Mitsubishi MELSEC-WS0-CPU0, MELSEC-WS0-CPU3, MELSEC-WS, MELSEC-WS0-CPU1, MELSEC-WS0-XTIO User Manual
...
Safety Controller
User's Manual
-WS0-CPU0
-WS0-CPU1
-WS0-CPU3
-WS0-XTDI
-WS0-XTIO
-WS0-4RO
This document is protected by the law of copyright, whereby all rights established
therein remain with the company Mitsubishi Electric Corporation. Reproduction of this
document or parts of this document is only permissible within the limits of the legal
determination of Copyright Law. Alteration or abridgement of the document is not
permitted without the explicit written approval of the company Mitsubishi Electric
Corporation.
Precautions regarding warranty and specifications
MELSEC-WS series products are jointly developed and manufactured by Mitsubishi
and SICK AG, Industrial Safety Systems, in Germany.
Note that there are some precautions regarding warranty and specifications of
MELSEC-WS series products.
<Warranty>
The gratis warranty term of the product shall be for one (1) year after the date of
delivery or for eighteen (18) months after manufacturing, whichever is less.
The onerous repair term after discontinuation of production shall be for four (4) years.
Mitsubishi shall mainly replace the product that needs a repair.
It may take some time to respond to the problem or repair the product depending on
the condition and timing.
<Specifications>
General specifications of the products differ.
Operating ambient temperature -25 to 55°C*1 0 to 55°C 0 to 55°C
Operating ambient humidity 10 to 95%RH 5 to 95%RH
Storage ambient temperature -25 to 70°C -25 to 75°C -40 to 75°C
Storage ambient humidity 10 to 95%RH 5 to 95%RH
*1 When the WS0-GCC100202 is included in the system, operating ambient temperature will
be 0 to 55 °C.
MELSEC-WS MELSEC-Q MELSEC-QS
5 to 95
%RH
5 to 95
%RH
EMC standards that are applicable to the products differ.
MELSEC-WS MELSEC-Q, MELSEC-QS
EMC standards EN61000-6-2, EN55011 EN61131-2
SAFETY PRECAUTIONS
(Read these precautions before using this product.)
Before using this product, please read this manual and the relevant manuals carefully and pay full
attention to safety to handle the product correctly.
In this manual, the safety precautions are classified into two levels: " WARNING" and " CAUTION".
Under some circumstances, failure to observe the precautions given under " CAUTION" may lead to
serious consequences.
Observe the precautions of both levels because they are important for personal and system safety.
Make sure that the end users read this manual and then keep the manual in a safe place for future
reference.
[Design Precautions]
WARNING
When the MELSEC-WS safety controller detects a fault in the external power supply or itself, it
turns off the outputs. Configure an external circuit so that the connected devices are powered off
according to the output status (off) of the MELSEC-WS safety controller. Incorrect configuration
may result in an accident.
When a load current exceeding the rated current or an overcurrent caused by a load short-circuit
flows for a long time, it may cause smoke and fire. To prevent this, configure an external safety
circuit, such as a fuse.
For safety relays, configure an external circuit using a device such as a fuse or breaker to protect
a short-circuit current.
When changing data and operating status, and modifying program of the running MELSEC-WS
safety controller from the PC, configure a safety circuit in the sequence program or external to the
MELSEC-WS safety controller to ensure that the entire system operates safely.
Before operating the MELSEC-WS safety controller, read the relevant manuals carefully and
determine the operating procedure so that the safety can be ensured.
Furthermore, before performing online operations for the MELSEC-WS safety controller from the
PC, determine corrective actions to be taken for communication errors caused by failure such as a
poor contact.
Create an interlock program using a reset button to prevent the MELSEC-WS safety controller
from restarting automatically after the safety function is activated and the safety controller turns off
the outputs.
1
CAUTION
Ensure that an entire system using the MELSEC-WS safety controller meets the requirements for
the corresponding safety category.
The life of safety relays in the safety relay output module depends on the switching condition
and/or load. Configure a system satisfying the number of switching times of the safety relays in
the module.
Do not install the communication cables together with the main circuit lines or power cables. Keep
a distance of 100 mm or more between them.
Failure to do so may result in malfunction due to noise.
If a mechanical switch such as a relay is connected to an input terminal of a safety I/O module,
consider contact bounce.
Observe the protective notes and measures.
Observe the following items in order to ensure proper use of the MELSEC-WS safety controller.
When mounting, installing and using the MELSEC-WS safety controller, observe the standards
and directives applicable in your country.
The national/international rules and regulations apply to the installation, use and periodic
technical inspection of the MELSEC-WS safety controller, in particular.
Machinery Directive 2006/42/EC
EMC Directive 2004/108/EC
Provision and Use of Work Equipment Directive 89/655/EC
Low-Voltage Directive 2006/95/EC
The work safety regulations/safety rules
Manufacturers and owners of the machine on which a MELSEC-WS safety controller is used
are responsible for obtaining and observing all applicable safety regulations and rules.
The notices, in particular the test notices of this manual (e.g. on use, mounting, installation or
integration into the existing machine controller), must be observed.
The test must be carried out by specialized personnel or specially qualified and authorized
personnel and must be recorded and documented and retraced at any time by third parties.
The external voltage supply of the device must be capable of buffering brief mains voltage
failures of 20 ms as specified in EN 60204.
The modules of the MELSEC-WS safety controller conform to Class A, Group 1, in accordance
with EN 55011. Group 1 encompasses all the ISM devices in which intentionally generated
and/or used conductor-bound RF energy that is required for the inner function of the device
itself occurs.
The MELSEC-WS safety controller fulfils the requirements of Class A (industrial
applications) in accordance with the “Interference emission” basic specifications.
The MELSEC-WS safety controller is therefore only suitable for use in an industrial environment
and not for private use.
2
[Installation Precautions]
WARNING
Do not use the MELSEC-WS safety controller in flammable gas atmosphere or explosive gas
atmosphere. Doing so may result in a fire or explosion due to such as an arc caused by switching
the relays.
CAUTION
Use the MELSEC-WS safety controller in an environment that meets the general specifications in
this manual. Failure to do so may result in electric shock, fire, malfunction, or damage to or
deterioration of the product.
Latch the module onto the DIN mounting rail. Incorrect mounting may cause malfunction, failure or
drop of the module.
To ensure full electromagnetic compatibility (EMC), the DIN mounting rail has to be connected to
functional earth (FE).
Ensure that the earthling contact is positioned correctly. The earthling spring contact of the
module must contact the DIN mounting rail securely to allow electrical conductivity.
Shut off the external power supply (all phases) used in the system before mounting or removing
the module.
Failure to do so may result in damage to the product.
Do not directly touch any conductive part of the module.
Doing so can cause malfunction or failure of the module.
The MELSEC-WS safety controller is only suitable for mounting in a control cabinet with at least
IP 54 degree of protection.
Failure to meet the installation method may cause the module to fail or malfunction due to the
deposition of dust or the adhesion of water.
3
[Wiring Precautions]
WARNING
Shut off the external power supply (all phases) used in the system before wiring.
Failure to do so may result in electric shock or damage to the product.
The system could start up unexpectedly while you are connecting the devices.
CAUTION
Individually ground the GND wires of the MELSEC-WS safety controller with a ground resistance
of 100 Ω or less.
Failure to do so may result in electric shock or malfunction.
Check the rated voltage and terminal layout before wiring to the module, and connect the cables
correctly.
Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or
failure.
Tighten the terminal screw within the specified torque range.
Undertightening can cause short circuit, fire, or malfunction. Overtightening can damage the
screw and/or module, resulting in drop, short circuit, or malfunction.
Prevent foreign matter such as dust or wire chips from entering the module.
Such foreign matter can cause a fire, failure, or malfunction.
Mitsubishi MELSEC-WS safety controllers must be installed in control cabinets. Connect the main
power supply to the MELSEC-WS safety controller through a relay terminal block.
Wiring and replacement of an external power supply must be performed by maintenance
personnel who is familiar with protection against electric shock. (For wiring methods, refer to
Chapter 7.)
Place the cables in a duct or clamp them.
If not, dangling cable may swing or inadvertently be pulled, resulting in damage to the module or
cables or malfunction due to poor contact.
4
[Startup and Maintenance Precautions]
WARNING
Do not touch any terminal while power is on.
Doing so will cause electric shock.
Shut off the external power supply (all phases) used in the system before cleaning the module or
retightening the terminal screws. Failure to do so may result in electric shock.
Tighten the terminal screw within the specified torque range. Undertightening can cause short
circuit, fire, or malfunction.
Overtightening can damage the screw and/or module, resulting in drop, short circuit, or
malfunction.
Safety-oriented devices must be suitable for safety related signals.
A function interruption of safety outputs results in a loss of the safety functions so that the risk of
serious injury exists.
Do not connect any loads that exceed the rated values of the safety outputs.
Wire the MELSEC-WS safety controller so that 24 V DC signals cannot unintentionally contact
safety outputs.
Connect the GND wires of the power supply to earth so that the devices do not switch on when
the safety output line is applied to frame potential.
Use suitable components or devices that fulfill all the applicable regulations and standards.
Actuators at the outputs can be wired single-channeled. In order to maintain the respective Safety
Integrity Level the lines have to be routed in such a manner that cross circuits to other live signals
can be excluded, for example by routing them within protected areas such as in a control cabinet
or in separate sheathed cables.
5
CAUTION
Before performing online operations (Force mode) for the running MELSEC-WS safety controller
from the PC, read the relevant manuals carefully and ensure the safety.
The online operations must be performed by qualified personnel, following the operating
procedure determined at designing.
Fully understand the precautions described in the Safety Controller Setting and Monitoring Tool
Operating Manual before use.
Do not disassemble or modify the modules.
Doing so may cause failure, malfunction, injury, or a fire.
Mitsubishi does not warrant any products repaired or modified by persons other than Mitsubishi or
FA Center authorized by Mitsubishi.
Shut off the external power supply (all phases) used for the MELSEC-WS safety controller before
mounting or removing the module.
Failure to do so may cause the module to fail or malfunction.
After the first use of the product, do not mount/remove the module from/to the DIN mounting rail,
and the terminal block to/from the module more than 50 times (IEC 61131-2 compliant)
respectively.
Exceeding the limit of 50 times may cause malfunction.
Before handling the module, touch a grounded metal object to discharge the static electricity from
the human body.
Failure to do so may cause the module to fail or malfunction.
[Disposal Precautions]
CAUTION
When disposing of this product, treat it as industrial waste.
Disposal of the product should always occur in accordance with the applicable country-specific
waste-disposal regulations (e.g. European Waste Code 16 02 14).
6
CONDITIONS OF USE FOR THE PRODUCT
(1) Although MELCO has obtained the certification for Product's compliance to the international safety
standards IEC61508, ISO13849-1 from TUV Rheinland, this fact does not guarantee that Product will
be free from any malfunction or failure. The user of this Product shall comply with any and all
applicable safety standard, regulation or law and take appropriate safety measures for the system in
which the Product is installed or used and shall take the second or third safety measures other than
the Product. MELCO is not liable for damages that could have been prevented by compliance with
any applicable safety standard, regulation or law.
(2) MELCO prohibits the use of Products with or in any application involving, and MELCO shall not be
liable for a default, a liability for defect warranty, a quality assurance, negligence or other tort and a
product liability in these applications.
1) power plants,
2) trains, railway systems, airplanes, airline operations, other transportation systems,
3) hospitals, medical care, dialysis and life support facilities or equipment,
4) amusement equipments,
5) incineration and fuel devices,
6) handling of nuclear or hazardous materials or chemicals,
7) mining and drilling,
8) and other applications where the level of risk to human life, health or property are elevated.
7
REVISIONS
*The manual number is given on the bottom left of the back cover.
Print date *Manual number Revision
September, 2009 SH(NA)-080855ENG-A First edition
March, 2010 SH(NA)-080855ENG-B A new module, CC-Link interface module, was added.
July, 2011 SH(NA)-080855ENG-C Description on Flexi Link system was added.
December, 2011 SH(NA)-080855ENG-D Correction of errors in writing
August, 2012 SH(NA)-080855ENG-E A new function was added to WS0-XTIO modules.
June, 2013 SH(NA)-080855ENG-F Correction of errors in writing
August, 2014 SH(NA)-080855ENG-G A new module, WS0-CPU3 module, was added.
A new function was added to WS0-XTIO and WS0-XTDI
modules.
Description on Flexi Line system was added.
August, 2016 SH(NA)-080855ENG-H Description on the corporate logo was changed
November, 2018 SH(NA)-080855ENG-I Correction of errors in writing
Japanese manual version SH-080852-I
This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses.
Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which
may occur as a result of using the contents noted in this manual.
2009 MITSUBISHI ELECTRIC CORPORATION
8
CONTENTS
SAFETY PRECAUT IONS ........................................................................................... 1
CONDITIONS OF USE FOR THE PRODUCT ........................................................... 7
REVISIONS ................................................................................................................ 8
CONTENTS ................................................................................................................ 9
GENERIC TERMS AND ABBREVIATIONS .............................................................. 13
1. About this document ............................................................................................. 14
1.1 Function of this document ............................................................................... 14
1.2 Target group .................................................................................................... 15
1.3 Depth of information ........................................................................................ 15
1.4 Scope .............................................................................................................. 16
1.5 Abbreviations used ......................................................................................... 16
1.6 Symbols used .................................................................................................. 16
2. On safety .............................................................................................................. 18
2.1 Qualified safety personnel .............................................................................. 18
2.2 Application areas for the device ...................................................................... 18
2.3 Correct use ...................................................................................................... 19
2.4 General protective notes and protective measures ........................................ 21
2.5 Environmental protection ................................................................................ 22
2.5.1 Disposal .................................................................................................... 22
2.5.2 Material separation ................................................................................... 22
3. Product description ............................................................................................... 23
3.1 System properties ........................................................................................... 23
3.2 System configuration ...................................................................................... 24
3.3 Version, compatibility and features ................................................................. 25
3.4 Memory plug ................................................................................................... 27
3.5 CPU module WS0-CPU0 ................................................................................ 27
3.5.1 Description ................................................................................................ 27
3.5.2 Display elements and terminal description ............................................... 28
3.6 CPU module WS0-CPU1 ................................................................................ 30
3.6.1 Description ................................................................................................ 30
3.6.2 Display elements and terminal description ............................................... 31
9
3.7 CPU module WS0-CPU3 ................................................................................ 32
3.7.1 Description ................................................................................................ 32
3.7.2 Display elements and terminal description ............................................... 33
3.8 WS0-XTIO safety I/O combined module ......................................................... 34
3.8.1 Description ................................................................................................ 34
3.8.2 Display elements and terminal description ............................................... 35
3.8.3 Internal circuits ......................................................................................... 36
3.8.4 Disabling the test pulses of WS0-XTIO outputs Q1 to Q4 ....................... 37
3.8.5 Extended fault detection time for cross-circuits on the outputs
Q1 to Q4 on the WS0-XTIO for switching loads with high capacitance .. 38
3.8.6 Single channel usage of WS0-XTIO outputs ............................................ 39
3.9 WS0-XTDI safety input module ....................................................................... 40
3.9.1 Description ................................................................................................ 40
3.9.2 Display elements and terminal description ............................................... 41
3.9.3 Internal circuits ......................................................................................... 41
3.10 WS0-4RO safety relay output module .......................................................... 42
3.10.1 Description .............................................................................................. 42
3.10.2 Display elements and terminal description ............................................. 43
4. Connecting devices .............................................................................................. 45
4.1 Safety command devices and electro-mechanical safety switches ................ 48
4.1.1 Emergency stop pushbuttons (e.g. SICK ES21) ...................................... 48
4.1.2 Electro-mechanical safety switches with and without interlock ................ 49
4.1.3 Enabling switch (e.g. SICK E100) ............................................................ 50
4.1.4 Two-hand control ...................................................................................... 51
4.1.5 Safety mats and bumpers ........................................................................ 52
4.1.6 User mode switches ................................................................................. 53
4.1.7 Potential-free contacts .............................................................................. 53
4.2 Non-contact safety sensors ............................................................................ 54
4.2.1 Magnetic safety switches (e.g. SICK RE) ................................................ 54
4.2.2 Inductive safety switches (e.g. SICK IN4000 and IN4000 Direct) ............ 54
4.2.3 Transponder (e.g. SICK T4000 Compact and T4000 Direct) ................... 55
4.3 Testable single-beam photoelectric safety switches ....................................... 55
4.3.1 Testable Type 2 single-beam photoelectric safety switches ..................... 55
4.3.2 Testable Type 4 single-beam photoelectric safety switches ..................... 56
4.3.3 Customized testable single beam photoelectric safety switches ............. 57
4.3.4 Information for mounting testable single-beam photoelectric
safety switches ......................................................................................... 57
4.4 Electro-sensitive protective equipment (ESPE) .............................................. 59
4.5 Safety outputs Q1 to Q4 ................................................................................. 59
4.6 EFI devices ..................................................................................................... 59
4.6.1 Connection of EFI devices ....................................................................... 59
4.7 Flexi Link ......................................................................................................... 60
4.7.1 Flexi Link overview ................................................................................... 60
4.7.2 System requirements and restrictions for Flexi Link ................................. 61
4.7.3 Connection of a Flexi Link system............................................................ 61
4.8 Flexi Line ......................................................................................................... 64
4.8.1 Flexi Line overview ................................................................................... 64
4.8.2 Connection of a Flexi Line system ........................................................... 64
4.9 EMC measures for Flexi Link and Flexi Line .................................................. 66
10
5. Special functions................................................................................................... 67
5.1 Enhanced Function Interface - EFI ................................................................. 67
5.1.1 Definition ................................................................................................... 67
5.1.2 Properties ................................................................................................. 67
5.1.3 Functions .................................................................................................. 68
5.1.4 Benefits ..................................................................................................... 68
5.2 Muting ............................................................................................................. 69
6. Mounting/Dismantling ........................................................................................... 70
6.1 Steps for mounting the modules ..................................................................... 70
6.2 Steps for dismantling the modules .................................................................. 72
7. Electrical installation ............................................................................................. 73
7.1 Electrical installation requirements ................................................................. 73
7.2 Internal circuit power supply ........................................................................... 75
8. Configuration ........................................................................................................ 76
9. Commissioning ..................................................................................................... 77
9.1 Full approval of the application ....................................................................... 77
9.2 Tests before the initial commissioning ............................................................ 78
10. Diagnostics ......................................................................................................... 79
10.1 In the event of faults or errors ....................................................................... 79
10.1.1 ERROR operating states ........................................................................ 79
10.2 Error displays of the status LEDs, error messages and
rectification measures ................................................................................... 81
10.3 Additional error displays of SICK EFI-compatible devices ........................... 88
10.4 Mitsubishi support ......................................................................................... 88
10.5 Extended diagnostics .................................................................................... 88
11. Maintenance ....................................................................................................... 89
11.1 Regular inspection of the protective device by
qualified safety personnel ............................................................................. 89
11.2 Device replacement....................................................................................... 90
12. Technical data ..................................................................................................... 91
12.1 Response times of the MELSEC-WS safety controller ................................. 91
12.1.1 Calculation of the response times .......................................................... 92
11
12.1.2 Min. switch off time ................................................................................. 97
12.2 Data sheet ..................................................................................................... 98
12.2.1 CPU modules: WS0-CPU0 , WS0-CPU1 and WS0-CPU3 .................... 98
12.2.2 WS0-XTIO safety input/output combined module ................................ 100
12.2.3 WS0-XTDI safety input module ............................................................ 104
12.2.4 WS0-4RO safety relay output module .................................................. 107
12.3 Dimensional drawings .................................................................................. 111
12.3.1 WS0-CPUx module with memory plug .................................................. 111
12.3.2 WS0-XTIO module, WS0-XTDI module, and WS0-4RO module .......... 111
13. Ordering information .......................................................................................... 112
13.1 Available modules and accessories ............................................................ 112
13.2 Recommended products .............................................................................. 112
14. Annex ............................................................................................................... 113
14.1 EC declaration of conformity ........................................................................ 113
14.2 Manufacturers checklist ............................................................................... 115
14.3 Wiring examples........................................................................................... 116
14.4 Troubleshooting .......................................................................................... 125
14.4.1 Basics of troubleshooting ..................................................................... 125
14.4.2 Troubleshooting flowchart (for CPU module) ....................................... 126
14.4.3 Troubleshooting flowchart (for safety I/O module) ............................... 132
14.4.4 Troubleshooting flowchart (for safety relay output module) ................. 139
14.5 Example for the calculation of the response time of Flexi Line .................. 142
14.6 SICK contact ............................................................................................... 144
12
GENERIC TERMS AND ABBREVIATIONS
Generic
term/abbreviation
WS0-MPL0 The abbreviation for the WS0-MPL000201 MELSEC-WS safety
controller memory plug
WS0-MPL1 The abbreviation for the WS0-MPL100201 MELSEC-WS safety
controller memory plug
WS0-CPU0 The abbreviation for the WS0-CPU000200 MELSEC-WS safety
controller CPU module
WS0-CPU1 The abbreviation for the WS0-CPU130202 MELSEC-WS safety
controller CPU module
WS0-CPU3 The abbreviation for the WS0-CPU320202 MELSEC-WS safety
controller CPU module
WS0-XTIO The abbreviation for the WS0-XTIO84202 MELSEC-WS safety
controller safety I/O combined module
WS0-XTDI The abbreviation for the WS0-XTDI80202 MELSEC-WS safety
controller safety input module
WS0-4RO The abbreviation for the WS0-4RO4002 MELSEC-WS safety
controller safety relay output module
WS0-GETH The abbreviation for the WS0-GETH00200 MELSEC-WS safety
controller Ethernet interface module
WS0-GCC1 The abbreviation for the WS0-GCC100202 MELSEC-WS safety
controller CC-Link interface module
CPU module A generic term for the WS0-CPU0, WS0-CPU1 and WS0-CPU3
Safety I/O module A generic term for the WS0-XTIO and WS0-XTDI
Network module A generic term for the WS0-GETH and WS0-GCC1
Description
13
About this document
1 About this document
Please read this chapter carefully before working with the documentation and the
MELSEC-WS system.
1.1 Function of this document
For the MELSEC-WS system there are three sets of manuals with clearly defined
application as well as user’s manuals (hardware) for each module.
All the MELSEC-WS modules and their functions are described in detail in the
user’s manuals (hardware). Use this manual in particular for the planning of
MELSEC-WS safety controllers.
The hardware manual are designed to address the technical personnel of the
machine manufacturer or the machine operator in regards to safe mounting,
electrical installation, commissioning as well as on operation and maintenance of
the MELSEC-WS safety controller.
The hardware manual does not provide instructions for operating machines on
which the safety controller is, or will be, integrated. Information on this is to be found
in the manuals of the machine.
The Safety Controller Setting and Monitoring Tool Operating Manual describes the
software-supported configuration and parameterization of the MELSEC-WS safety
controller. In addition the manual contains the description of the diagnostics
functions that are important for operation and detailed information for the
identification and elimination of errors. Use the manual in particular for the
configuration, commissioning and operation of MELSEC-WS safety controllers.
The user’s manuals for each network module describe important information on the
configuration of the network modules.
Chapter 1
The user's manuals (hardware) are enclosed with each MELSEC-WS module. They
inform on the basic technical specifications of the modules and contain simple
mounting instructions. Use the user’s manual (hardware) when mounting the
MELSEC-WS safety controller.
14
Chapter 1
Table 1:
Overview of the MELSECWS manuals
About this document
The following shows the relevant manuals.
Title Number
Safety Controller User’s Manual
Safety Controller Ethernet Interface Module User’s Manual
Safety Controller CC-Link Interface Module User’s Manual
Safety Controller Setting and Monitoring Tool Operating
Manual
Safety Controller CPU Module User's Manual (Hardware)
Safety Controller Safety I/O Module User's Manual
(Hardware)
Safety Controller Safety Relay Output Module User's Manual
(Hardware)
Safety Controller Ethernet Interface Module User's Manual
(Hardware)
Safety Controller CC-Link Interface Module User's Manual
(Hardware)
WS-CPU-U-E
(13JZ32)
WS-ET-U-E
(13JZ33)
WS-CC-U-E
(13JZ45)
SW1DNN-WS0ADR-B-O-E
(13JU67)
WS-CPU-U-HW-E
(13JZ91)
WS-IO-U-HW-E
(13JZ92)
WS-SR-U-HW-E
(13JZ93)
WS-ET-U-HW-E
(13JZ95)
WS-CC-U-HW
(13J209)
Note
1.2 Target group
This manual is addressed to the planning engineers, designers and operators of
systems which are to be protected by a MELSEC-WS safety controller. It also
addresses people who integrate the MELSEC-WS safety controller into a machine,
commission it initially or who are in charge of servicing and maintaining the unit.
1.3 Depth of information
This manual contains information on the MELSEC-WS safety controller in the
following subjects:
mounting
electrical installation
hardware commissioning
Planning and using other company's protective devices also require specific technical
skills which are not detailed in this documentation.
When operating the MELSEC-WS safety controller, the national, local and statutory
rules and regulations must be observed.
For the acquisition of Setting and Monitoring Tool, please contact your local Mitsubishi
representative.
error diagnostics and remedying
part numbers
conformity and approval
15
The SICK EFI-compatible devices and SICK configuration and diagnostics software
CDS are the products of SICK.
For details of the SICK products, please contact your local SICK representative (see
Section 14.6).
www.sens-control.com
About this document
Chapter 1
1.4 Scope
These operating instructions are original operating instructions.
This manual is valid for all modules of the MELSEC-WS safety controller with the
exception of the network modules.
This document is the original manual.
To configure and undertake diagnostics on these devices you will need version V1.7.0
or later of the Setting and Monitoring Tool. To check the version of the software, on
the Extras menu select Info.
1.5 Abbreviations used
EDM
EFI
ESPE
NC
NO
OSSD
PFHd
SIL
SILCL
Recommendation
Note
, ,
Action
External device monitoring
Enhanced function interface = safe SICK device communication
Electro-sensitive protective equipment (e.g. light curtains)
Normally closed
Normally open
Output signal switching device
Probability of dangerous failure per hour
Safety integrity level (safety class)
Safety integrity level claim limit
1.6 Symbols used
Recommendations are designed to give you some assistance in your decision-making
process with respect to a certain function or a technical measure.
Notes provide special information on the device.
LED symbols describe the state of a diagnostics LED. Examples:
The LED is illuminated constantly.
The LED is flashing.
The LED is off.
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
ATTENTION
ATTENTION!
An “ATTENTION” indicates concrete or potential dangers. It is intended to protect you
from harm and help avoid damage to devices and systems.
Read warnings carefully and follow them!
Otherwise the safety function may be impaired and a dangerous state may occur.
The term “dangerous state”
The dangerous state (standard term) of the machine is always shown in the drawings
and diagrams of this document as a movement of a machine part. In practical
operation, there may be a number of different dangerous states:
machine m ovements
electrical conductors
16
Chapter 1
About this document
visible or invisible radiation
a combination of several risks and hazards
17
2 On safety
This chapter deals with your own safety and the safety of the equipment operators.
Please read this chapter carefully before working with the MELSEC-WS safety
2.1 Qualified safety personnel
The MELSEC-WS safety controller must be mounted, commissioned and serviced
only by qualified safety personnel.
Qualified safety personnel are defined as persons who
have undergone the appropriate technical training
and
have been instructed by the responsible machine owner in the operation of the
and
are sufficiently familiar with the applicable official health and work safety
and
have access to the MELSEC-WS manuals and have read and familiarized
and
have access to the manuals for the protective devices (e.g. light curtains)
On safety
controller or with the machine protected by the MELSEC-WS safety controller.
machine and the current valid safety guidelines
regulations, directives and generally recognized engineering practice (e.g. DIN
standards, VDE stipulations, engineering regulations from other EC member
states) that they can assess the work safety aspects of the power-driven
equipment
themselves with them
connected to the safety controller and have read and familiarized themselves with
them.
Chapter 2
2.2 Application areas for the device
The MELSEC-WS safety controller is a configurable controller for safety
applications. It can be used …
in accordance with IEC61508 to SIL3
in accordance with IEC 62061 to SILCL3
in accordance with EN/ISO 13849-1 up to Performance Level e
The degree of safety actually attained depends on the external circuit, the realization
of the wiring, the parameter configuration, the choice of the pick-ups and their
location at the machine.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safety
switches, sensors, encoders, emergency stop pushbuttons) are connected to the
safety controller and are linked logically. The corresponding actuators of the
machines or systems can be switched off safely via the switching outputs of the
safety controller.
18
Chapter 2
ATTENTION
ATTENTION
On safety
2.3 Correct use
The MELSEC-WS safety controller fulfills the requirements of Class A
(industrial applications) in accordance with the “Interference emission” basic
specifications.
The MELSEC-WS safety controller is therefore only suitable for use in an industrial
environment and not for private use.
The MELSEC-WS safety controller may only be used within specific operating limits
(voltage, temperature, etc., refer to the technical data in Chapter 12) in the sense of
Section 2.2 and Section 7.1. It may only be used by specialist personnel and only at
the machine at which it was mounted and initially commissioned by qualified
personnel in accordance with the MELSEC-WS manuals.
All warranty claims against Mitsubishi Electric Corporation are forfeited in the case
of any other use, or alterations being made to the software or to devices, even as
part of their mounting or installation.
Pay attention to the safety notes and protective measures of the user’s manuals
(hardware) and Safety Controller Setting and Monitoring Tool Operating Manual!
Make sure that on the implementation of safety-related functional logic, the
regulations in the national and international standards are met, in particular the
control strategies and the measures for risk reduction that are stipulated for your
application.
The external voltage supply of the device must be capable of buffering brief mains
voltage failures of 20 ms as specified in IEC 60204.
The MELSEC-WS safety controller may not start up normally when power is
restored immediately after the external power supply has been shut off (within 5
seconds). To restore the power, wait for 5 or more seconds after power-off.
The modules of the MELSEC-WS safety controller conform to Class A, Group 1,
in accordance with EN 55011. Group 1 encompasses all ISM devices in which
intentionally generated and/or used conductor-bound RF energy that is required
for the inner function of the device itself occurs.
19
Note
On safety
Chapter 2
UL/CSA applications
Only use the following cables:
– for spring clamp terminals: 24 to 16 AWG, copper, suitable for temperatures of
60 to 75 °C
– for plug-in terminals: 30 to 12 AWG, copper, suitable for temperatures of 60 to
75 °C
The plug-in terminal tightening torque must be 0.5 to 0.6 N·m.
Use the devices only in an environment with a pollution degree of 2 or better.
The modules shall be supplied by an isolating power source protected by an
UL248 fuse, rated max. 100/V, where V is the DC supply voltage with the
maximum value of 42.4 V DC, such that the limited voltage/current requirements
of UL508 are met.
Max. WS0-XTIO Q1 … Q4 total current I
= 3.2 A
sum
Network modules (WS0-GETH and WS0-GCC1) are intended to be used with
Class 2. Therefore the CPU module must be supplied in this case with a Class 2
power source or Class 2 transformer in accordance with UL 1310 or UL 1585.
The safety functions are not evaluated by UL. The approval is accomplished
according to UL 508, general use applications.
20
Chapter 2
ATTENTION
On safety
2.4 General protective notes and protective measures
Observe the protective notes and measures!
Please observe the following items in order to ensure proper use of the MELSECWS safety controller.
Note
When mounting, installing and using the MELSEC-WS safety controller, observe
the standards and directives applicable in your country.
The national/international rules and regulations apply to the installation, use and
periodic technical inspection of the MELSEC-WS safety controller, in particular:
*1
– Machinery Directive 2006/42/EC
– EMC Directive 2004/108/EC
– Provision and Use of Work Equipment Directive 2009/104/EC
– Low-Voltage Directive 2006/95/EC
– the work safety regulations/safety rules
Manufacturers and owners of the machine on which a MELSEC-WS safety
controller is used are responsible for obtaining and observing all applicable safety
regulations and rules.
The notices, in particular the test notices (see Chapter 9) of this manual (e.g. on
use, mounting, installation or integration into the existing machine controller) must
be observed.
The tests must be carried out by specialized personnel or specially qualified and
authorized personnel and must be recorded and documented to ensure that the
tests can be reconstructed and retraced at any time by third parties.
This manual must be made available to the user of the machine where the
MELSEC-WS safety controller is used. The machine operator is to be instructed
in the use of the device by qualified personnel and must be instructed to read the
manual.
*1 WS0-4RO only.
21
ATTE NT IO N
On safety
Chapter 2
2.5 Environmental protection
The MELSEC-WS safety controller has been designed to minimize environmental
impact. It uses only a minimum of power and natural resources.
At work, always act in an environmentally responsible manner.
2.5.1 Disposal
Disposal of unusable or irreparable devices should always occur in accordance with
the applicable country-specific waste-disposal regulations (e.g. European Waste
Code 16 02 14).
2.5.2 Material separation
Material separation may only be performed by qualified safety personnel!
Exercise care when disassembling the devices. The danger of injury is present.
Before you can turn over the devices for environmental-friendly recycling, you must
separate the different materials of the MELSEC-WS module from one another.
Table 2:
Overview of disposal by
component
Separate the housing from the remaining components (especially the PCB).
Send the separated components to the corresponding recycling centers (see the
following table).
Component Disposal
Product
Housing
PCBs, cables, plugs and electrical connection
pieces
Packaging
Cardboard, paper
Plastic recycling
Electronics recycling
Paper/cardboard recycling
22
Chapter 3
Product description
3 Product description
This chapter provides information on the features and properties of the MELSEC-WS
safety controller and describes the structure and operating principle.
3.1 System properties
Figure 1:
MELSEC-WS safety
controller
The MELSEC-WS safety controller is characterized by the following system
properties:
modular structure: 1 CPU module, up to 12 - safety I/O modules, up to 4 safety
relay output modules, and up to 2 different network modules each with 22.5 mm
compact width
8 to 96 inputs and 4 to 48 safe outputs
programmable
use of up to 255 standard and application-specific logic blocks
standard logic blocks, e.g. AND, OR, NOT, XNOR, XOR
application-specific logic blocks, e.g. emergency stop, two-hand, muting, press,
ramp down, operating mode selector switch, reset, restart
integration in different networks via network modules possible (Ethernet and CC-
Link)
2 EFI interfaces on the WS0-CPU1 and WS0-CPU3 modules, see Section - 3.6
The Setting and Monitoring Tool is available for configuring the control tasks.
For the acquisition of Setting and Monitoring Tool, please contact your local Mitsubishi
representative.
23
Figure 2:
Examples for the minimum
configuration of a MELSECWS safety controller with
WS0-CPU0 and WS0-XTDI
or WS0-CPU1 and WS0XTIO
Product description
Chapter 3
3.2 System configuration
A MELSEC-WS safety controller consists of the following modules:
a memory plug
CPU module
up to 2 network modules
up to 12 additional safety I/O modules.
in addition up to 4 WS0-4RO safety relay output modules (meaning a max. of 16
safe relay outputs).
Figure 3:
Maximum configuration of
the MELSEC-WS safety
controller (without safety
relay output module)
Table 3:
Overview of the modules
Type Kind Inputs Outputs
WS0-CPU0
– –
CPU module
WS0-CPU3 4*1 –
WS0-XTIO Safety I/O combined module 8 4 –
WS0-XTDI Safety input module 8 – –
WS0-4RO Safety relay output module – 4 – 4×*2
WS0-GETH Ethernet interface module – – – 2×
WS0-GCC1 CC-Link interface module – – – –
*1 EFI terminals.
*2 Max. of 16 safe relay outputs.
Logic
blocks
255 1× WS0-CPU1 4*1 –
occurrence
Max.
12×
24
Chapter 3
Table 4:
Required firmware and
software versions
Product description
3.3 Version, compatibility and features
For the MELSEC-WS series several firmware versions and function packages exist
that allow different functions. This section gives an overview which firmware version,
which function package and/or which version of the Setting and Monitoring Tool is
required to use a certain function or device.
Feature WS0-CPU
Logic offline simulation –*1 – V1.2.0
Logic import/export – – V1.3.0
Automatic wiring diagrams – – V1.3.0
Online edit – – V1.3.0
Central tag name editor – – V1.3.0
Flexi Link (only with WS0CPU1/3)
Flexi Line (only with WS0CPU3)
Function block
documentation within the
Setting and Monitoring Tool
Input/output relation matrix – – V1.3.0
Invertable inputs for the AND,
OR, RS Flip-Flop and
Routing N:N function blocks
Ramp down detection
function block
Adjustable on-delay timer
and Adjustable off-delay
timer function blocks
Fast Shutoff function block
with bypass (only with
WS0-XTIO)
It is possible to deactivate the
test signals on Q1-Q4 on the
XTIO
Verification without identical
hardware possible
Status input data and Status
output data in logic
Data recorder V2.01
Extended cross-circuit
detection time for switching
loads with high capacitance
Adjustable filter time for OnOff filters and Off-On filters
on the inputs I1 to I8 on the
WS0-XTIO/XTDI
Minimum required firmware or software version
WS0-XTIO/
WS0-XTDI
V2.01
(Revision 2.xx)
V3.02
(Revision 3.xx)
– – V1.3.0
V2.01
(Revision 2.xx)
V1.11
(Revision 1.xx)
V2.01
(Revision 2.xx)
V2.01
(Revision 2.xx)
–
V2.01
(Revision 2.xx)
V2.01
(Revision 2.xx)
(Revision 2.xx)
–
–
– V1.3.0
– V1.7.0
– V1.3.0
– V1.3.0
– V1.3.0
V2.00
(Revision 2.xx)
V2.00
(Revision 2.xx)
– V1.0.0
V2.00
(Revision 2.xx)
– V1.7.0
V3.10
(Revision 3.xx)
V3.10
(Revision 3.xx)
Setting and
Monitoring Tool
V1.7.0
V1.3.0
V1.3.0
V1.7.0
V1.7.0
25
Product description
Chapter 3
Note
Device WS0-CPU
Ethernet interface module V1.11
CC-Link interface module V1.11
ROHS conformity WS0-XTIO
*1 “–” means “any” or “not applicable”.
*2 All other modules from product launch onwards.
Minimum required firmware or software version
(Revision 1.xx)
(Revision 1.xx)
–
WS0-XTIO/
WS0-XTDI
– V1.2.0
– V1.2.1
Hardware version
V1.01 or higher
*2
Setting and
Monitoring Tool
–
You can find the firmware version on the type label of the MELSEC-WS modules in
the field firmware version.
To be able to use modules with a new firmware version, you will need a new
version of the Setting and Monitoring Tool. For WS-CPU0/1 ≥ V2.01 as well as
WS0-XTIO/XTDI ≥ V2.00 the Designer with at least V1.3.0 is required. This aspect
is to be taken into account on the replacement of devices in existing systems.
You will find the hardware version of the MELSEC-WS modules in the hardware
configuration of the Setting and Monitoring Tool in the Online state or in the report if
the system was online previously.
The version of the Setting and Monitoring Tool can be found in the Extras menu
under About.
For the acquisition of the newest version of the Setting and Monitoring Tool, please
contact your local Mitsubishi representative.
The function package (Revision 1.xx or Revision 2.xx) must be selected in the
Setting and Monitoring Tool hardware configuration. Function package Revision
2.xx is available with Setting and Monitoring Tool 1.3.0 and higher.
In order to use function package Revision 2.xx, the respective module must have at
least firmware version V2.00.0. Otherwise you will receive an error message when
you try to upload a configuration using Revision 2.xx to a module with a lower
firmware version.
Newer modules are downward compatible so that any module can be replaced by a
module with a higher firmware version.
The same firmware version and function package revision as those of the module
used must be set to the new project after a project stored in the memory plug is
modified.
You will find the device’s date of manufacture at the bottom of the type label in the
format yywwnnnn (yy = year, ww = calendar week, nnnn = continuos serial number
in the calendar week).
26
Chapter 3
Product description
3.4 Memory plug
On each CPU module there is a memory plug. The system configuration for the entire
MELSEC-WS safety controller is only saved in the memory plug. On the replacement
of modules this situation has the advantage that it is not necessary to re-configure that
the MELSEC-WS safety controller.
There are two different variants of the memory plug that can only be used with specific
CPU modules.
Table 5: Variants of the
memory plug
Note
Memory plug Compatible CPU modules Functions
WS0-MPL0 WS0-CPU0
WS0-CPU1
WS0-MPL1 WS0-CPU3 Electrical supply of the MELSEC-WS safety
Electrical supply of the MELSEC-WS safety
controller
Storing the system configuration (without
EFI-compatible devices)
controller
Storing the system configuration (including
EFI-compatible devices)
The CPU module, the internal logic for all modules as well as the inputs (I1…I8)
and test outputs (X1…X8) on the safety I/O modules are only supplied electrically
via the memory plug. On the other hand the outputs are supplied separately (Q1 to
Q4, Y1 to Y6 as well as IY7 and IY8).
The data saved in the memory plug are also retained on an interruption in the
supply of power.
If modules are replaced, ensure that the memory plug is reconnected to the correct
CPU module. Mark all the connecting cables and plug connectors unambiguously
on the MELSEC-WS safety controller to avoid confusion.
If you use a memory plug WS0-MPL0, then after the replacement of EFI-compatible
devices connected you must configure the devices again.
27
Note
3.5 CPU module WS0-CPU0
3.5.1 Description
The WS0-CPU0 module is the central process unit of the entire system in which all the
signals are monitored and processed logically in accordance with the configuration
stored in the memory plug. The outputs of the system are switched as a result of the
processing, whereby the FLEXBUS+ backplane bus serves as the data interface.
The CPU module WS0-CPU0 can only be operated together with the memory plug
WS0-MPL0.
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