Mitsubishi MELSEC-WS0-CPU0, MELSEC-WS0-CPU3, MELSEC-WS, MELSEC-WS0-CPU1, MELSEC-WS0-XTIO User Manual

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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.

 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.

 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.

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.

[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.

[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.

[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.

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).

 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.

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

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

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

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

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

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

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.

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

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

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

Chapter 1

About this document

 visible or invisible radiation

 a combination of several risks and hazards

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.

Chapter 2

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.

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.

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:

– 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.

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

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.

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×

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)

–

– V1.3.0

– V1.7.0

– 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

V1.7.0

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)

–

WS0-XTIO/

WS0-XTDI

– V1.2.0

– V1.2.1

Hardware version

V1.01 or higher

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).

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.

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.

Figure 4: Display elements WS0CPU0

Product description

3.5.2 Display elements and terminal description

Chapter 3

Product description

Table 6: Displays of the MS LED WS0-CPU0

MS LED Meaning Notes



Red/Green (1 Hz) A self test is being carried

Supply voltage is outside range

Switch on the supply voltage and check it at the terminals A1 and A2.

Please wait … out or the system is being initialized

Green (1 Hz) System is in Stop state Start the application in the Setting and

Monitoring Tool.

Green (2 Hz) Identify (e.g. for Flexi Link) –



Green System is in Run state –

Red (1 Hz) Invalid configuration Check the module type and version of

the CPU module and safety I/O

modules whose MS LED flashes

Red/green.

If appropriate, adapt the configuration

using the Setting and Monitoring Tool.

For detailed information refer to the

Setting and Monitoring Tool,

Diagnostics view.

Red (2 Hz) Critical error in the system,

possibly in this module. Application is stopped. All outputs are switched off.

Switch the supply voltage off and on

again. If the error is not eliminated after

multiple repetition, replace this module.

For detailed diagnostics information

refer to the Setting and Monitoring Tool.

Table 7: Displays of the CV LED WS0-CPU0

Table 8: Memory plug pin assignment



Red Critical error in the system,

possibly in another module. Application is stopped. All outputs are switched off.

Switch the supply voltage off and on

again.

If the error is not eliminated after

multiple repetition, replace the module

which displays Red (2 Hz). If this is

not the case, use the diagnostic

functions of the Setting and Monitoring

Tool to narrow down the respective

module.

CV LED Meaning Note



Yellow (2 Hz) Storing of configuration

Configuration in progress –

Supply voltage may not be interrupted

data in the non-volatile memory

until the storage process has been

completed.

Yellow (1 Hz) Unverified configuration Verify configuration with the Setting and

Monitoring Tool.



Yellow Verified configuration –

Pin Assignment

A1 24 V voltage supply for all the modules, with the exception of the outputs

(Q1…Q4)

A2 GND of the voltage supply

Table 9: Pin assignment of the RS-232 interfacee CPU0

on WS0-

Note

Product description

Chapter 3

RS-232 interface

The CPU module furthermore has an RS-232 interface with the following functions:

 Transferring the configuration from the Setting and Monitoring Tool to the memory

plug

 Uploading the configuration from the memory plug to the Setting and Monitoring

Tool

 Diagnostics of the MELSEC-WS safety controller with the Setting and Monitoring

Tool

Assignment PC-

Plug/socket Pin Signal Color

Reserved

RxD

3 GND (Internally electrically

connected with connection A2 of the CPU module)

4 TxD Black Pin 2

Brown

White

Blue

sided RS-232

D-Sub (9 pins)

–

Pin 3

Pin 5

 If the RS-232 interface at the CPU module is connected permanently for usage as

an alternative to a network module, the maximum permissible cable length is 3 m.

Note

 Avoid ground loops between the GND of the RS-232 interface and the connection

A2 of the CPU module, e.g. by using optocouplers.

3.6 CPU module WS0-CPU1

3.6.1 Description

The WS0-CPU1 module has the same functions as the WS0-CPU0. Please observe the notes in Section 3.6.

The CPU module WS0-CPU1 can only be operated together with the memory plug WS0-MPL0.

In addition this module has 2 EFI interfaces. If SICK EFI-compatible devices are connected, the following additional functions can be used:

 Transferring the configuration from the Setting and Monitoring Tool to the memory

plug and to the connected SICK EFI-compatible devices

 Uploading the configuration from the memory plug and the connected SICK EFI-

compatible devices to the Setting and Monitoring Tool

 Diagnostics of the MELSEC-WS safety controller and the connected SICK EFI-

compatible devices with the Setting and Monitoring Tool

 Process data exchange between CPU module and SICK EFI-compatible devices.

 Connection of up to four WS0-CPU1 modules as a Flexi Link system (see Section

4.7).

For further information about EFI interfaces refer to Section 5.1.

Chapter 3

Figure 5: Display elements WS0-CPU1

Product description

3.6.2 Display elements and terminal description

The displays of the MS and CV LEDs as well as the pin assignment of the RS-232 interface are identical with those of the WS0-CPU0, see Section 3.5.2.

Table 10: Displays of the EFI LEDs on WS0-CPU1

EFI LED

(EFI1 or EFI2)





Red Waiting for integration of any SICK EFI-compatible

OK –

device or Flexi Link station after power up

Red (1 Hz)

Error, e.g.:

 Any expected SICK EFI-compatible device or

Flexi Link station not found within 3 minutes

 Integration check failed

 Communication interruption

 SICK EFI-compatible device address conflict

 Flexi Link ID conflict

Red

Identify, (e.g. for Flexi Link) –

(2 Hz, alternating)

Meaning Note

–

Check the wiring. Later integration is still possible.

Note

Product description

Chapter 3

3.7 CPU module WS0-CPU3

3.7.1 Description

The CPU module WS0-CPU3 has the same functions as the CPU module WS0CPU1.Please observe the notes in Section 3.7.

In addition this module has a Flexi Line interface that permits the safe networking of

up to 32 MELSEC-WS stations (see Section 4.8).

The CPU module WS0-CPU3 can only be operated together with the memory plug WS0-MPL1.

Chapter 3

Figure 6: Display elements WS0-CPU3

Product description

3.7.2 Display elements and terminal description

The indications on the MS and CV LEDs as well as the terminal assignment for the RS-232 interface are identical to the CPU module WS0-CPU3 (see section 3.5.2).

The indications on the EFI1 and EFI2 LEDs are identical to the CPU module WS0CPU1 (see section 3.6.2).

Table 11: Displays of the EFI LEDs on WS0-CPU3

LINE LED Meaning





Green Flexi Line in operation

Green (1 Hz)

Green (2 Hz) Teaching required

Red/Green (2

Hz)

Red(1 Hz) Error on the Flexi Line bus, e.g. communication interrupted



Red Critical fault, Flexi Line stopped

Flexi Line not configured and not in operation

Flexi Line started, waiting for neighboring stations

Flexi Line configuration required

USB interface

WS-CPU3 module furthermore has a USB interface with the following functions:

 Transferring the configuration from the Setting and Monitoring Tool to the memory

plug

 Uploading the configuration from the memory plug to the Setting and Monitoring

Tool

 Diagnostics of the MELSEC-WS safety controller with the Setting and Monitoring

Tool

Note

Product description

Chapter 3

3.8 WS0-XTIO safety I/O combined module

3.8.1 Description

The WS0-XTIO module is an input/output extension with 8 safe inputs and 4 safe outputs. It has two test signal generators: One for test output X1 and one for test output X2.

 The WS0-XTIO module offers the following functions:

 Monitoring of the connected safety devices, also refer to Chapter 4.

 Passing on the input information to the CPU module

 Receiving the control signals from the CPU module and corresponding switching of

the outputs

 Fast shut-off: Direct shut-down of the actuators connected to the module possible

from firmware version V1.11.0 on the CPU module CPU0 or CPU1 as well as with all firmware versions on the CPU module CPU3. Version V1.2.0 or later of the Setting and Monitoring Tool required for this purpose.

This feature significantly reduces the response time of the overall system. For switching off outputs, only 8 ms have to be added to the response times of the devices connected to the inputs and outputs. The response time on the FLEXBUS+ backplane bus as well as the logic execution time are irrelevant in this case. See also Section 12.1.

 Enabling or disabling of test pulses for outputs Q1 to Q4 with firmware version

V2.00.0 or higher and Setting and Monitoring Tool version V1.3.0 or higher.

The WS0-XTIO module cannot be used alone and always requires a WS0-CPU0 or WS0-CPU1 module. See the Safety Controller Setting and Monitoring Tool Operating Manual.

The simultaneous use of several WS0-XTIO modules is possible, see Section 3.2.

Voltage for the internal logic and the test outputs is supplied from the memory plug via the FLEXBUS+ backplane bus.

Voltage for the WS0-XTIOs outputs Q1…Q4 must be supplied directly via A1/A2 on the respective module.

 Short-circuits between test signal generators on MELSEC-WS safety controller I/O

module are detected, also between test signal generators on different modules, provided the test gaps are ≤ 4 ms and the test periods are ≥ 200 ms for the relevant test outputs.

 Short circuits to 24 V DC (stuck at high) at inputs connected to test outputs are

detected independently of the test gap time.

Chapter 3

Figure 7: Display elements WS0-XTIO

Product description

3.8.2 Display elements and terminal description

Table 12: Terminal assignment WS0-XTIO

Terminal Assignment

X1/X2 Test outputs 1 and 2

I1…I4 Safe inputs 1 to 4

A1 24 V

A2 GND

I5…I8 Safe inputs 5 to 8

Q1…Q4 Outputs 1 to 4

MS LED Meaning Notes



Supply voltage is outside range Switch on the supply voltage and check it at the

terminals A1 and A2.

Red/green

(1 Hz)

With firmware V1.xx.0: Invalid configuration –

With firmware ≥ V2.00.0: Recoverable external error

Check the wiring of the flashing inputs and outputs. If all output LEDs flash, check the supply voltage at

terminals A1 and A2 of this module.

Green

(1 Hz)



Green

Red

(1 Hz)

System is in Stop state Start the application in the Setting and Monitoring

Tool.

System is in Run state –

With firmware V1.xx.0: Recoverable external error Check the wiring of the flashing inputs and outputs.

If all output LEDs flash, check the supply voltage at terminals A1 and A2 of this module.

With firmware ≥ V2.00.0: Invalid configuration –

Red

(2 Hz)

With firmware ≥ V2.00.0: Critical error in the system, possibly in this module. Application is stopped. All outputs are switched off.

Switch the supply voltage off and on again. If the error is not eliminated after multiple repetition,

replace the module. For detailed diagnostics information refer to the Setting and Monitoring Tool ., Diagnostics view.



Red

With firmware V1.xx.0: Critical error in the system, possibly in this module or another module. Application is stopped. All outputs are switched off.

With firmware ≥ V2.00.0: Critical error in the system, possibly in another module. Application is stopped. All outputs are switched off.

Table 13: Displays of the MS LED

Switch the supply voltage off and on again. If the error is not eliminated after multiple repetition,

replace the module which displays Red (2 Hz). If this is not the case, use the diagnostic functions of the Setting and Monitoring Tool to narrow down the respective module.

Product description

Chapter 3

Table 14: Displays of the input/output

on WS0-XTIO

LEDs

Note

Figure 8: Internal circuits WS0-XTIO safe inputs and test outputs

Input LEDs (I1…I8)

Output LEDs (Q1…Q4)





Green Input/output is active.

Green (1 Hz) synchronous with the

red MS LED

Green (1 Hz) alternating with the red

MS LED

Input/output is inactive.

Input/output is inactive and there is a correctable error.

Input/output is active and there is a correctable error.

Meaning

The input and output LEDs display the states with a refresh rate of approx. 64 ms.

3.8.3 Internal circuits

Figure 9: Internal circuits WS0-XTIO outputs Q1 to Q4

Chapter 3

ATTENTION

Product description

3.8.4 Disabling the test pulses of WS0-XTIO outputs Q1 to Q4

It is possible to disable the test pulses on one or several outputs of WS0-XTIO modules with firmware version V2.00.0 and higher.

Disabling the test pulses of any output reduces the safety parameters of all outputs!

Disabling the test pulses of one or more outputs of an WS0-XTIO module will reduce the parameters for all outputs Q1 to Q4 of this module. Consider this to ensure that your application conforms to an appropriate risk analysis and avoidance strategy!

For detailed information on the safety parameters see chapter 12.

Use protected or separate cabling!

If you disable the test pulses of one or more outputs Q1 to Q4, you have to use protected or separate cabling for the outputs with disabled test pulses, because a short circuit to 24 V can not be detected if the output is High. This could inhibit the switch-off capability for the other outputs in case of an internal detected hardware failure due to reverse powering.

Perform cyclic tests if the test pulses of any safety output are disabled!

If you disable the test pulses of one or more safe outputs Q1 to Q4, at least once per year either all outputs without test pulses have to be switched off at the same time for at least one second as a result of the logic program of the CPU module. Alternatively a power reset of the safety controller has to be performed.

How to disable the test pulses of an XTIO output Q1 to Q4:

 Connect an output element to the WS0-XTIO module.

 Double-click the output element using the left mouse button.  Deactivate the option Enable test pulses of this output. The test pulses of this

output are switched off. A notice will be displayed in the hardware configuration area under the respective WS0-XTIO module.

Table 15: Maximum extended fault detection times for crosscircuits on WS0-XTIO

Product description

Chapter 3

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

From firmware version V3.10 it is possible to configure an extended fault detection time for cross-circuits for the outputs Q1 to Q4 on WS0-XTIO modules.

This configuration can be necessary for switching loads on which there is a crosscircuit fault immediately after switching off (change from high to low) with a normal fault detection time because the voltage at the load does not drop to the low level as quickly as expected. Examples of such cases are:

 Loads with higher capacitance than permitted as standard for the output, e.g. the

supply voltage for programmable controller output cards for safety-related switching.

For this application the test pulse for the output must also be deactivated (see section 3.8.4).

 Inductive loads that cause an overshoot in the positive voltage range after the

induction voltage has decayed.

WS0-XTIO

firmware

Version

≤ V2.xx Not possible 3 ms

Option for switching loads

with high capacitance

Maximum time to low level (≤ 3.5 V)

allowed after switching off the output

(Q1 to Q4)

ATTENTION

≥ V3.10 Deactivated 3 ms

Activated 43 ms

The capacitance beyond the value that is permitted for the output as standard must be discharged to the low level in the customer’s installation after switching off the output. If this condition is not met within the maximum time allowed, there will be a crosscircuit fault on the output independent of whether the test pulses on this output are activated or deactivated.

Pay attention to the suitability of the programmable controller output card for the safety-related shut down of the outputs by switching the supply voltage!

The safety-related shut down capability can be affected or even lost as a result of the following faults:

 Undetected cross-circuit on an output on the programmable controller output card

that can result in the reverse supply of the programmable controller output card. In some circumstances this fault can be excluded by laying wiring in an adequately protected area.

 Undetected fault on the programmable controller output card that can result in the

external supply of the programmable controller output card by another live signal.

 Extension of the response time by a buffer capacitor in the supply for the

programmable controller output card.

Please note that the outputs on the WS0-XTIO modules cannot discharge this buffer capacitor, as it is normally behind a reverse polarization protection diode.

Chapter 3

ATTENTION

Product description

How to activate the option for switching loads with high capacitance on output Q1 to Q4 on the WS0-XTIO:

 Connect an output element to the WS0-XTIO module.

 Double-click the output element using the left mouse button.  Select the Enable switching extended capacitive loads with this output option.

Note the increased error detection time!

Activating the option for switching loads with high capacitance increases the error detection time. This applies primarily to single-channel outputs.

3.8.6 Single channel usage of WS0-XTIO outputs

Take into account possible brief switching to high on signal-channel outputs!

In the case of an internal hardware fault outputs Q1 to Q4.which would normally be low, may briefly switch to high until the fault is detected. and there is a response to the fault. The fault detection time plus the fault reaction time is dependent on the configuration selected for the output.

WS0-XTIO firmware

version

Activation of the switching of

loads with high capacitance

Error detection time +

error response time

≤ V2.xx Not possible ≤ 10 ms

≥ V3.10 Deactivated ≤ 10 ms

Activated ≤ 50 ms

Take into account this aspect in your risk analysis and risk reduction strategy, above all for single-channel outputs. Otherwise the operator of the machine will be in danger.

ATTENTION

Product description

Chapter 3

3.9 WS0-XTDI safety input module

3.9.1 Description

The WS0-XTDI module is the input extension with 8 safe inputs. It offers the following functions:

 monitoring of the connected sensor equipment, also refer to Chapter 4.

 passing the input information to the CPU module

The WS0-XTDI module cannot be used alone and always requires a main CPU module.

The simultaneous use of several WS0-XTIO modules is possible, see Section 3.2.

Voltage for the internal logic and the test outputs is supplied from the memory plug via the FLEXBUS+ backplane bus.

Limited short-circuit recognition!

A WS0-XTDI has two test signal generators. One test signal generator is responsible for the odd-numbered test outputs X1, X3, X5 and X7, the other for the evennumbered test outputs X2, X4, X6 and X8.

Short-circuits between test signal generators on module are detected, also between test signal generators on different modules, provided the test gaps are ≤ 4 ms and the test periods are ≥ 200ms for the relevant test outputs. Short circuits to 24 V DC (stuck at high) at inputs connected to test outputs are detected independently of the test gap time.

Please be aware that at the WS0-XTDI the odd-numbered test outputs X1, X3, X5 and X7 are connected to one common test signal generator and that the even-numbered test outputs X2, X4, X6 and X8 are connected to another common test signal generator. Therefore short circuits between test outputs X1, X3, X5 and X7 cannot be detected. The same applies respectively for test outputs X2, X4, X6 and X8.

 Take this into consideration during the wiring (e.g. separate routing, sheathed

cables)!

Chapter 3

Figure 10: Display elements WS0-XTDI

Table 16: Terminal assignment WS0-XTDI

Product description

3.9.2 Display elements and terminal description

The displays of the MS LED as well as the input LEDs I1…I8 are identical with those of the WS0-XTIO, see Section 3.7.2.

Terminal Assignment

X1/X3 Test output 1 (test signal generator 1)

X2/X4 Test output 2 (test signal generator 2)

I1…I4 Safe inputs 1 to 4

I5…I8 Safe inputs 5 to 8

X5/X7 Test output 1 (test signal generator 1)

X6/X8 Test output 2 (test signal generator 2)

Figure 11: Internal circuits WS0-XTDI – safe inputs and test outputs

3.9.3 Internal circuits

Figure 12: Example of the inclusion of a relay output module in the MELSEC-WS safety controller

Product description

Chapter 3

3.10 WS0-4RO safety relay output module

3.10.1 Description

The WS0-4RO safety relay output module provides dual-channel contact-based outputs with positively guided relay contacts.

The WS0-4RO safety relay output module cannot be used independently, but need to be switched via a WS0-XTIO module. To this purpose a control output of the WS0-XTIO module (Q1…Q4) has to be jumpered to a control input of the relay output module (B1, B2), see the following figure.

ATTENTION

Note

Monitor the feedback contacts using an EDM function block!

It is not sufficient to connect the control outputs B1 or B1/B2. Additionally, the feedback contacts Y1/Y2 and Y3/Y4 on the WS0-4RO safety relay module must be monitored using an EDM function block in the Setting and Monitoring Tool logic editor.

The safety relay output module is not participating at the FLEXBUS+ backplane bus communication. Control signals can therefore not be received from the CPU module.

A max. of four WS0-4RO safety relay output modules can be connected to a MELSEC-WS safety controller, i.e. a maximum of 16 safe relay outputs are available.

WS0-4RO

The WS0-4RO has two control inputs (B1, B2). These control two times two internal relays that provide two independently redundant switch-off paths.

Control input (B1) controls two internal relays and provides a redundant switch-off path consisting of:

 two safe enabling circuits (13/14, 23/24), dual-channel and potential-free,

 a signaling circuit (Y14), dual-channel and connected to internal 24 V DC,

 a feedback EDM (Y1/Y2), dual-channel and potential-free.

Control input (B2) controls two internal relays and forms a redundant switch-off path consisting of:

Chapter 3

Figure 13: Internal configuration WS0-4RO

Figure 14: WS0-4RO display elements

Product description

 two safe enabling circuits (33/34, 43/44), dual-channel and potential-free,

 a signaling circuit (Y24), dual-channel and connected to internal 24 V DC,

 a feedback EDM (Y3/Y4), dual-channel and potential-free.

3.10.2 Display elements and terminal description

Table 17: WS0-4RO displays

Display Meaning

PWR (green) Supply voltage via safety bus is applied

K1/2 (green) Relay K1/K2 - safety contacts closed

K3/4 (green) Relay K3/K4 - safety contacts closed

Product description

Chapter 3

Table 18: WS0-4RO terminals

Assignment Description

B1 Connecting relay K1/K2

B2 Connecting relay K3/K4

13/14 and 23/24 Safety contacts for switch-off circuit outputs K1/K2

33/34 and 43/44 Safety contacts for switch-off circuit outputs K3/K4

Y1/Y2 Feedback EDM K1/K2, NC contact

Y3/Y4 Feedback EDM K3/K4, NC contact

Y14

Y24

NO safety contact K1/K2, current-limited (see

Chapter 12)

NO safety contact K3/K4, current-limited (see Chapter 12)

Chapter 4

Connecting devices

4 Connecting devices

This chapter describes the connection of safety sensors and actuators to the MELSEC-WS safety controller and provides configuration information for the selected functions.

The MELSEC-WS safety controller supports applications up to Performance Level (PL) e (in accordance with EN/ISO 13849-1) and up to Safety Integrity Level SILCL3 (in accordance with IEC 62061).

The degree of safety actually attained depends on the external circuitry, the realization of the wiring, the parameter configuration, the choice of the safety sensors and how they are mounted on the machine. Take and evaluate these using e.g. a failure analysis (FMEA).

For further information that has to be taken into consideration during the electrical installation see Chapter 7.

Loss of the safety function through an incorrect configuration!

 Plan and carry out configuration carefully!

ATTENTION

The configuration of safety applications must be carried out with the greatest accuracy and must match the status and the condition of the machine or system to be monitored.

 Check whether the configured safety application monitors the machine or system as

planned and whether the safety of a configured application is ensured at all times. This must be ensured in each operating mode and partial application. Document the result of this check!

 In each case, observe the instructions for commissioning and daily checking in the

manuals of the protective devices integrated into the safety application!

Note

 Note the warnings and function descriptions of protective devices connected to the

MELSEC-WS safety controller! Contact the respective manufacturer of the protective device if in doubt!

 Take into account that the minimum switch-off time of the connected sensors must

be greater than the execution time of the logic (see the chapter about the logic editor in the Safety Controller Setting and Monitoring Tool Operating Manual and the logic editor in the Setting and Monitoring Tool) so that it is ensured that the MELSEC-WS safety controller can detect the switching of the sensors. The minimum switch-off time of sensors is usually specified in the technical data of the sensors.

 If an odd-numbered test output is used, odd-numbered inputs have to be used. If an

even-numbered test output is used, even-numbered inputs have to be used.

 You have to use the test outputs of the module to which the device to be tested is

connected.

ATTENTION

Connecting devices

Chapter 4

Protect single channel inputs against short circuits and cross circuits!

If a stuck-at-high error occurs on a single channel input with test pulses that was previously inactive, the logic may see a pulse for this signal. The stuck-at-high first causes the signal to become Active (High) and then after the error detection time back to Inactive (Low) again. Due to the error detection a pulse may be generated. Therefore single channel signals with test pulses need special attention:

 If the stuck-at-high occurs on a single channel signal input with test pulses that was

previously Active (High), the logic will see a delayed Active (High) to Inactive (Low) transition.

 If a single channel input is used and an unexpected pulse or a delayed falling edge

at this input may lead to a dangerous situation, the following measures have to be taken:

– Protected cabling of the related signal (to exclude cross circuits to other signals)

– No cross circuit detection, i.e. no connection to test output (See the Safety

Controller Setting and Monitoring Tool Operating Manual.)

This needs especially to be considered for the following inputs:

– Reset input on the Reset function block

– Restart input on the Restart function block

– Restart input on the Press function blocks (Eccentric Press Contact, Universal

Press Contact, N-break, Press Setup, Press Single Stroke, Press Automatic)

– Override input on a Muting function block

– Reset input on a Valve function block

– Reset to zero input and Reload input on a Counter function block

After the configuration you obtain the following documentation in the Setting and Monitoring Tool under “Report”:

 Logic report

 Parts list

 Wiring diagrams

Chapter 4

Figure 15: Example extract of the documentation in the Setting and Monitoring Tool

Connecting devices

Table 19: Connection of emergency stop pushbuttons

Table 20: Functions of emergency stop pushbuttons

Note

Connecting devices

Chapter 4

4.1 Safety command devices and electro-mechanical safety switches

4.1.1 Emergency stop pushbuttons (e.g. SICK ES21)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Single-channel, connected to 24 V

Single-channel, connected to test output

Dual-channel, connected to 24 V

Dual-channel, connected to test output

The dual-channel emergency stop pushbuttons preconfigured in the Setting and Monitoring Tool have equivalent switching contacts. Corresponding elements for implementing dual-channel complementary switching contacts are available in the element window under the group named “Potential-free contacts and restart”.

Function Notes

Testing Possible

Series connection/ cascading If emergency stop pushbuttons are connected in series, the

max. line resistance shall not exceed 100 Ω (see Chapter 12).

Discrepancy times See Setting and Monitoring Tool.

Further information is available in the manual for the emergency stop pushbutton, SICK ES21 or in the manuals for devices used.

Contact between 24 V and I1

Contact between X2 and I2

Channel 1: Contact between 24 V and I3

Channel 2: Contact between 24 V and I4

Channel 1: Contact between X1 and I5

Channel 2: Contact between X2 and I6

Chapter 4

Connecting devices

4.1.2 Electro-mechanical safety switches with and without interlock

Note

Table 21: Connection of electromechanical safety switches

Table 22: Connection of interlocks

Table 23: Functions of electromechanical safety switches and interlocks

Note

The contact symbols in this chapter show the switching status while the door is closed.

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Single-channel, connected to 24 V

Single-channel, connected to test

Contact between 24 V and I1

Contact between X2 and I2

output

Dual-channel, connected to 24 V

Dual-channel, connected to test output

Channel 1: Contact between 24 V and I3

Channel 2: Contact between 24 V and I4

Channel 1: Contact between X1 and I5

Channel 2: Contact between X2 and I6

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Single-channel, connected to 24 V

Single-channel, connected to test output

Dual-channel, connected to 24 V

Dual-channel, connected to test output

Contact between 24 V and I1

Coil at Q1

Contact between X1 and I1

Coil at Q1

Channel 1: Contact between 24 V and I1

Channel 2: Contact between 24 V and I2

Coil at Q1

Channel 1: Contact between X1 and I1

Channel 2: Contact between X2 and I2

Coil at Q1

Function Notes

Testing Possible

Series connection/ cascading If safety switches are connected in series, the max. line

resistance shall not exceed 100 Ω (see Chapter 12).

Discrepancy times See Setting and Monitoring Tool.

Further information is available in the manuals of the electro-mechanical safety switches or in the manuals for devices used.

Table 24: Connection of enabling switches

Table 25: Functions of enabling switches

Note

Connecting devices

Chapter 4

4.1.3 Enabling switch (e.g. SICK E100)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

2 positions, connected to 24 V

2 positions, connected to test output

3 positions, connected to 24 V

Channel 1: Contact E31 between 24 V and I1

Channel 2: Contact E41 between 24 V and I2

Channel 1: Contact E31 between X1 and I3

Channel 2: Contact E41 between X2 and I4

Channel 1: Contact E13 between 24 V and I5

Channel 2: Contact E23 between 24 V and I6

Channel 3: Contact E31 between 24 V and I7

Channel 4: Contact E41 between 24 V and I8

3 positions, connected to test output

Channel 1: Contact E13 between 24 V and I1

Channel 2: Contact E23 between 24 V and I2

Channel 3: Contact E31 between X1 and I3

Channel 4: Contact E41 between X2 and I4

Function Notes

Testing Possible

Series connection Not possible

Discrepancy times See Setting and Monitoring Tool.

Further information is available in the manual of the enabling switch, SICK E100 or in the manuals of devices used.

Chapter 4

Connecting devices

4.1.4 Two-hand control

Note

Table 26: Connection of two-hand control

Table 27: Functions with two-hand control unit type IIIA

The contact symbols in this chapter show the switching status while both two-hand buttons are not pressed.

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Type IIIA

connected to 24 V

Type IIIC

connected to 24 V

Channel 1: Contact between 24 V and I1

Channel 2: Contact between 24 V and I2

Channel 1: Left side NO contact between 24 V and I1

Channel 2: Left side NC contact between 24 V and I2

Channel 3: Right side NO contact between 24 V and

Channel 4: Right side NC contact between 24 V and

Type IIIA

At Type IIIA two equivalent inputs (NO contacts of the two two-hand buttons) are monitored.

A valid input signal is only generated if the ON state (High level) exists at both inputs within a period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were in the OFF state (Low level) beforehand.

Function Notes

Tested Possible

Series connection/

cascading

Discrepancy time Fixed Value: 500 ms

Not possible

See Two-hand control type IIIA function block in the logic in the

CPU module with which these inputs are to be evaluated.

Table 28: Functions with two-hand control unit typeIIIC

Connecting devices

Chapter 4

Type IIIC

At Type IIIC two pairs of antivalent inputs (NO/NC contact pairs of the two two-hand buttons) are monitored.

A valid input signal is only generated if the ON state (High/Low level) exists at both inputs within a period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were in the OFF state (Low/High level) beforehand.

Function Notes

Tested Possible

Note

Table 29: Connection of safety mats

Table 30: Function of safety mats

Series connection/

cascading

Discrepancy time Possible: 0-500 ms

Synchronization time Fixed Value: 500 ms

Not possible

See Two-hand control type IIIC function block in the logic in the

CPU module with which these inputs are to be evaluated.

See Two-hand control type IIIC function block in the logic in the

CPU module with which these inputs are to be evaluated.

Further information is available in the manual of the two-hand control.

4.1.5 Safety mats and bumpers

The contact symbols in this chapter show the switching status while the safety mat or bumper is not pressed.

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Pressure-sensitive short-

circuiting switching mats in

4-wire technology, connected to test output

Channel 1: Contact between X1 and I1

Channel 2: Contact between X2 and I2

Function Notes

Parallel connection Possible

ATTENTION

Note

Ensure that the switch off condition is sufficient!

The duration of the switch off condition of safety mats and bumpers must be at least as long as the greatest value for the “test period” of both used test outputs to ensure that the switch off condition is detected and that no sequence error occurs.

Further information is available in the manual of the safety mats.

Chapter 4

Table 31: Connection of user mode switches

Table 32: Function of user mode switches

Note

Connecting devices

4.1.6 User mode switches

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Mode switch (1 of 2) connected to 24 V

Mode switch (1 of 2)

connected to test output

Function Notes

Testing Possible

 User mode switches without test pulses allow 2 to 8 operating modes; user mode

switches with test pulses allow 2 to 4 operating modes.

 When wiring the tested user mode switches it should be noted that odd-numbered

inputs (I1, I3, I5, I7) have to be used if an odd-numbered test output (X1, X3, X5, X7) is used, and even-numbered inputs (I2, I4, I6, I8) have to be used if an evennumbered test output (X2, X4, X6, X8) is used.

 Further information is available in the manual of the user mode switch.

Channel 1: Contact between 24 V and I1

Channel 2: Contact between 24 V and I2

Channel 1: Contact between X1 and I1

Channel 2: Contact between X1 and I3

Table 33: Functions of potential-free contacts

4.1.7 Potential-free contacts

The Setting and Monitoring Tool makes a series of potential-free contacts available for “free” configuration of contact elements. This allows different NC-/NO-contact combinations with and without testing to be implemented. In addition elements are available for the start and stop button, reset button and external device monitoring (EDM).

Function Notes

Testing Possible

Series connection Possible

Discrepancy time See Setting and Monitoring Tool.

Connecting devices

4.2 Non-contact safety sensors

4.2.1 Magnetic safety switches (e.g. SICK RE)

Chapter 4

Note

Table 34: Connection of magnetic safety switches with equivalent inputs

Table 35: Connection of magnetic safety switches with complementary inputs

Table 36: Functions of magnetic safety switches

Note

The contact symbols in this chapter show the switching status while the switch is actuated (e.g. while the door is closed).

Magnetic safety switches with equivalent inputs (e.g. SICK RE13, RE27)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Connected to test output

Channel 1: Contact between X1 and I1

Channel 2: Contact between X2 and I2

Magnetic safety switches with complementary inputs (e.g. SICK RE11, RE21, RE31, RE300)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

Connected to test output

NC contact between X1 and I3

NO contact between X2 and I4

Function Notes

Testing Possible

Series connection/ cascading

Possible; observe the max. line resistance of 100 Ω and the correct setting of the test impulse time

Discrepancy time Default: 1.5 s. See Setting and Monitoring Tool.

Further information is available in the manuals of the SICK magnetic safety switches or in the manuals of devices used.

Table 37: Connection of inductive safety switches

Table 38: Functions of inductive safety switches

Note

4.2.2 Inductive safety switches (e.g. SICK IN4000 and IN4000 Direct)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

IN4000

IN4000 Direct (with OSSD)

Test input TE (IN4000) at X1

Output A (IN4000) at I1

OSSD1 (IN4000) at I3

OSSD2 (IN4000) at I4

Function Notes

Testing Necessary on IN4000

Series connection/ cascading

IN4000 direct cannot be cascaded IN4000: up to 6 sensors per input

Max. off-on delay of the cascade 10 ms (otherwise the test gap will lead to switching off)

Observe the max. line resistance of 100 Ω and the correct setting of the test pulse time

Further information is available in the manuals of the SICK inductive safety switches or in the manuals of devices used.

Chapter 4

Table 39: Connection of transponders

Table 40: Functions of transponders

Note

Connecting devices

4.2.3 Transponder (e.g. SICK T4000 Compact and T4000 Direct)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

T4000 Compact (connected to 24 V)

T4000 Compact (connected to test output)

T4000 Direct (with OSSD)

Function Notes

Testing Possible for T4000 Compact

Not necessary for T4000 Direct, since self monitored

Series connection/ cascading

T4000 Compact is not cascadable;

Take the max. line resistance of 100 Ω into account at the T4000 (see Chapter 12)

For further information refer to the manuals of the Transponder SICK T4000 Compact or T4000 Direct or in the manuals of devices used.

24 V at +LA, I1 at LA

24 V at +LB, I2 at LB

X1 at +LA, I3 at LA

X2 at +LB, I4 at LB

24 V at UB (T4000), I5 at OA

24 V at UB (T4000), I6 at OB

Table 41: Connection of testable Type 2 single-beam photoelectric safety switches

Note

4.3 Testable single-beam photoelectric safety switches

4.3.1 Testable Type 2 single-beam photoelectric safety switches

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

SICK Wx12/18/24/27, Vx18

SICK L21, L27/L28

Use protected or separate cabling for the test output of the module (X1...X8) to the test input of the transmitter and for the output of the receiver to the safe input of the module (I1...I8). Otherwise a cross circuit between these signals can inhibit the error detection by this test.

Test input TE (transmitter) at X1

Output Q (receiver) at I1

Test input TE (transmitter) at X2

Output Q (receiver) at I2

Connecting devices

Chapter 4

Table 42: Functions of testable Type 2 single-beam photoelectric safety switches

Note

Function Notes

Testing Possible

Series connection/ cascading

SICK Wx12/18/24/27, Vx18:

 max. 2 pairs per input can be cascaded with test gap = 4 ms

(standard element)

 max. 5 pairs per input can be cascaded with test gap = 12 ms

(customized element required)

SICK L21:

 max. 10 pairs per input can be cascaded with test gap = 4 ms

(standard element)

 max. 25 pairs per input can be cascaded with test gap = 8 ms

(customized element required)

SICK L27/L28:

 max. 7 pairs per input can be cascaded with test gap = 4 ms

(standard element)

 max. 18 pairs per input can be cascaded with test gap = 12 ms

(customized element required)

Take the max. line resistance of 100 Ω into account.

For further information refer to the manual of the testable Type 2 single-beam photoelectric safety switches.

Table 43: Connection of testable Type 4 single-beam photoelectric safety switches

Note

Table 44: Functions of testable Type 4 single-beam photoelectric safety switches

Note

4.3.2 Testable Type 4 single-beam photoelectric safety switches

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

SICK L41

Test input TE (transmitter) at X1

Output Q (receiver) at I1

Function Notes

Testing Necessary

Series connection/ cascading

SICK L41:

 max. 10 pairs per input can be cascaded with test gap = 4 ms

(standard element)

 max. 25 pairs per input can be cascaded with test gap = 8 ms

(customized element required)

Take the max. line resistance of 100 Ω into account

For further information refer to the manual of the testable Type 4 single-beam photoelectric safety switches.

Chapter 4

Note

Connecting devices

4.3.3 Customized testable single beam photoelectric safety switches

For information on how to create customized elements please see the Safety Controller Setting and Monitoring Tool Operating Manual.

 In the Settings dialog for the customized element, select the minimum value for the

desired test gap.

 Regardless of the test gap, the overall off-on-delay of the cascade must be smaller

than the Max. off-on delay of the respective test output (as shown in the Setting and Monitoring Tool report) –2 ms. Otherwise the test gap will lead to switching off. For WS0-XTIO or WS0-XTDI module this value is = 12 ms – 2 ms = 10 ms.

 Use protected or separate cabling for the test output of the module (X1...X8) to the

test input of the transmitter and for the output of the receiver to the safe input of the module (I1...I8). Otherwise a cross circuit between these signals can inhibit the error detection by this test.

4.3.4 Information for mounting testable single-beam photoelectric safety switches

Note

Figure 16: Minimum distance “a” to reflective surfaces, correct mounting and alignment

Observe the information for mounting in the manual of the respective sensors and in particular the following points:

 Single-beam photoelectric safety switches may only be used as access protection

in accordance with EN/ISO 13855. Usage as finger and hand protection is not permissible.

 Observe the minimum distance to reflective surfaces.

 It is imperative that the safety distance between the light beam and hazardous point

be observed at access protection.

S = Sender

R = Receiver

D = Distance between sender and

receiver

a = Minimum distance from reflective

1) = Limit to hazardous area

2) = Reflective surface

3) = Direction of access to hazardous area

4) = Optical axis

surfaces

Figure 17: Minimum distance “a” as a factor of the distance “D” for testable single-beam photoelectric safety switches with a field of view of 10° (e.g. SICK Wx12/18/24/27, Vx18)

Note

Connecting devices

Chapter 4

Diagrams for SICK L21 and L41 are available in the respective manual.

Avoiding mutual influence at single-beam photoelectric safety switches and between cascades

 If several single-beam photoelectric safety switch pairs are used, the field of view of

the sensors has to be observed in order to prevent mutual influence.

Figure 18: Mounting to avoid mutual optical influence

 If the senders are only mounted on one side, the light beams may not overlap on

the receiver side so that the light beam of one sender does not reach two receivers.

 If the senders and receivers are mounted alternatively, ensure that the light beam of

Sender S1 cannot be received by Receiver R3 and that the light beam of Sender S3 cannot be received by Receiver R1.

Chapter 4

Table 45: Connection of ESPE

ATTENTION

Note

Connecting devices

4.4 Electro-sensitive protective equipment (ESPE)

Electrical connection: Example from Setting and Monitoring Tool with WS0-XTIO

SICK C2000, C4000, M2000, M4000, S300, S3000, V300, MiniTwin

OSSD1 (receiver) at I1

OSSD2 (receiver) at I2

Further information is available in the manual of the corresponding SICK ESPE or in the manuals of devices used.

4.5 Safe outputs Q1 to Q4

Safety-oriented devices must be suitable for safety related signals!

A function interruption of safe 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 outputs Q1 to Q4.

 Connect the GND wires of the power supply to earth so that the devices do not

switch on when the output line is applied to frame potential.

Note

4.6 EFI devices

If your MELSEC-WS safety controller contains a WS0-CPU1 or a WS0-CPU3, you can connect intelligent SICK EFI-compatible devices and sensors to your CPU module.

4.6.1 Connection of EFI devices

If shielding is required, for example for EMC reasons, when connecting the EFI devices, use an earth terminal that is placed in the control cabinet near the CPU module for this purpose. Connect this earth terminal with the shielding.

 No external termination resistor is required for EFI connections on the CPU module.

 The CPU module and all connected SICK EFI-compatible devices must have the

same 0 V DC of the power supply.

 The maximum permitted voltage at EFI inputs is ± 30 V (to terminal A2 = 0 V DC)

 You will find information on connecting SICK EFI-compatible devices incl. pin

assignments in the manuals for the corresponding devices.

Cables

SICK offers cables for the connection of SICK EFI-compatible devices. For cables, please contact your local SICK representative (see Section 14.6).

www.sens-control.com

Note

Connecting devices

Chapter 4

EMC measures

To increase the EMC resistance of the EFI communication, it is recommended to connect the EFI cable shield on one or both sides to functional earth.

Connect this shield to the same DIN mounting rail to which the functional earth (FE) of the MELSEC-WS safety controller is connected in order to minimize interferences on the EFI cable. The connection of the shield to FE should be close to the cable inlet of the control cabinet.

 The FE terminal of the MELSEC-WS safety controller is located at the bottom of the

housing and connects automatically to the DIN mounting rail when the module is mounted.

 To avoid further interferences, the functional earth of the SICK sensors (e.g.

M4000, S3000) must be connected to the EFI shield as well.

 If other cables are present within the same cable duct where the EFI cable is routed

and these cables emit a high degree of EMC interference (drives or motor related), this can lead to availability problems in the application. In this case, it is recommended to install the EFI cable in a separate duct.

Table 46: Available process data bits depending on the connection method

Note

4.7 Flexi Link

4.7.1 Flexi Link overview

Flexi Link allows you to combine up to four Flexi Link stations via EFI for safe data communication. Only modules from WS0-CPU1 or WS0-CPU3 can be used in a Flexi Link system. The connection of WS0-CPU0 modules is not possible. The process data of each station (inputs and outputs, logic results etc.) can be made available to all other stations in the Flexi Link system. The Teach function allows to temporarily deactivate single stations without impairing the function of the overall system.

Features

 safe connection of up to four Flexi Link stations via EFI.

 connection via EFI1 or EFI1 and EFI2.

 transfer/receive up to 52 bit of information per station (26 bit per EFI channel).

 Each bit can be assigned a global tag name.

 Teaching simulates the presence of temporarily suspended (switched off) stations.

 Any station can be used as access point to address and configure the entire system

with the Setting and Monitoring Tool.

 The configuration of the entire Flexi Link system is stored in a single project file.

The Flexi Link system can be connected using only EFI1 or using both EFI1 and EFI2. The overall number of process data bits per station that can be made available to the other stations in the Flexi Link system depends on the connection method:

Connection method Available process data bits per station

EFI1 26

EFI1/EFI2 52

You can not use Flexi Link and EFI communication at the same time, i.e. it is not possible to connect other SICK EFI-compatible devices on the EFI2 connection while EFI1 is used for Flexi Link.

Chapter 4

Table 47: System requirements for Flexi Link

Table 48: Available status bits depending on the connection method

Connecting devices

4.7.2 System requirements and restrictions for Flexi Link

For Flexi Link the following system requirements must be met as a minimum:

System component Version

Hardware WS0-CPU1 with firmware version V2.01.0 or higher, or WS0-CPU3

Software WS0-CPU1: Setting and Monitoring Tool version 1.3.0 or higher

WS0-CPU3: Setting and Monitoring Tool version 1.7.0 or higher

The Flexi Link system can be connected using only EFI1 or using both EFI1 and EFI2. The overall number of status bits per station that can be made available to the other stations in the Flexi Link system depends on the connection method.

Connection method Available status bits per station

EFI1 26

EFI1/2 52

Notes

ATTENTION

 You can not use Flexi Link and EFI communication at the same time, i.e. it is not

possible to connect other EFI compatible devices on the EFI2 connection while EFI1 is used for Flexi Link.

 The process data sent by any station are received almost simultaneously by all

other stations. The processing (logic) in the individual stations is, however, not necessarily simultaneous, as the stations are not synchronized.

 The data on EFI1 and on EFI2 are consistent. The data on EFI1 and EFI2 can,

however, be inconsistent for a short time, as they are transferred separately.

4.7.3 Connection of a Flexi Link system

Do not use buffering elements in a Flexi Link system!

It is not allowed to use buffering elements such as e.g. CAN bridges, CAN repeaters or CAN optical light barriers in a Flexi Link system. As a general rule, no components other than Flexi Link stations are allowed. Otherwise the operator of the machine will be in danger.

There are two possibilities for wiring a Flexi Link system:

 connection via EFI1 (26 bits)

 connection via EFI1 and EFI2 (52 bits)

Either way, always the identically named terminals have to be connected (e.g. EFI1 A on station A with EFI1 A on station B etc.).

Figure 19: Connection of Flexi Link stations via EFI1 and EFI2

Note

Connecting devices

No external termination resistor is required for EFI connections on the CPU.

 Stub lines or star-shaped wiring are not permitted.

Chapter 4

 The max. permitted overall cable length (all stations) for EFI1 and EFI2 is 100 m

each.

 Unused conductors must be connected to FE on both ends.

 All connected Flexi Link stations must have the same 0 V DC of the power supply

(terminal A2 of memory plug).

 The max permitted voltage at EFI inputs is ± 30 V (to terminal A2 = 0 V DC)

Chapter 4

Table 49: Possible cable lengths and types for Flexi Link connections

Connecting devices

Flexi Link cable

The Flexi Link stations can be connected using CAN cables (shielded, twisted pair).

Cable length Type

Up to 40 m 2 × 2 × 0.25 mm² (23 AWG)

Up to 100 m 2 × 2 × 0.34 mm² (22 AWG)

SICK offers a suitable cable for connection lengths up to 100 m. Please also see Section 13.2. For cables, please contact your local SICK representative (see Section

14.6).

www.sens-control.com

EMC measures

Please observe the notes in section4.9

Potential equalization

 Always connect the cable screen on both sides to earth potential. Be aware that the

earth potential may differ on the earth connections. If this is the case, you must install an additional potential equalization. Follow the relevant standards and regulations.

Table 50: Update rate for a Flexi Line system as a function of the maximum length of cable and the size of the process image

Connecting devices

Chapter 4

4.8 Flexi Line

4.8.1 Flexi Line overview

Flexi Line enables you to reliably network up to 32 MELSEC-WS stations. Only WS0-CPU3 modules can be used in a Flexi Line system. The connection of all the other CPU modules (WS0-CPU0, WS0-CPU1) is not possible.

A uniform process image is defined for the entire Flexi Line system. Each byte of this process image is either global, i.e. in the entire system, or local, i.e. only for the related station and its neighboring stations. Each Flexi Line station communicates with its neighboring stations via this process image. The topology permits communication without addressing.

Features

 Reliable connection of up to 32 MELSEC-WS stations via the Flexi Line

interface

 Topology without addressing: In case of a change in the order of the stations, it

is sufficient to confirm the new arrangement using a Teach pushbutton.

 The EFI interface remains available without limitation:

– It is possible to connect EFI-compatible sensors.

– It is possible to connect a Flexi Link system.

 A global process image is defined for all stations.

 Within the process image, global or local bytes can be defined.

 The process image can contain up to 12 bytes or 96 bits.

 The maximum cable length between 2 stations is 1000 meters. The possible

total length of a system with 32 stations is therefore 31 kilometers.

 The overall system has a fixed update rate. This rate is dependent on the

maximum length of cable between two stations and the size of the process image.

Max. cable length 32 bits 64 bits 96 bits

125 m 2 ms 2 ms 4 ms

250 m 2 ms 4 ms 8 ms

500 m 4 ms 8 ms 12 ms

1000 m 8 ms 12 ms 20 ms

ATTENTION

4.8.2 Connection of a Flexi Line system

Do not use buffering elements in a Flexi Line system!

It is not allowed to use buffering elements such as e.g. CAN bridges, CAN repeaters or CAN optical light barriers in a Flexi Line system. As a general rule, no components other than Flexi Line stations are allowed. Otherwise the operator of the machine will be in danger.

The stations in a Flexi Line system are connected together as follows:  Connect the Next connection of each station with the Prev connection of the

next station

 Connect together the identically labeled terminals, that is A to A and B to B.

Chapter 4

Figure 20: Connection of a Flexi Line system

Notes

Table 51: Possible cable lengths and types for Flexi Line connections

Connecting devices

 An external terminator is not required for the Flexi Line connections on the CPU

module.

 Stub lines or star-shaped wiring are not permitted.

 Unused conductors must be connected to FE on both ends.

 The max permitted voltage at Flexi Line inputs is ±30V (to terminal A2=0VDC).

Flexi Line cable

The Flexi Line stations can be connected using CAN cables (shielded, twisted pair).

Cable length Type

Up to 125 m 2 × 0.34 mm² (22 AWG)

Up to 1000 m 2 × 0.75 mm² (18 AWG)

For recommended cables, see Section 13.2.

EMC measures

Please observe the notes in section 4.9.

Equipotential bonding

 Always connect the cable screen on both sides to earth potential. If this is not

possible, then earth the side that is connected to the PRE terminals.

 Be aware that the earth potential may differ on the earth connections. If this is the

case, you must install an additional equipotential bonding. Follow the relevant standards and regulations.

Figure 21: Connection of the cable

Connecting devices

Chapter 4

4.9 EMC measures for Flexi Link and Flexi Line

Flexi Link or Flexi Line cables are used to transmit communication signals. Electromagnetic influences may disturb the signal transfer and interrupt the communication. In order to minimize electromagnetical interference, the following measures are required:

 Connect all inactive metallic parts (control cabinet doors and housing, DIN

mounting rails etc.) to the same reference potential.

 Connect the reference potential to the protective earth conductor.

 Connect the protective earth conductor to the external earth potential.

 Connect both ends of the shield of the shielded cables to the reference potential

directly at the entrance to the system (control cabinet, frame, DIN mounting rail).

 Connect the cable shield again to the reference potential as close as possible to

the CPU module (e.g. on the mounting rail) using suitable cable clamps. The cable clamps must completely enclose the cable shield.

Note

 Keep the stripped cable ends as short as possible.

 Isolate the screening braiding end e.g. with a suitable shrink tube.

 All connections must be made electrically well conducting with low impedance.

 Stub lines or star-shaped EFI wiring are not permitted.

 Load cables (e.g. for frequency changers, electronic speed controllers, contactors,

brakes etc.) and small-signal cables (e.g. measuring lines, analog sensors, field bus lines etc.) must be laid separately and with low inductive coupling.

Chapter 5

Special functions

5 Special functions

5.1 Enhanced Function Interface - EFI

The WS0-CPU1 and WS0-CPU3 CPU modules have 2 EFI interfaces each. This section describes the properties, the functions and the benefits of these interfaces.

The general EFI function description and the possibilities for combining SICK products with regard to EFI are available in the corresponding manuals of SICK products.

5.1.1 Definition

An EFI interface is a safe communication interface between SICK devices. With it information from the sensor equipment can be read out, as well as commands transferred to the sensor equipment.

5.1.2 Properties

 Up to 4 SICK devices are possible per EFI line, in as far as the SICK EFI-

compatible devices support this number.

 Connection of the devices using a 2-wire cable

 Various device combination possibilities

– Sensor with sensor within the same product family

– Sensor with safety controllers and network modules

– Connection of up to four WS0-CPU1 or WS0-CPU3 modules in a Flexi Link

system (see Section 4.7).

 Transferring of status information (process data) between SICK devices using an

EFI interface

 Transferring the configuration from the Setting and Monitoring Tool to the SICK

EFI-compatible devices

 Uploading the configuration from the SICK EFI-compatible devices to the Setting

and Monitoring Tool

 Activation/utilization of sensor functions

Special functions

Chapter 5

5.1.3 Functions

In addition to the product-specific functions of the respective SICK EFI-compatible devices the following functions are available:

General functions

 Status information (process data) of the SICK EFI-compatible devices are

available in the MELSEC-WS safety controller and at the sensor

 Diagnostics information of all the SICK EFI-compatible devices is available in

the controller

 Transfer of configuration information

Special functions

 Simultaneous protective field evaluation

 Protective field switching

 Function changeover

 Operating mode selection

 Signal routing

 Decentralized diagnostics information via Ethernet

 Information on the location of the protective field interruption at host-guest

applications

 Evaluation of signals and forwarding of the results

5.1.4 Benefits

 Reduction of the installation work (only 2 wires) when signals from several

sensors are used

 Reduction of the required material through possibility of saving function blocks

and I/Os

 High availability through provision of the diagnostics information with high

information contents for rapid and correct handling options

Chapter 5

Special functions

5.2 Muting

Muting is the automatic temporary bypassing of safety-oriented functions of the control system or of the safety device. Muting is used when certain objects, such as pallets with material, may be moved into the hazardous area. During this transportation through electro-sensitive protective equipment (ESPE), such as a safety light curtain, the muting function inhibits monitoring by the ESPE.

Observe the information in the Safety Controller Setting and Monitoring Tool Operating Manual for the further procedure.

Mounting/Dismantling

6 Mounting/Dismantling

This chapter describes the mounting of the modules of the MELSEC-WS safety controller.

6.1 Steps for mounting the modules

The MELSEC-WS safety controller must be mounted in a control cabinet with

ATTENTION

at least IP 54 enclosure rating!

 In a MELSEC-WS safety controller, the WS0-CPU0, WS0-CPU1 or WS0-CPU3 is

positioned at the far left.

 The two optional network modules follow directly to the right of the CPU module.

 Connect further MELSEC-WS safety I/O modules (e.g. WS0-XTIO or WS0-XTDI)

on the right side of the network modules or on the right side of the CPU module, if no network module is used. The I/O modules can be mounted in any order.

 Connect an additional safety relay output module (WS0-4RO) on the far right of

the entire MELSEC-WS safety controller.

Chapter 6

 The modules are located in a 22.5 mm wide modular system for 35 mm DIN

mounting rails to IEC/EN 60715.

 The modules are connected to each other via the FLEXBUS+ plug connection

integrated in the housing. Take into account that, when replacing a module, the MELSEC-WS modules have to be pushed approx. 10 mm apart before the corresponding module can be removed from the DIN mounting rail.

 Mount the modules in accordance with EN 50274.

 Ensure that suitable ESD protective measures are taken during mounting.

Otherwise the FLEXBUS+ backplane bus may be damaged.

 Take suitable measures to ensure that foreign matter does not enter the

connector openings, in particular that of the memory plug.

Chapter 6

Mounting/Dismantling

Figure 22: Mounting the module onto the DIN mounting rail

Figure 23: Installing end clips

 Make sure that the voltage supply of the MELSEC-WS safety controller is

switched off.

 Hang the device onto the DIN mounting rail (1)).

 Ensure that the earthing spring contact is positioned correctly (2)). The earthing

spring contact of the module must contact the DIN mounting rail securely to allow electrical conductivity.

 Snap the module onto the DIN mounting rail by pressing it lightly in the direction

of the arrow (3)).

 If there are several modules, slide the modules together individually in the

direction of the arrow until the side plug connection latches in.

 Install end clips on the left and right.

The following steps are necessary after mounting:

 completing the electrical connections

 configuration (See the Safety Controller Setting and Monitoring Tool Operating

Manual.)

 checking the installation

Figure 24: Removing the plug-in terminals

Figure 25: Disconnecting the plug connections

Mounting/Dismantling

6.2 Steps for dismantling the modules

 Remove plug-in terminals with the wiring and the end clips.

Chapter 6

Figure 26: Removing modules from the DIN mounting rail

 If there are several modules, slide the modules away from each other individually

in the direction of the arrow until the side plug connection is separated.

 Press the module downwards at the rear (1)) and remove it from the DIN

mounting rail in the direction of the arrow while keeping it pressed down (2)).

Chapter 7

Electrical installation

7 Electrical installation

7.1 Electrical installation requirements

Note

ATTENTION

Note

This chapter deals with the electrical installation of the MELSEC-WS safety controller in the control cabinet. You will find additional information on the electrical connection of other devices to the MELSEC-WS safety controller in the section on the respective device in Chapter 4.

Switch off the entire machine/system!

The system could start up unexpectedly while you are connecting the devices.

Observe the relevant safety standards!

All safety related parts of the installation (cabling, connected sensors and actuators, configuration settings, EDM) must be according to the relevant safety standards (e.g. IEC 62061 or ISO/EN 13849-1). This may mean that safety related signals need to be redundant or that single channel signals need protected wiring or short circuit detection by using test outputs and/or periodical function tests.

 Take into account that short circuits between test outputs and the corresponding

input cannot be detected.

 Consider if protected or separate cabling is required for these signals.

 The MELSEC-WS safety controller fulfills the EMC requirements in accordance

with the basic specification IEC 61000-6-2 for industrial use.

 Mitsubishi industrial safety devices are designed for local DC supply applications

only. If the device is used in power supply networks, e.g. according to IEC 613263-1, additional protective measures have to be taken.

 Machines where safety devices are used must be installed and designed

according to the Lightning Protection Zone (LPZ) according to IEC 62305-1. Required immunity levels can be achieved through the use of external protective devices. The installed surge protective devices (SPD) should meet the requirements according to IEC 61643-11.

 The installation must prevent common mode disturbances according to IEC

61000-4-16 in the frequency range from 0 Hz to 150 kHz.

 To ensure full electromagnetic compatibility (EMC), the mounting rail has to be

connected to functional earth (FE).

 The MELSEC-WS safety controller must be mounted in a control cabinet with at

least IP 54 enclosure rating.

 Electrical installation in accordance with IEC 60204-1

 The voltage supply of the devices must be capable of buffering brief mains

voltage failures of 20 ms as specified in IEC 60204-1.

 The voltage supply as well as all signals connected have to fulfill the regulations

for extra-low voltages with safe separation (SELV, PELV) in accordance with IEC 60664 and EN 50178 (equipment of electrical power installation with electronic devices).

 You must connect all modules of the MELSEC-WS safety controller, the

connected protective devices (e.g. the EFI devices) as well as the voltage supply/ies with the same 0 V DC (GND). The GND of the RS-232 interface is connected internally to the GND of the supply of the CPU module (A2).

 If the RS-232 interface at the CPU module is used as an alternative to a network

module, the maximum permissible cable length is 3 m.

ATTENTION

Electrical installation

Chapter 7

 Avoid ground loops between the GND of the RS-232 interface and the connection

A2 of the CPU module, e.g. by using optocouplers.

 Depending on the external loads, especially for inductive loads, additional

external protective elements, e.g. varistors or RC elements may be necessary in order to protect the outputs. For operating limits see Chapter 12. Take into account that the response times may increase, depending on the type of protective element.

 If a module is replaced the correct terminal assignment has to be guaranteed, for

example by labelling or suitable cable routing.

 If standing behind the protective devices (e.g. safety light curtain) is possible,

mount the reset button so that it cannot be actuated by a person located in the hazardous area. When operating the control device of the reset button, the operator must have full visual command of the hazardous area.

 Between the supply circuit and output circuit, and between the input circuit and

output circuit in the WS0-4RO module are isolated. On the other hand, those in the safety I/O module are not isolated.

Limited short-circuit recognition!

An WS0-XTDI has two test signal generators. One test signal generator is responsible for the odd-numbered test outputs X1, X3, X5 and X7, the other for the even-numbered test outputs X2, X4, X6 and X8.

Short-circuits between test signal generators on MELSEC-WS I/O modules are detected, also between test signal generators on different modules, provided the test gaps are ≤ 4 ms and the test periods are ≥ 200 ms for the relevant test outputs. Short circuits to 24 V DC (stuck at high) at inputs connected to test outputs are detected independently of the test gap time.

Please be aware that at the WS0-XTDI the odd-numbered test outputs X1, X3, X5 and X7 are connected to one common test signal generator and that the evennumbered test outputs X2, X4, X6 and X8 are connected to another common test signal generator. Therefore short circuits between test outputs X1, X3, X5 and X7 cannot be detected. The same applies respectively for test outputs X2, X4, X6 and X8. Take this into consideration during the wiring (e.g. separate routing, sheathed cables)!

Reverse current at WS0-XTIO / WS0-XTDI inputs in case of ground interruption

In case of an internal or external ground interruption there can be a reverse current from the power supply of the CPU module (memory plug terminal A2) to the safe inputs I1…I8 of WS0-XTIO / WS0-XTDI modules. This must be considered if other inputs are connected in parallel to these inputs, so that this reverse current does not lead to an unintended High level at the parallel connected inputs.

Chapter 7

Electrical installation

7.2 Internal circuit power supply

Figure 27: Safety controller power supply internal circuit

Chapter 8

Configuration

8 Configuration

Check the safety function before commissioning and after every change!

ATTENTION

If you change the configuration, you must check the effectiveness of the safety function. Please observe the test notes in the manuals of the connected protective devices.

Note

The Setting and Monitoring Tool and the WS0-MPL0 or WS0-MPL1 memory plug are required to configure the MELSEC-WS safety controller.

Configuration and verification of devices that are connected to the safety controller is generally not carried out via the Setting and Monitoring Tool. These devices have their own mechanisms for configuration and verification. One exception are SICK EFI-compatible devices connected to the WS0-CPU1 or WS0-CPU3 (the SICK EFIcompatible devices can be found under “EFI elements” in the elements window). These devices can be configured directly in the Setting and Monitoring Tool by double-clicking the icon, or alternatively configured and verified locally at the device via its RS-232 interface. The SICK configuration and diagnostics software CDS is required for the configuration of the SICK EFI-compatible devices.

 The SICK configuration and diagnostics software CDS included in Setting and

Monitoring Tool is the product of SICK. For the CDS, please contact your local SICK representative (see Section 14.6). www.sens-control.com

 The system configuration of the complete MELSEC-WS safety controller (with

exception of the SICK EFI-compatible devices) is stored in the memory plug. This offers the advantage when safety I/O modules or network modules are replaced that the system does not have to be reconfigured.

 The data stored in the memory plug is retained when the voltage supply is

interrupted.

 The transfer of configuration information via the EFI interface is possible.

Chapter 9

Commissioning

9 Commissioning

Do not commission without a check by qualified safety personnel!

ATTENTION

Before initial commissioning of a system using a MELSEC-WS safety controller, it must be checked and released by qualified safety personnel.

Check the hazardous area!

Ensure that no one is located in the hazardous area before commissioning.

 Check the hazardous area and secure it against being entered by people (e.g. set

up warning signs, attach blocking ropes or similar). Observe the relevant laws and local regulations.

9.1 Full approval of the application

System commission may only be carried out if full approval was successful. Full approval may only be performed by professionals trained accordingly.

The full approval includes the following items to be checked:

 Check whether all safety related parts of the installation (cabling, connected

sensors and actuators, configuration settings) are according to the relevant safety standards (e.g. EN/ISO 13849-1 or IEC 62061).

 Check the devices connected to the safety controller in accordance with the test

notes in the accompanying manual.

 Label all connections (connection cables and plugs) at the safety controller clearly

and without ambiguity to avoid confusion. Since the MELSEC-WS safety controller has several connections of the same design, ensure that disconnected cables or plugs cannot be connected back unintentionally to the wrong connection.

 Check the signal paths and the correct inclusion in higher-level controllers.

 Check the correct data transfer from and to the MELSEC-WS safety controller.

 Check the logic program of the safety controller.

 Perform a complete validation of the safety functions of the system in each

operating mode and an error simulation. Observe the response times of the individual applications in particular.

 Completely document the configuration of the system, the individual devices and

the result of the safety check.

 In order to prevent unintentional overwriting of the configuration, activate the write

protection of the configuration parameters of the MELSEC-WS safety controller. Modifications are only possible if the write protection has been deactivated.

Commissioning

Chapter 9

9.2 Tests before the initial commissioning

A report that provides the configuration can be created with the Setting and Monitoring Tool.

The purpose of the initial commissioning tests is to confirm the safety requirements specified in the national/international rules and regulations, especially in the Machine and Work Equipment Directive (EC Conformity).

 Check the effectiveness of the protective device at the machine, using all the

selectable operating modes and functions.

 Ensure that the operating personnel of the machine fitted with the safety controller

become instructed by the qualified personnel of the machine owner before beginning work. Arranging the instruction is the responsibility of the machine owner.

Chapter 10

Diagnostics

10 Diagnostics

10.1 In the event of faults or errors

Cease operation if the cause of the malfunction has not been clearly identified!

Stop the machine if you cannot clearly identify or allocate the error and if you cannot

ATTENTION

safely remedy the malfunction.

Complete functional test after remedying malfunction!

Carry out a full functional test after a malfunction has been remedied.

10.1.1 ERROR operating states

With certain malfunctions or a faulty configuration, the MELSEC-WS safety controller enters the safe status. The LEDs of the individual modules of the safety controller indicate the corresponding error level.

Depending on the error there are different error levels:

Configuration error

 The system will be in state Configuration required (MS LED

 Applications in all modules are in operating state “Stop”.

 All safe outputs in the system are switched off.

 All safety process data is set to zero. Typically also not safety related process data

is set to zero.

Recoverable error

 Applications in all modules remain in operating state Run (MS LED of the effected

modules = Green).

 If safe outputs on the system are effected, then as a minimum these outputs are

switched off.

 If safe inputs are effected, then at least the process data for these safe inputs are

set to zero.

Critical fault

 The system will be in state Critical fault (MS LED of the module which detected the

critical fault = error origin =  Red).

 Applications in all modules are in operating state ‘Stop’.

 All safe outputs in the system are switched off.

Red/green alternating (1 Hz), MS LED of not effected modules = 

Red (2 Hz). MS LED of the modules which are unclear about the

Red (1Hz)).

 All safety process data is set to zero. Typically also not safety related process data

is set to zero.

Diagnostics

Chapter 10

How to place the device back in operation:

 Rectify the cause of the malfunction in accordance with the display of the MS and

CV LEDs.

 In the case of critical faults, switch the voltage supply of the MELSEC-WS safety

controller off for at least 3 seconds and back on again.

The MELSEC-WS safety controller may restart when it detects a recoverable error caused by noise. The MELSEC-WS safety controller is ready for operation again if the error cause has been eliminated after the restart. 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.

Chapter 10

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS = Red (1 Hz)

Diagnostics

10.2 Error displays of the status LEDs, error messages

This section lists and describes the most important error codes, possible causes and potential rectification measures. These error messages can be displayed in the Diagnostics view of the Setting and Monitoring Tool if you are connected to the MELSEC-WS safety controller.

Note

 For information on how to perform diagnostics see the Safety Controller Setting and

Monitoring Tool Operating Manual.

 Error displays for the individual modules and error elimination are described in the

sections on the individual modules, see Sections 3.5 to 3.10.

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

All safety I/O modules: MS =

Red (1 Hz) (firmware ≥ V2.00.0) or

Red/green

MS = (1 Hz) (firmware V1.xx.0)

and rectification measures

Possible error

codes

CPU module: 0x000E4006, 0x00160005, 0x000F0013

CPU module: 0x00170005, 0x000F0013

CPU module: 0x000E4013, 0x00274006

CPU module: 0x000E0006, 0x0005000D. WS0-XTIO/

WS0-XTDI: 0x4901, 0x4904

Configuration in memory plug is incompatible because it is for a different CPU module type:

 Memory plug has been used before

 Wrong CPU module type is used in

Configuration in memory plug is incompatible because it is for a newer firmware version of the CPU module:

 Memory plug has been configured

 An older CPU module firmware

Configuration in memory plug is incompatible for at least one safety I/O module:

 Safety I/O module is missing in the

Configuration in memory plug is invalid:

 The last configuration procedure

 Memory plug hardware failure.

 The memory plug is empty (out-of-

Possible reasons Possible measures

in a system with different CPU module type (e.g. WS0-CPU0 instead of WS0-CPU1 or vice versa).

the hardware installation.

for an incompatible higher CPU module firmware version (e.g. V1.xx instead of V2.xx).

version is used in the hardware installation.

hardware installation.

has not been completed successfully, e.g. because the power supply has been turned off before writing to the memory plug has been completed.

the-box value).

 Download a configuration with the

same CPU module type as in the hardware installation.

 Replace the CPU module in the

hardware installation by a module with the same module type as selected in the project file.

 Download a configuration with the

same or a smaller CPU firmware version (e.g. V1.xx instead of V2.xx).

 Replace the CPU module in the

hardware installation by a module with an equal or higher firmware version selected in the project file.

 Download a configuration with a

matching list of safety I/O modules.

 Add missing safety I/O module in

the hardware installation.

 Download the configuration again

and ensure that the power supply at the CPU module is on until the download procedure has been completed.

 Replace the memory plug and

download configuration again.

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS = Red (1 Hz)

EFI =

Red (1 Hz)

MS = Green (1 Hz) CV =

Yellow (1

Hz)

MS = Green (1 Hz)

CV =  Yellow

MS =  Green

Diagnostics

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

One or more safety I/O modules: MS =

Red (1 Hz) (firmware ≥ V2.00.0) or

Red/green

MS = (1 Hz) (firmware V1.xx.0)

Green (1 Hz)

MS =

MS = Green (1 Hz)

MS =  Green

One or more safety I/O modules :

Red/green

MS = (1 Hz) (firmware ≥ V2.00.0) or MS =

Red (1 Hz) (firmware V1.xx.0)

and Q1+Q2+Q3+Q4 =

Green (1 Hz)

Possible error

codes

CPU module: 0x0014000A

CPU module: 0x0015000A

CPU module: 0x001F0006, 0x00230006, 0x00234006, 0x001F4006

WS0-XTIO: 0x4804, 0x4806, 0x4807

Chapter 10

Possible reasons Possible measures

If WS0-CPU1: EFI device address conflict:  There are at least 2 CPU modules

with the same EFI address connected.

If WS0-CPU1 and Flexi Link: Wrong Flexi Link ID:  EFI1 and EFI2 is swapped in the

wiring.

 There is at least 1 CPU module

with a different Flexi Link ID connected.

Configuration in memory plug is incompatible for at least one safety I/O module:

 Wrong type or version of module

(whose MS LED is flashing red or red/green).

 Too many safety I/O modules are

connected (whose MS LED is flashing red or red/green).

 Safety I/O modules are missing

(MS LED of all other modules is flashing red or red/green).

System is in Stop state (ready to run). Start application in Setting and

System is in operation. No error detected.

Module power supply of WS0-XTIO is too low or missing.

 Change the EFI device address

with Setting and Monitoring Tool, either of the CPU module or of the connected device.

 Check wiring between the Flexi Link

stations: EFI1 connected with EFI1, and if applies EFI2 with EFI2.

 Connect Flexi Link stations with

matching Flexi Link IDs.

 Download configuration to all Flexi

Link stations with same Flexi Link IDs.

 Download a configuration with the

same module type and the same or a smaller firmware version for all safety I/O modules.

 Replace the affected safety I/O

module in the hardware installation by a module with the same module type and the same or smaller firmware version as selected in the project file.

Monitoring Tool.

For automatic start after power up a verification of the project is necessary with Setting and Monitoring Tool.

Monitoring Tool.

Check supply voltage at terminals A1 (24 V) and A2 (0 V) at the WS0-XTIO module, also under worst case load conditions.

Error is reset automatically after approx. 8 seconds, if the error reason no longer exists.

Chapter 10

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS =  Green One or more safety

Diagnostics

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

I/O modules : MS =

Red/green (1 Hz) (firmware ≥ V2.00.0)

Red (1 Hz)

MS = (firmware V1.xx.0) and Q1 or Q2 or Q3 or Q4 =

Green (1 Hz)

One or more safety I/O modules :

Red/green

MS = (1 Hz) (firmware ≥ V2.00.0)

Red (1 Hz)

MS = (firmware V1.xx.0)

and I1 or I2 or I3 or I4 or I5 or I6 or I7 or I8 =

Green (1 Hz)

Possible error

codes

WS0-XTIO: 0x4701, 0x4702, 0x4704, 0x4705.

WS0-XTIO/ WS0-XTDI:

0x4601

Possible reasons Possible measures

Short circuit to 24 V or cross circuit in wiring of safe output Q1…Q4 (whose LED is flashing).

 Capacitive load exceeded the

allowed maximum value (e.g. by capacitor for spark quenching).

 Inductive load exceeded the

maximum value allowed

 Internal Hardware failure of WS0-

XTIO module

 Short circuit to 0 V in wiring of

safety output Q1…Q4 (whose LED is flashing).

 Power supply on the XTIO module

interrupted briefly

For inputs which are connected to test output:

 Short circuit to 24 V or cross circuit

in wiring for tested sensors:

a) Short circuit to 24 V or cross

circuit in wiring from X1, X2,…or X8 to tactile switch or test input of testable input.

b) Short circuit to 24 V or cross

circuit in wiring from tactile switch or output of testable sensor to I1, I2,…or I8.

 Defect testable sensor.

 Cable interruption in wiring for

safety mat:

a) Cable interruption in wiring from

X1, X2,…or X8 to safety mat.

b) Cable interruption in wiring from

safety mat to I1, I2,…or I8.

 Defect safety mat.

 Check wiring of all output.

 Check capacitive load.

 Check inductive load.

Replace XTIO module.

To reset the error all outputs of the effected module have to be turned off from logic of by turning off related input signals, e.g. E-stop. Error reset can take up to 8 seconds. Alternatively power cycle the CPU module.

 Check wiring of effected input.

 Replace testable sensor.

To reset the error turn off the effected input (input state Low/Low for equivalent dual channel inputs, Low/High for complementary dual channel inputs) or power cycle the CPU module.

Diagnostics

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS =  Green One or more safety

MS =  Red MS =  Red CPU module:

MS =  Red

MS =

Red (2 Hz) (with firmware ≥ V2.01.0)

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

I/O modules : MS =

Red/green (1 Hz) (firmware ≥ V2.00.0)

Red (1 Hz)

MS = (firmware V1.xx.0) and

I1+I2 or I3+I4 or I5+I6 or I7+I8 =

Green (1 Hz)

Red (2 Hz)

MS = (with firmware ≥ V2.00.0)

MS =  Red CPU module:

Possible error

codes

WS0-XTIO/ WS0-XTDI: 0x4429 or 0x442A

0xXXXCXXXX.

Safety I/O modules: 0xCXXX (X= any value)

CPU module: 0xXXXCXXXX.

Safety I/O modules: 0xCXXX (X= any value)

0xXXXCXXXX. Safety I/O modules: 0xCXXX (X= any value)

Possible reasons Possible measures

Discrepancy error or sequence error at dual channel inputs (whose LEDs are flashing green):

 Cable interruption or short circuit to

0 V at one of both input signals of the input pair.

 Hardware failure of sensor, e.g. one

of both contacts/outputs is permanently closed (High) or opened (Low).

 Defect sensor (one of both signals

does not change to the corresponding state to the other input within the configured discrepancy time.

 Opening or closing of safety door

was too slow so that the 2 contacts switches (e.g. reed contacts) did not switch within the configured discrepancy time.

 Only one of both inputs has caused

the switch off condition and has changed back to the on condition, without the other input having changed at all (sequence error).

 Power supply 0 V at WS0-XTIO

module missing (firmware V1.xx.0 only).

 Internal error in safety I/O module.

 Internal error in CPU module.

Internal error in safety I/O module (whose MS LED is flashing).

Internal error in CPU module or in the system.

Chapter 10

 Check wiring of effected input and

check switching capability of both contacts/outputs of the connected sensor.

 Check mechanical dependency of

both switches.

 Replace switch/sensor in hardware

installation

To reset the error the effected input pair has to be Low/Low for equivalent dual channel inputs and Low/High for complementary dual channel inputs.

 Check connection of terminal A2 of

WS0-XTIO modules to 0 V of power supply.

 Check installation for EMC

influence (earthing of DIN mounting rail,…).

 To reset the error power cycle the

CPU module.

 If the error persists, then replace

modules.

 Check installation for EMC

influence (earthing of DIN mounting rail,…).

 To reset the error power cycle the

CPU module

 If the error persists, then replace

the module whose MS LED is flashing.

 Check installation for EMC

influence (earthing of DIN mounting rail,…).

 To reset the error power cycle the

CPU module

 If the error persists, then replace

subsequently CPU module and safety I/O modules

Chapter 10

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS =  Red or

Red (2 Hz) (with firmware ≥ V2.01.0) or

MS =  Red (firmware V1.xx.0)

Diagnostics

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

MS =  Red

Red (2 Hz)

or (with firmware ≥ V2.00.0) or

MS =  Red (firmware V1.xx.0)

Possible error

codes

CPU module: 0x0006C002, 0x0007C002, 0x0001C005, 0x0003C006, 0x0005C006, 0x0029C006, 0x0003C013

CPU module: 0x0001C013, 0x0004C013, 0x0005C013, 0x000CC013

CPU module: 0x002AC006

WS0-XTIO/

WS0-XTDI:

0xC306 CPU module: 0x0029C006

WS0-XTIO/ WS0-XTDI:

0xC307 CPU module: 0x0029C006

WS0-XTIO: 0xC30A

CPU module: 0x0029C006

Possible reasons Possible measures

 Follow on error for other critical

errors.

 Disturbance of CPU module internal

signals due to heavy EMC disturbance.

 Hardware failure in CPU module or

any safety I/O module.

 FLEXBUS+ communication

(backplane communication to I/O modules and to network modules) disturbed due to EMC disturbance.

 FLEXBUS+ communication

(backplane communication to I/O modules and to network modules) disturbed due to critical fault in I/O modules. In this case this is a follow on error and there will be also other critical faults with almost the same time stamp (± 1 s) in the diagnosis history.

Unequal input data from safety I/O

module:

 A dual channel input at WS0-XTIO

module or WS0-XTDI module has 2 signal dips (High to Low) with a time distance of 2 ms (e.g. test gaps of an OSSD output or bouncing relay contacts).

 A signal channel input at WS0-

XTIO module or WS0-XTDI module changes state in intervals of 4 ms for a duration of 40 ms or more (e.g. proximity switch to a tooth wheel).

 Internal hardware failure of WS0-

XTIO or WS0-XTDI module.

 Follow on error of CPU module:

0x0029C006

 Power supply at terminal A2 (GND)

of WS0-XTIO module interrupted.

 Internal hardware failure of WS0-

XTIO or WS0-XTDI module.

 Follow on error of CPU module:

0x0029C006

 Short circuit to 24V or cross-circuit

in wiring of safe output Q1…Q4 (whose LED is flashing).

 Capacitive load exceeded the

allowed maximum value (e.g. by capacitor for spark quenching).

 Inductive load exceeded the

maximum value allowed

 Internal hardware failure of WS0-

XTIO module.

 Follow on error of CPU module:

0x0029C006

 Check the other diagnosis

messages for critical faults with almost the same time stamp.

 To reset the error power cycle the

CPU module.

 If error persists, then replace

subsequently CPU module and safety I/O modules.

 To reset the error power cycle the

CPU module.

 Check installation for EMC aspects

(FE connection of DIN mounting rail and control cabinet, star wiring of 24 V power supply, local separation of power parts and control parts,…)

 Check the other diagnosis

messages with almost same time stamp.

 To reset the error power cycle the

CPU module.

 Change the configuration by

activating the ON-OFF filter and activating the OFF-ON filter for inputs of the effected WS0XTIO/WS0-XTDI module. Please be aware that this increases the response time for this signal by at least 8 ms.

 To reset the error power cycle the

CPU module.

 Replace WS0-XTDI/WS0-XTIO

module in hardware installation.

 Check supply voltage at terminals

A1 (24 V) and A2 (0 V) at the WS0XTIO module, also under worst case load conditions.

 To reset the error power cycle the

CPU module.

 If the error persists, replace WS0-

XTDI/WS0-XTIO module in hardware installation.

 Check wiring of effected output.

 Check capacitive load.

 Check inductive load.

 To reset the error power cycle the

CPU module.

 If the error persists, replace WS0-

XTIO module in hardware installation.

Diagnostics

LED indication on module

CPU module

(WS0-CPU0, WS0-

CPU1 or WS0-CPU3)

MS =  Green All safety I/O modules:

All LEDs temporarily off and then LED test sequence.

Safety I/O module

(WS0-XTIO or

WS0-XTDI)

MS =  Green

All LEDs temporarily off and then LED test sequence.

Possible error

codes

CPU module: 0x000A0011

CPU module: 0x00100011

CPU module: 0x002D4006

CPU module: 0x003E4006

Possible reasons Possible measures

Function block error with dual channel input evaluation (e.g. Emergency stop, Magnetic switch): Discrepancy error at pair 1 of function block:

 Cable interruption or short circuit to

0 V at one of both input signals of the input pair.

 Hardware failure of sensor, e.g. one

of both contacts/outputs is permanently closed (High) or opened (Low).

 Defect sensor (one of both signals

does not change to the corresponding state to the other input within the configured discrepancy time.

 Opening or closing of safety door

was too slow, so that the 2 contacts switches (e.g. reed contacts) did not switch within the configured discrepancy time.

 Function block error (EDM or Valve

monitor): Feedback signal did not follow the control signal within the max. feedback delay time.

 Hardware failure of connected

relay/valve or failure in the wiring.

 Used relay/valve has greater

switching delay for monitor contact.

 Power supply of CPU module had

short voltage dip (to almost 0 V).

 Power supply of CPU module had a

voltage drop (approx. down to 6 V…16 V) and increased back to operating range.

The system has performed a restart because interferences have been detected in the FLEXBUS+ communication:

 FLEXBUS+ communication

(backplane communication to I/O modules and to network modules) disturbed due to EMC disturbance.

 FLEXBUS+ communication

(backplane communication to I/O modules and to network modules) disturbed due to critical fault in any safety I/O module (I/O modules or network module). In this case this is a follow on error and there will be also other critical faults with almost the same time stamp (± 1 s) in the diagnosis history.

Chapter 10

 Check the wiring of the effected

input and check switching capability of both contacts/outputs of the connected sensor.

 Check mechanical dependency of

both switches.

 Replace switch/sensor in hardware

installation

To reset the error the effected input pair has to change within the configured discrepancy time from Low/Low to High/High for equivalent dual channel inputs, from Low/High to High/Low for complementary dual channel inputs.

 Increase Max. feedback delay time

of the function block, if acceptable for the application.

 Replace relay/valve in the hardware

installation.

 Ensure that power supply is

capable to buffer power interruption up to 20 ms.

 Ensure that power supply is

capable to drive the load, so that switching of loads does not cause a drop of the supply voltage.

 Check power supply wiring of CPU

module. Use separate wires to other heavy loads to avoid voltage drops on the supply cable by other load currents.

 Check installation for EMC aspects

(FE connection of DIN mounting rail and control cabinet, star wiring of power supply (24 V and 0 V), local separation of power parts and control parts,…)

 Check the other diagnosis

messages with almost the same time stamp.

Chapter 10

Diagnostics

Table 52: Error codes and error messages of the MELSEC-WS safety controller and possible rectification measures

*1 After one of the dual channel inputs is set to ON and another is OFF, when the discrepancy time

passes, “Discrepancy error at dual channel input Ii” should occur. This discrepancy can be cleared when both inputs turn OFF (the left side figure below). However both inputs turn ON during the discrepancy, it is not cleared and this error should occur (the right side figure below).

*2 “Unequal input data from safety I/O module” may occur by following signal inputs.

1) “A dual channel input has 2 single dips (high to low) with a time distance of 2ms.”

2) “A signal channel input changes state in intervals of 4ms for a duration of 40ms or more.”

Behavior of a discrepancy error

Behavior of unequal input data

Note

Diagnostics

Chapter 10

10.3 Additional error displays of SICK EFI-compatible devices

SICK EFI-compatible devices (see Section 5.1) have extended functions in connection with the WS0-CPU1 or WS0-CPU3 module.

Error displays and error elimination are described in the manuals of the corresponding devices.

10.4 Mitsubishi support

If you cannot remedy a malfunction using the information in this chapter, please contact your local Mitsubishi representative.

When you send in a WS0-MPL0 or WS0-MPL1 memory plug for repair or analysis, it is returned in the state of delivery, i.e. with an empty configuration. Therefore save your configuration(s) to project files with the Setting and Monitoring Tool.

10.5 Extended diagnostics

The Setting and Monitoring Tool contains extended diagnostic possibilities. If you cannot identify what kind of error is occurring or if you have serviceability problems, it allows you to locate the error more accurately.

For detailed information refer to the Safety Controller Setting and Monitoring Tool Operating Manual.

Chapter 11

Maintenance

11 Maintenance

The following sections inform about regular tests and the exchange of MELSEC-WS modules.

Do not try to dismantle, repair or modify the MELSEC-WS modules. This can lead to a loss of the safety function(s). In addition Mitsubishi accepts no claims for liability.

11.1 Regular inspection of the protective device by

 Check the system at the inspection intervals specified in the national rules and

regulations. This procedure ensures that any changes on the machine or manipulations of the protective device are detected before use/re-use.

 Each safety application must be checked at an interval specified by you. The

effectiveness of the protective device must be checked by authorized commissioned persons.

qualified safety personnel

 If any modifications have been made to the machine or the protective device, or if

the MELSEC-WS safety controller has been changed or repaired, the system must be checked again as specified in the checklist in Chapter 14.

 Carry out regular or daily inspections in order to keep the MELSEC-WS modules

in an optimal operating mode.

 Check whether the implementation of the MELSEC-WS modules fulfills all the

technical data of the device.

 Check the mounting conditions and whether the wiring of the MELSEC-WS

modules is still correct.

 Regularly verify that the safety functions fulfill the requirements of the application

as well as all relevant regulations and standards (e.g. regular checking) in order to ensure the reliability of the safety functions.

Note

Maintenance

Chapter 11

11.2 Device replacement

A critical fault in a MELSEC-WS module impairs the complete network. Devices that have critical faults must therefore be repaired or replaced rapidly. We recommend keeping spare devices of the MELSEC-WS modules at hand so that network operation can be re-established as fast as possible.

Safety measures for replacing devices

Observe the following safety measures when replacing MELSEC-WS modules:

 Do not try to dismantle or repair the MELSEC-WS modules. Not only does

Mitsubishi accept no claims for liability, but it is also dangerous as it makes verifying the original safety functions impossible.

 Reset the device into a state in which safety is ensured.

 Carry out replacement only when the voltage supply is switched off in order to

avoid an electric shock or unexpected device behavior.

 In order to continue using the system configuration check:

– Is the new module of the same type (same material number) and is there no

error at the new module after the replacement?

– Is the new module plugged in at the same position as the replaced module?

– Have all connectors been re-connected to the correct terminals?

 Otherwise you have to completely reconfigure and commission the new system,

including all the necessary tests (see Chapter 9).

 After the replacement ensure that no errors arise with the new MELSEC-WS

modules.

 Always carry out a function test before commissioning a replacement module.

 SICK EFI-compatible devices do not have to be reconfigured after the

replacement of a MELSEC-WS module.

 If you send in MELSEC-WS modules for repair, generate a report on your project

and carry out diagnostics with the Setting and Monitoring Tool, enclose a detailed description of the problem with the device and send the MELSEC-WS modules with all available information to your local Mitsubishi representative.

Chapter 12

Technical data

12 Technical data

12.1 Response times of the MELSEC-WS safety controller

In order to calculate the response times of a MELSEC-WS safety controller, all paths have to be taken into consideration.

Figure 28: Response times within a MELSEC-WS safety controller

Note

Fast Shut Off

The Fast Shut Off function can be realized on a single WS0-XTIO module. A response time of 8 ms can be reached this way.

The Fast Shut Off function has only an effect on the inputs and outputs of the same WS0-XTIO module.

Flexi Link

The response time in a Flexi Link system is increased for a remote input compared to a local input by 4.5 ms + 2 × logic execution time of the remote Flexi Link station.

Flexi Line

The response time in a Flexi Line system is increased for a remote input by

the input time of the remote station (E1 to E4 from Table 53),

the logic response time of the station that evaluates this input (item 2.a from Table

53)

and N × (10 ms + 2 × Flexi Line update rate)

Where N = the number of connection segments between the stations.

If the Flexi Line function is used in a station, the response time is increased by the logic execution time of this station.

Technical data

Chapter 12

12.1.1 Calculation of the response times

The following table can be used to calculate the response times of corresponding paths within the MELSEC-WS safety controller.

Evaluation

1. Inputs

2. Logic

Response time of the considered input in the signal path

a) Response time of CPU module logic

b) Response time of the routing (applies only for

output to network module)

c) Response time of Fast shut off logic (applies

only for WS0-XTIO modules)

3. Outputs

Response time of the considered output in the signal path

Total response time

Occurrence In1: Digital inputs Out1: Digital outputs

General

Response time of the sensor*3

General Input processing time 6.5 ms Output processing time

If On/Off filter enabled If I1 … I8 is connected at

the test output X1… X8 a) Safety mats and

bumpers

b) Testable type 4

+ min. filter time*4 + Max. off-on delay*1 of used test output

+ Long gap of used test output*1 + Test period*1 of the test output. Use

the greater value of both test outputs. + Test period*1 of the test output.

sensors (e.g. L41)

c) All other sensors

+ Test gap*1 of the test output (if test gap*1 is >1 ms)

Total In1 Total Out1

Occurrence In2: Input from EFI device Out2: Output to EFI device

If EFI functions are used via SICK EFI-compatible devices Constant:

a) Scanner (e.g. S3000) + 3.5 ms + 24 ms b) Light grid (e.g.

C4000, M4000)

c) Flexi Link + 0.5 ms + 4 ms

Total In2 Total Out2

Response time of the EFI data source (as

Response time of the message receiver (e.g. a rule a sensor) for external OSSDs via EFI*3 or Flexi Link remote station

+ 1.5 ms + 4 ms

Occurrence In3: Network module — data from the

network

General Response time field bus for data input to

network module (e.g. from programmable controller)*3

General 2 × internal update interval for data from

the network module to the CPU module*5

If 1 network module + 5 ms + 8 ms If 2 network modules – 4 ms – 4 ms

Total In3 Total Out3

Table 53: Calculation of the response times of the MELSEC-WS safety controller in ms

*1 Take the values from the Setting and Monitoring Tool report. *2 Time values have a tolerance of 10 ms, i.e. for each selected value 10 ms must be considered

additionally for the response time. E.g. for a 10 ms off delay, 20 ms must be used for the calculation. *3 Take values from the corresponding manual. *4 Switch off is delayed until the signal has been Low for at least the filter time selected. For WS0-XTIO

and WS0-XTDI firmware version  V2.00 the filter time is fixed at 8 ms.

Response time field bus for data from

2 × internal update interval for data from the

In1 or In2 or In3 or In4 (from table below)

2 × logic execution time*1 Delay through logic application*2

(e.g. On- or Off-delay timer function block) No delay 0 ms

No delay 0 ms

Out1 or Out2 or Out3 or Out4 (from table below)

Response time of the actuator

a) From logic (via FLEXBUS+): + 4.5 ms b) From Fast Shut Off: + 1.5 ms

scanner with protective field switching via

EFI) EFI cycle time of the EFI receiver

Out3: Network module — data to the network

network module (e.g. to programmable controller)

CPU module to the network module

Chapter 12

Technical data

*5 The update interval between the CPU and a network module depends on the amount of data to be

transferred and the number of network modules used in the system. Take the values from the Setting

and Monitoring Tool report. The update interval amounts to a multiple of 4 ms for each 10 bytes to be

transferred to or from the network module if the system contains one network module. If 2 network

modules are used the update rate amounts to a multiple of 8 ms.

Figure 29: Example of a MELSEC-WS safety controller

Technical data

Chapter 12

Example 1:

Calculation of the response time for a MELSEC-WS safety controller consisting of a WS0-CPU1 and a WS0-XTIO:

Digital inputs: WS0-XTIO[1].I5I6.C4000: One C4000 safety light curtain

Digital outputs: WS0-XTIO[1].Q3Q4.Robot: Robot, dual-channel

Input from EFI device: WS0-CPU1[0].EFI1.1.OSSD [OSSD]: one C4000

receiver (stand-alone) (safety light curtain with high resolution for hazardous point, hazardous area and access protection at machines)

2 paths have to be considered and calculated separately:

Chapter 12

–

Technical data

Figure 30: Response times within a MELSEC-WS safety controller

Occurrence In1: Digital inputs Out1: Digital outputs

General C4000 response time 14.0 ms Robot response time 40.0 ms General Input processing time 6.5 ms Output processing time 4.5 ms When On/Off filter 8.0 ms When X1 … X8 is

connected at the test output

a) Safety mats and

bumpers

b) Testable sensors Type 4

(e.g. L41)

c) All other sensors

–

Total In1 20.5 ms Total Out1 44.5 ms

Evaluation

1. Inputs

2. Logic

3. Outputs

Response time of the considered input in the signal path (path 1)

Response time of the logic

Response time of the considered output in the signal path (path 1)

Total response time 73.0 ms

Table 54: Example for the calculation of the response time of path 1 of a MELSEC-WS safety controller

In1 20.5 ms

2 × logic execution time 8.0 ms Delay through logic application Out1 44.5 ms

Occurrence In2: Input from EFI device

If EFI functions are used via SICK EFI-compatible devices

Response time of the EFI data source (C4000 receiver

12.0 ms General Robot response time 40.0 ms

(stand-alone)) Constant (C4000) 1.5 ms General Output processing time 4.5 ms

Total In2 13.5 ms Total Out1 44.5 ms

Evaluation

1. Inputs

2. Logic

3. Outputs

Response time of the considered input in the signal path (path 2)

Response time of the logic

Response time of the considered output in the signal path (path 2)

Total response time 66.0 ms

Table 55: Example for the calculation of the response time of path 2 of a MELSEC-WS safety controller

Occurrence Out1: Digital outputs

In2 13.5 ms

2 × logic execution time 8.0 ms Delay through logic application Out1 44.5 ms

Technical data

–

Chapter 12

Example 2:

Calculation of the response time for a MELSEC-WS safety controller:

Figure 31: Response times within a MELSEC-WS safety controller

Flexi Link Station A

Logic execution time = 4 ms

Occurrence In1: Digital inputs

General Tactile sensor 0 ms

General Input processing time 6.5 ms Constant (Flexi Link) 4 ms When On/Off

filter When X1 … X8

is connected at the test output...

8.0 ms

Total In1 6.5 ms

Evaluation

1. Inputs

2. Logic

3. Outputs

Total response time 18.5 ms

Response time of the considered input in the signal path

Response time of the logic

Response time of the considered output in the signal path

Occurrence Out2: Output to EFI device

If EFI functions are used via SICK EFIcompatible devices

In1 6.5 ms

2 × logic execution time 8.0 ms Delay through logic application Out2 4.0 ms

Response time of the message receiver (see table below for Flexi Link station B)

Total Out2 4 ms

Flexi Link Station B

Logic execution time = 8 ms

Occurrence In2: Input from EFI device

If EFI functions are used via SICK EFIcompatible devices

Total In2 19.0 ms Total Out1 44.5 ms

Evaluation

1. Inputs

2. Logic

3. Outputs

Total response time (remote input to local output) 79.5 ms

Response time of the EFI data source (see table above for Flexi Link station A)

Constant (Flexi Link) 0.5 ms General Output processing time 4.5 ms

Response time of the considered input in the signal path

Response time of the logic

Response time of the considered output in path 2 Out1 44.5 ms

Table 56: Example for the calculation of the response time of a remote input in a MELSEC-WS safety controller

18.5 ms General

Occurrence

Out1: Digital outputs

Response time of the actuator (Robot response time)

In2 19.0 ms

2 × logic execution time 16.0 ms Delay through logic application

40.0 ms

Chapter 12

Technical data

12.1.2 Min. switch off time

The minimum switch-off time (e.g. of connected sensors) is the minimum time for which a switch-off condition must be present in order to be detected so that errorfree switching is possible. The min. switch-off time must be …

 greater than the logic execution time + 1 ms, and

 greater than the test gap + Long gap, if the input is connected to test output

X1…X8 and the test gap is > 1 ms, and

 greater than the test period (i.e. the higher value of the two test outputs used) +

the max. Off-on delay, if safety mats or bumpers are used.

*1 Take the values from the Setting and Monitoring Tool report.

Mitsubishi MELSEC-WS0-CPU0, MELSEC-WS0-CPU3, MELSEC-WS, MELSEC-WS0-CPU1, MELSEC-WS0-XTIO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Precautions regarding warranty and specifications

 SAFETY PRECAUTIONS 

 CONDITIONS OF USE FOR THE PRODUCT 

REVISIONS

CONTENTS

GENERIC TERMS AND ABBREVIATIONS

1 About this document

1.1 Function of this document

1.2 Target group

1.3 Depth of information

1.4 Scope

1.5 Abbreviations used

1.6 Symbols used

2 On safety

2.1 Qualified safety personnel

2.2 Application areas for the device

2.3 Correct use

2.4 General protective notes and protective measures

2.5 Environmental protection

2.5.1 Disposal

2.5.2 Material separation

3 Product description

3.1 System properties

3.2 System configuration

3.3 Version, compatibility and features

3.4 Memory plug

3.5 CPU module WS0-CPU0

3.5.1 Description

3.5.2 Display elements and terminal description

3.6 CPU module WS0-CPU1

3.6.1 Description

3.6.2 Display elements and terminal description

3.7 CPU module WS0-CPU3

3.7.1 Description

3.7.2 Display elements and terminal description

3.8 WS0-XTIO safety I/O combined module

3.8.1 Description

3.8.2 Display elements and terminal description

3.8.3 Internal circuits

3.8.4 Disabling the test pulses of WS0-XTIO outputs Q1 to Q4

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

3.8.6 Single channel usage of WS0-XTIO outputs

3.9 WS0-XTDI safety input module

3.9.1 Description

3.9.2 Display elements and terminal description

3.9.3 Internal circuits

3.10 WS0-4RO safety relay output module

3.10.1 Description

3.10.2 Display elements and terminal description

4 Connecting devices

4.1 Safety command devices and electro-mechanical safety switches

4.1.1 Emergency stop pushbuttons (e.g. SICK ES21)

4.1.2 Electro-mechanical safety switches with and without interlock

4.1.3 Enabling switch (e.g. SICK E100)

4.1.4 Two-hand control

4.1.5 Safety mats and bumpers

4.1.6 User mode switches

4.1.7 Potential-free contacts

4.2 Non-contact safety sensors

4.2.1 Magnetic safety switches (e.g. SICK RE)

4.2.2 Inductive safety switches (e.g. SICK IN4000 and IN4000 Direct)

4.2.3 Transponder (e.g. SICK T4000 Compact and T4000 Direct)

4.3 Testable single-beam photoelectric safety switches

4.3.1 Testable Type 2 single-beam photoelectric safety switches

4.3.2 Testable Type 4 single-beam photoelectric safety switches

4.3.3 Customized testable single beam photoelectric safety switches

4.3.4 Information for mounting testable single-beam photoelectric safety switches

4.4 Electro-sensitive protective equipment (ESPE)

4.5 Safe outputs Q1 to Q4

4.6 EFI devices

4.6.1 Connection of EFI devices

4.7 Flexi Link

4.7.1 Flexi Link overview

4.7.2 System requirements and restrictions for Flexi Link

4.7.3 Connection of a Flexi Link system

4.8 Flexi Line