frequency is greater than the switch point and the feedback contact
is open, the output LEDs K1/K2 flash.
With resulting standstill and continually open feedback circuit the output relays
K1/K2 are not energised.
The switching outputs remain open.
There is no error message.
Transistor output Y7 remains closed ("HIGH" state).
(→7.5Feedbackcontact)
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6 Installation
6.1 Installation of the device
► Mount the device on a DIN rail in a housing protected against dust and
humidity (min. IP54 - degree of soiling 2).
6.2 Installation of the pulse pick-ups (sensors)
► Mount the pulse pick-ups mechanically separated from each other.
(Not together on a mounting bracket.)
► Lay the cables to the pulse pick-ups separately and protect them against
damage.
6.3 Arrangement of the damping cams
The arrangement of the damping cams and the gaps must ensure that at
leastonesensorisalwaysdamped(→5.8Sensormonitoring).
6.3.1 Example rack
3 x D ≥ 5 x D
3 x D
D
D
Mechanical requirements
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6.3.2 Example cam disc
≥ 5 x D
D
D
3 x D
Mechanical requirements
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7 Electrical connection
► Use 60/75°C copper conductors only.
Do not use unconnected terminals as support point terminal.
7.1 Connections (overview)
A3
A2
A1
C1
C2
S34 S43S33
A3
S44
Y5 Y6Y4A2 Y7
Y2L-A1 L+
13C1 14
23C2 24
Combicon connector
Connector Terminal Connection
A1 L-, L+ Supply voltage (→7.2)
Y2 Switch point setting (bridging) (→7.3)
A2 Y4, Y5 Feedback contact (→7.5)
Y6 Switch point setting (bridging) (→7.3)
Y7 Transistor output (→7.7)
A3 S34, S43 Pulse inputs (→7.4)
S33, S44 Switch point setting (bridging)
Supply voltage sensors
(→7.3)
(→7.4)
C1 13, 14 Switching output 1
(→7.6)
C2 23, 24 Switching output 2
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7.2 Supply voltage
► Connect the supply voltage of the device to terminals L+ and L-.
For safety reasons the unit can only be restarted by separation from the voltage
supply in case of a fault.
It is thus recommended to install a RESET button in series with the L+ circuit.
Y2L-A1 L+
24 V DC
Y2L-A1 L+
24 V DC
RESET
Supply voltage RESET button
The external supply unit must have a safe separation. In case of a fault the
supply voltage can exceed the value of 60 V DC for a maximum of 200 ms,
but must not exceed the value of 120 V DC.
After power on or a RESET the device carries out self diagnostic functions.
This self diagnosis lasts approx. 6 seconds. The unit is then ready for
operation.
7.3 Switch point setting
► Set the requested switch point via a hard-wired bridge on the terminals S33,
S44, Y2 or Y6.
Only change the switch point when disconnected from power.
When switched on, a change of the circuitry will produce an error message
of the device.
Wiring Wiring
0.2 Hz
S33 S44
Y2 Y6
1.0 Hz
S33 S44
Y2 Y6
0.5 Hz
S33 S44
Y2 Y6
2.0 Hz
S33 S44
Y2 Y6
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7.4 Pulse pick-ups (sensors)
► Use pnp-switching sensors with the "normally open” function.
► Connect the supply voltage of the sensors to the terminals S33 and S44.
► Connect the mass of the sensors to the terminals L- and Y4.
E1 E2
Y5 Y6Y4A2 Y7
S34 S43S33
A3 S44
Y2L-A1 L+
24 V DC
24 V DC
L-
L+
L-
L+
1 2
Pulse pick-ups (sensors)
Observe the current consumption of the sensors.
Supply the sensors externally if the current consumption exceeds the
currentratingoftheterminalsS33andS44(→11Technicaldata).
7.5 Feedback contact
► Connect the feedback contact to input A2 (Y4-Y5).
► Observethecharacteristicdataoftheinput(→11Technicaldata).
If the monitoring function is not required, the terminals Y4-Y5 can be
permanently bridged.
Y5 Y6Y4A2 Y7 Y5 Y6Y4A2 Y7
Without monitoring with bridge 1: Feedback contact (normally closed )
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7.6 Switching outputs 14-23 and 24-24
► Connect to load to be controlled to the outputs C1 (13-14) and/or C2 (23-24).
► Observethemaximumandminimumloadconditions(→11Technicaldata).
13C1 14
K13,6 A
L1
L+
N
GND
23C2 24
K23,6 A
L1
L+
N
GND
Switching outputs
7.7 Y7 transistor output
► Connect transistor output Y7 to the signal input of the PLC.
► Observethecharacteristicdataoftheoutput(→11Technicaldata).
Y5 Y6Y4A2 Y7
SPS
Fault
Transistor output
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8 Set-up
The device is ready for operation after application of the supply voltage and the
self-diagnosis.
► After installation and electrical connection, check whether the device operates
safely.
9 Display elements
E1
K1
K2
E2
Power
Fault
Display elements
LED Colour Meaning (normal operation)
E
1 Yellow Input signal channel 1
K
1 Output relay channel 1
E
2 Yellow Input signal channel 2
K
2 Output relay channel 2
Power Green Supply voltage
Fault Red Error
Detailedstatusdescriptionanderrordescription(→9.1LEDindicationsand
switching characteristics)
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9.1 LED indications and switching characteristics
9.1.1 General
Status Power Fault K1, K2 E1, E2 Outputs
13-14, 23-24
Transistor
Y7
Standstill
*) ON HIGH
No standstill
*) OFF HIGH
Feedback contact
open
*) OFF HIGH
Overvoltage/
undervoltage
*) *) *) HIGH
Symbolsused(→1.1)
*) current status
9.1.2 External errors
Status Power Fault K1, K2 E1, E2 Outputs
13-14, 23-24
Transistor
Y7
S33 and S44
Short-circuit against
mass or U
B
OFF LOW
Inputs 1 and 2
simultaneously "0"
OFF LOW
Relay fault, e.g.
contacts welded
because of overload
or life expectancy
reached
OFF LOW
Impermissible pulse
difference between the
inputs(f1≠f2)
OFF LOW
Impermissible switchpoint change during
operation
OFF LOW
Symbolsused(→1.1)
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9.1.3 Internal faults
Status Power Fault K1, K2 E1, E2 Outputs
13-14, 23-24
Transistor
Y7
Device-internal error
OFF LOW
A flash code is output via the "Power" LED.
This flash code enables the manufacturer to analyse the device-internal error.
► If the error message is not reset in spite of the interruption of the supply
voltage,exchangethedevice(→4.1.2Product-dependentrequirements).
10 Maintenance, repair and disposal
If used correctly, no maintenance and repair measures are necessary.
► Observetheproduct-dependentrequirements(→4.1.1).
► Check the safe functioning of the unit after a fault.
Only the manufacturer is allowed to repair the unit.
After use dispose of the unit in an environmentally friendly way in accordance with
the applicable national regulations.
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11 Technical data
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12 Tests / approvals
The device was tested and certified by TÜV-Nord.
The device was developed and tested in accordance with the following directives
and standards:
• 2006/42/EC Machinery Directive
• 2004/108/EC EMC Directive
• 73/23/EEC or 93/68 Low voltage directive
• ISO 13849-1: 2008 Safety of machines - safety-related parts of control systems
• IEC 61508: 2011 Functional safety of electrical/electronic/programmable
electronic safety-related systems
• EN 60204-1: (1997) (where applicable) Electrical equipment of machines
• UL 508
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13 Terms and abbreviations
Cat. Classification of the safety-related parts of a controller
as regards their resistance to failures.
CCF Common Cause Failure
DC Diagnostic Coverage
MTTF Mean Time to Failure
MTTF
D
Mean Time To Dangerous Failure
PFH
(PFH
D
)
Probability of (dangerous) Failure per Hour
PL Performance Level PL to ISO 13849-1
SIL Safety Integrity Level SIL 1-4 to IEC 61508
PLC Programmable Logic Controller
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