Mitsubishi WS0-CPU3, SW1DNN-WS0ADR-B, WS0-CPU1, WS0-CPU0 User Manual

Safety Controller Setting and Monitoring Tool

Operating Manual

-WS0-CPU0

-WS0-CPU1

-WS0-CPU3 -SW1DNN-WS0ADR-B

This document is protected by the law of copyright, whereby all rights established therein remain with the company Mitsubishi Electric Corporation. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without the explicit written approval of the company Mitsubishi Electric Corporation.

Precautions regarding warranty and specifications

MELSEC-WS series products are jointly developed and manufactured by Mitsubishi and SICK AG, Industrial Safety Systems, in Germany.

Note that there are some precautions regarding warranty and specifications of MELSEC-WS series products.

<Warranty>

The gratis warranty term of the product shall be for one (1) year after the date of delivery or for eighteen (18) months after manufacturing, whichever is less.

The onerous repair term after discontinuation of production shall be for four (4) years.

Mitsubishi shall mainly replace the product that needs a repair.

It may take some time to respond to the problem or repair the product depending on the condition and timing.

<Specifications>

 General specifications of the products differ.

	MELSEC-WS	MELSEC-Q	MELSEC-QS
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	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	5 to 95%RH

*1 When the WS0-GCC100202 is included in the system, operating ambient temperature will be 0 to 55 °C.

 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.

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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 specialised 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.

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[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 for the system in all phases 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.

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[Wiring Precautions]

WARNING

Shut off the external power supply for the system in all phases 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.

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[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 for the system in all phases 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.

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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 for the MELSEC-WS safety controller in all phases 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).

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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.

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REVISIONS

*The manual number is given on the bottom left of the back cover.

Print date	*Manual number	Revision
September, 2009	SH(NA)-080856ENG-A	First edition
March, 2010	SH(NA)-080856ENG-B	A new module, CC-Link interface module, was added.
July, 2011	SH(NA)-080856ENG-C	Description on Flexi Link system was added.
August, 2012	SH(NA)-080856ENG-D	Setting and Monitoring Tool was upgraded.
August, 2014	SH(NA)-080856ENG-E	A new module, WS0-CPU3 module, was added.
		Description on Flexi Line system was added.
		Setting and Monitoring Tool was upgraded.
August, 2016	SH(NA)-080856ENG-F	Description on the corporate logo was changed.
November, 2018	SH(NA)-080856ENG-G	Errors in writing are corrected.

Japanese manual version SH-080853-H

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

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CONTENTS

SAFETY PRECAUTIONS...........................................................................................		1
CONDITIONS OF USE FOR THE PRODUCT ...........................................................		7
REVISIONS ................................................................................................................		8
CONTENTS ................................................................................................................		9
GENERIC TERMS AND ABBREVIATIONS..............................................................		15
1. About this document .............................................................................................		16
1.1	Function of this document...............................................................................	16
1.2	Target group ....................................................................................................	17
1.3	Function and structure of this manual.............................................................	18
1.3.1 Recommendations for familiarising yourself with Setting and Monitoring
	Tool ..........................................................................................................	18
1.3.2 Recommendations for experienced users................................................		18
1.4	Scope and version ..........................................................................................	18
1.5 Abbreviations used..........................................................................................		19
1.6	Symbols and notations used...........................................................................	19
2. On safety ..............................................................................................................		20
2.1	Qualified safety personnel ..............................................................................	20
2.2	Correct use......................................................................................................	20
2.3	General protective notes and protective measures ........................................	21
3. Version, compatibility and features.......................................................................		22
4. Installation and removal........................................................................................		24
4.1	System requirements ......................................................................................	24
4.2	Installation and Update ...................................................................................	24
4.3	Removal ..........................................................................................................	25
4.4	Troubleshooting...............................................................................................	25
5. The graphical user interface .................................................................................		26
5.1	Start view ........................................................................................................	26
5.2	Setting the desired language ..........................................................................	26
5.3	Standard views................................................................................................	27
5.4	Positioning windows........................................................................................	28
5.5	Hardware configuration view...........................................................................	29
5.5.1 Exercise for configuring the MELSEC-WS modules ................................		31
5.5.2 Module status bits in the Hardware configuration view ............................		33
5.5.3 Exercise for configuring the connected devices.......................................		35
5.5.4 Safe and non-safe elements in the hardware configuration.....................		36
5.5.5 Expanding elements .................................................................................		36
5.5.6 Parameterization of connected elements .................................................		37
5.5.7 Customized elements ...............................................................................		39

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5.5.8 Connection of SICK EFI-compatible devices ...........................................		42
5.5.9 Export and import of a partial application .................................................		44
5.5.10 RS-232 routing .......................................................................................		47
5.6	Logic editor view .............................................................................................	52
5.6.1 Exercise for using the logic editor ............................................................		53
5.6.2 Logic access levels...................................................................................		54
5.6.3 Validation of the configuration ..................................................................		55
5.6.4 Inputs and diagnostics bits of the main module in the logic editor ...........		56
5.6.5 EFI I/O error status bits in the logic editor ................................................		57
5.6.6 Module input and output status bits in the logic editor .............................		57
5.6.7 CPU markers ............................................................................................		58
5.6.8 Jump addresses .......................................................................................		59
5.6.9 I/O matrix ..................................................................................................		60
5.6.10 Tag name editor......................................................................................		61
5.6.11 Import and export tag names..................................................................		62
5.7	Report view .....................................................................................................	63
5.8	Diagnostics view .............................................................................................	64
5.9	Data recorder view..........................................................................................	66
6. Connecting to the MELSEC-WS safety controller ................................................		68
6.1	First steps for establishing a connection.........................................................	68
6.1.1 Connecting the PC to the MELSEC-WS safety controller via RS-232.....		68
6.1.2 Online status and background color.........................................................		69
6.2	Editing the communication settings ................................................................	70
6.3	Establishing a connection with the MELSEC-WS safety controller ................	76
6.4	User levels in the Setting and Monitoring Tool ...............................................	77
6.5	Identify project.................................................................................................	78
7. Flexi Link...............................................................................................................		79
7.1	Flexi Link overview..........................................................................................	79
7.1.1 System requirements and restrictions for Flexi Link ................................		79
7.2	Function principle............................................................................................	80
7.2.1 Flexi Link address.....................................................................................		80
7.2.2 Flexi Link ID..............................................................................................		80
7.3	Getting started.................................................................................................	82
7.3.1 Connecting to an existing Flexi Link system ............................................		82
7.3.2 Setting up a Flexi Link project in the Setting and Monitoring Tool............		85
7.3.3 Flexi Link configuration.............................................................................		86
7.3.4 Transferring and verifying the Flexi Link configuration.............................		90
7.4	Flexi Link functions .........................................................................................	93
7.4.1 Flexi Link system: System overview.........................................................		94
7.4.2 Flexi Link system: Process image ............................................................		96
7.4.3 Flexi Link system: Network settings .........................................................		97

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7.4.4 Flexi Link stations: Flexi Link data in the logic editor ...............................		98
7.4.5 Flexi Link stations: Station X view and process image ..........................		100
7.4.6 Flexi Link stations: Teach function..........................................................		102
7.4.7 Flexi Link teaching status and diagnostics .............................................		104
7.5	Flexi Link troubleshooting .............................................................................	106
7.5.1 Flexi Link ID mismatch ...........................................................................		106
8. Flexi Line ............................................................................................................		107
8.1	Flexi Line overview .......................................................................................	107
8.1.1 System requirements and restrictions for Flexi Line ..............................		107
8.2	Principle of operation Flexi Line....................................................................	108
8.2.1 Topology .................................................................................................		108
8.2.2 Flexi Line configuration...........................................................................		108
8.2.3 Flexi Line checksum (CRC).....................................................................		111
8.2.4 Flexi Line data in the logic editor.............................................................		112
8.2.5 Teach function..........................................................................................		113
8.2.6 Status and diagnostics ............................................................................		115
8.3	Getting started................................................................................................	116
8.3.1 Configuration and commissioning of a Flexi Line system .......................		116
8.3.2 Conversion of a Flexi Line system ..........................................................		117
8.3.3 Configuration of the Flexi Line logic ........................................................		118
9. Logic programming – Function blocks ...............................................................		120
9.1	General description.......................................................................................	120
9.2	Safety notes for the logic programming ........................................................	120
9.3	Function block Overview...............................................................................	122
9.4	Function block properties..............................................................................	123
9.5	Input and output signal connections of function blocks ................................	124
9.5.1 Function block input connections ...........................................................		124
9.5.2 Inversion of input connections................................................................		124
9.5.3 Function block output connections .........................................................		125
9.5.4 Fault present output................................................................................		126
9.6 Timer values and logic execution time..........................................................		127
9.7	Logic function blocks.....................................................................................	127
9.7.1 NOT ........................................................................................................		127
9.7.2 AND ........................................................................................................		128
9.7.3 OR ..........................................................................................................		129
9.7.4 XOR (exclusive OR) ...............................................................................		130
9.7.5 XNOR (exclusive NOR)..........................................................................		131
9.7.6 Multiple release ......................................................................................		131
9.7.7 RS Flip-Flop............................................................................................		132
9.7.8 JK Flip-Flop ............................................................................................		133
9.7.9 Multiple memory .....................................................................................		134

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9.7.10 Clock generator ....................................................................................	135
9.7.11 Event counter (Up, Down and Up and down) .......................................	136
9.7.12 Fast shut off and Fast shut off with bypass ..........................................	139
9.7.13 Edge detection......................................................................................	144
9.7.14 Binary encoder .....................................................................................	145
9.7.15 Binary decoder .....................................................................................	148
9.7.16 Log generator .......................................................................................	151
9.7.17 Routing 1:N...........................................................................................	153
9.7.18 Routing N:N ..........................................................................................	154
9.8 Application-specific function blocks...............................................................	155
9.8.1 Reset ......................................................................................................	155
9.8.2 Restart ....................................................................................................	156
9.8.3 Off-delay timer ........................................................................................	158
9.8.4 Adjustable off-delay timer .......................................................................	159
9.8.5 On-delay timer ........................................................................................	160
9.8.6 Adjustable on-delay timer .......................................................................	161
9.8.7 EDM (External device monitoring)..........................................................	162
9.8.8 Valve monitoring .....................................................................................	163
9.8.9 User mode switch ...................................................................................	167
9.8.10 Switch synchronization.........................................................................	169
9.8.11 Error output combination ......................................................................	172
9.8.12 Ramp down detection...........................................................................	173
9.8.13 Frequency monitor................................................................................	178
9.8.14 Start warning ........................................................................................	182
9.9 Function blocks for dual channel evaluation.................................................	187
9.9.1 Single-channel evaluation ......................................................................	187
9.9.2 Dual-channel evaluation (1 pair) and discrepancy time .........................	188
9.9.3 Double dual-channel evaluation (2 pair synchronization evaluation) and
synchronization time ..............................................................................	190
9.9.4 Emergency stop......................................................................................	192
9.9.5 Magnetic switch ......................................................................................	193
9.9.6 Light curtain monitoring ..........................................................................	194
9.9.7 Safety gate monitoring............................................................................	195
9.9.8 Tolerant dual channel monitor ................................................................	197
9.9.9 Two-hand control type IIIA......................................................................	202
9.9.10 Two-hand control type IIIC....................................................................	202
9.9.11 Multi operator (multiple two-hand control) ............................................	204
9.10 Function blocks for Parallel muting, Sequential muting and Cross muting
....................................................................................................................	206
9.10.1 Overview and general description ........................................................	206
9.10.2 Parameters of the function blocks ........................................................	209

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9.10.3 Information on wiring ............................................................................		216
9.10.4 State transition from Stop to Run .........................................................		217
9.10.5 Error states and information on resetting .............................................		217
9.10.6 Parallel muting......................................................................................		218
9.10.7 Sequential muting.................................................................................		220
9.10.8 Cross muting – direction of movement only forwards or backwards....		222
9.10.9 Cross muting – material transport in both directions............................		224
9.11 Function blocks for press contact monitoring..............................................		226
9.11.1 Overview and general description ........................................................		226
9.11.2 Eccentric press contact.........................................................................		226
9.11.3 Universal press contact ........................................................................		232
9.12	Function blocks for press cycle control.......................................................	240
9.12.1 Press setup...........................................................................................		240
9.12.2 Press single stroke ...............................................................................		243
9.12.3 Press automatic....................................................................................		247
9.12.4 N-break (press with N-PSDI mode)......................................................		250
9.13	User defined function blocks.......................................................................	258
9.13.1 Grouped function block.........................................................................		258
9.13.2 Customized function block ...................................................................		262
9.14	Simulation of the configuration....................................................................	265
9.15	Force mode.................................................................................................	267
10. I/O modules ......................................................................................................		271
10.1	Dual channel evaluation and discrepancy time monitoring ........................	271
10.2	ON-OFF filter and OFF-ON filter.................................................................	273
10.3	Disabling the test pulses of WS0-XTIO outputs..........................................	273
11. Transferring the system configuration...............................................................		274
11.1 Transferring project data to the safety controller.........................................		274
11.2 Compatibility check .....................................................................................		274
11.3 Verification of the configuration ...................................................................		275
11.4 Activating the write protection of the configuration in the
	safety controller ..........................................................................................	278
11.5 Configuration checksums............................................................................		278
11.6 Deletion of the configuration in the safety controller ...................................		278
12. Device states of the MELSEC-WS safety controller.........................................		279
12.1	Changing the device state ..........................................................................	280
12.2	Behaviour on startup...................................................................................	280
12.3	Software reset of the CPU module .............................................................	280
13. Technical commissioning..................................................................................		281
13.1	Wiring and voltage supply...........................................................................	281
13.2	Transferring the configuration .....................................................................	281
13.3	Technical test and commissioning ..............................................................	282

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14. Troubleshooting ................................................................................................		283
15. Annex................................................................................................................		284
15.1	Example application reports........................................................................	284
15.1.1 Example application Newspaper palletizer...........................................		284
15.1.2 Example application Wood scanner .....................................................		299
15.1.3 Example application Ramp down detection .........................................		310
15.2	List of function block status in simulation mode..........................................	320
15.3	Precautions .................................................................................................	321
15.4	SICK contact ...............................................................................................	322

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GENERIC TERMS AND ABBREVIATIONS

	Generic	Description
	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-CPU 320202 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

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	About this document	Chapter 1

1 About this document

Please read this chapter carefully before working with this manual and the MELSECWS safety controller.

1.1Function of this document

For the MELSEC-WS safety controller there are sets of manuals with clearly defined applications as well as user’s manuals (hardware) for each module.

All MELSEC-WS modules and their functions are described in detail in “MELSECWS series Safety Controller User's manual”. Use the Safety Controller User's manual in particular for the planning of MELSEC-WS safety controllers.

The Safety Controller User's manual is designed to address the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, electrical installation, commissioning, operation and maintenance of the MELSEC-WS safety controller.

The Safety Controller User's 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 operating instructions of the machine.

The software-based configuration and setting the parameters for the MELSECWS safety controller are described in “MELSEC-WS series Safety Controller Setting and Monitoring Tool Operating Manual". The operating manual also contain a description of the diagnostic functions most important for operation and detailed information on the identification and rectification of errors. Use the operating manual in particular for the configuration, commissioning and operation of MELSEC-WS safety controllers.

MELSEC-WS network interface modules and their functions are described in detail in the user's manuals for each network interface module. The network interface module interface manuals 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 maintenance of the MELSEC-WS network interface modules. The network interface module user's manuals also contain important information on the configuration of the network interface module using the software Setting and Monitoring Tool, on the exchange of data with networks as well as information on the status, the planning and the related mapping.

The user’s manuals (hardware) are included with each MELSEC-WS module. They provide basic technical specifications on the modules and contain simple mounting instructions. Use the user’s manuals (hardware) when mounting the MELSEC-WS safety controller.

16

Chapter 1	About this document

Table 1:

Overview of the MELSECWS manuals

The following shows the relevant manuals.

	Title		Number
	Safety Controller User’s Manual		WS-CPU-U-E
			(13JZ32)
	Safety Controller Ethernet Interface Module User’s Manual		WS-ET-U-E
			(13JZ33)
	Safety Controller CC-Link Interface Module User’s Manual		WS-CC-U-E
			(13JZ45)
	Safety Controller Setting and Monitoring Tool Operating		SW1DNN-WS0ADR-B-O-E
	Manual		(13JU67)
	Safety Controller CPU Module User's Manual (Hardware)		WS-CPU-U-HW-E
			(13JZ91)
	Safety Controller Safety I/O Module User's Manual		WS-IO-U-HW-E
	(Hardware)		(13JZ92)
	Safety Controller Safety Relay Output Module User's Manual		WS-SR-U-HW-E
	(Hardware)		(13JZ93)
	Safety Controller Ethernet Interface Module User's Manual		WS-ET-U-HW-E
	(Hardware)		(13JZ95)
	Safety Controller CC-Link Interface Module User's Manual		WS-CC-U-HW
	(Hardware)		(13J209)

1.2Target group

These user's manuals are addressed to the planning engineers, designers and operators of systems which are to be protected by a MELSEC-WS safety controller. They also are addressed to 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.

These user's manuals do not provide instructions for operating the machine or system in which a MELSEC-WS safety controller is integrated. Information of this kind will be found in the operating instructions for the machine or system.

17

	About this document	Chapter 1

1.3Function and structure of this manual

This manual instructs the technical personnel of the machine manufacturer or machine operator in the software configuration, operation and diagnostics of a MELSEC-WS safety controller using the Setting and Monitoring Tool. It only applies in combination with the Safety Controller User’s Manual.

Planning and using SICK protective devices also require specific technical skills which are not detailed in this documentation.

Chapter 2 contains fundamental safety instructions. These instructions must be read.

When operating the MELSEC-WS modular safety controller, the national, local and statutory rules and regulations must be observed.

Note For the acquisition of Setting and Monitoring Tool, please contact your local Mitsubishi representative.

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 15.4).

www.sick.com

1.3.1Recommendations for familiarising yourself with Setting and Monitoring Tool

We recommend the following procedure for users who want to familiarize themselves with Setting and Monitoring Tool for the first time:

Read Chapter 5 to familiarize yourself with the graphical user interface and do the exercises for the configuration of example applications.

1.3.2Recommendations for experienced users

We recommend the following procedure for experienced users who have already worked with Setting and Monitoring Tool:

Familiarize yourself with the most recent version of the software by reading Section 1.4.

The table of contents lists all functions provided by the Setting and Monitoring Tool. Use the table of contents to obtain information about the basic functions.

1.4Scope and version

These user's manuals are original manuals.

These user's manuals apply for the Setting and Monitoring Tool software version V1.2.0 or higher, CPU0 and CPU1 with firmware version V1.11 or higher, and CPU3 with firmware version V3.02 or higher.

This version of the user's manuals describes version V1.7.0 of the Setting and Monitoring Tool software.

18

Chapter 1	About this document

1.5Abbreviations used

EDM External device monitoring

EFI Enhanced function interface

ESPE Electro-sensitive protective equipment (e.g. C4000)

OSSD Output signal switching device

Rev Revolutions (1 Rev = 360°)

1.6Symbols and notations used

Recommendation Recommendations are designed to give you some assistance in your decisionmaking process with respect to a certain function or a technical measure.

Note Note provides special information on a device or a software function.

Action 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.

Menus and	The names of software menus, submenus, options and commands, selection boxes
commands	and windows are highlighted in bold. Example: Click Edit in the File menu.

The term “dangerous state”

The dangerous state (standard term) of the machine is always shown in the drawings and diagrams of this document as the movement of a machine part. In practical operation, there may be a number of different dangerous states:

 machine movements  electrical conductors

 visible or invisible radiation

 a combination of several risks and hazards

Key Keys are shown in uppercase.

Keys to be pressed sequentially are hyphenated with “-”.

Example: “CTRL+ALT+DEL” indicates to press these keys simultaneously. “F12-2” indicates to press these keys sequentially. The key names are based on the standard keyboard. Some users may use a keyboard with a different language layout such as German.

19

	On safety	Chapter 2

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 a MELSEC-WS safety controller.

2.1Qualified safety personnel

The MELSEC-WS safety controller must be installed, configured, 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 operator in the operation of the machine and the current valid safety guidelines

and

are sufficiently familiar with the applicable official health and work safety 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

and

have access to the MELSEC-WS manuals and have and read and familiarised themselves with them

and

have access to the operating instructions for the protective devices (e.g. C4000) connected to the safety controller and have read and familiarised themselves with them.

2.2Correct use

The Setting and Monitoring Tool is used to configure a MELSEC-WS safety controller consisting of modules of the safety controller.

The MELSEC-WS safety controller may only be used by qualified safety personnel and only at the machine at which it was mounted and initially commissioned by qualified safety personnel in accordance with the MELSEC-WS manuals.

		Mitsubishi Electric Corporation accepts no claims for liability if the software or the
	ATTENTION	devices are used in any other way or if modifications are made to the software or the
		devices - even in the context of mounting and installation.

Observe the safety instructions and protective measures of the Safety Controller User’s Manual and this manual!

When implementing a safety-relevant functional logic, ensure that the regulations of the national and international rules and standards are observed, in particular the controlling strategies and the measures for risk minimisation that are mandatory for your application.

20

Chapter 2	On safety

2.3General protective notes and protective measures

Observe the protective notes and measures!

Please observe the following items in order to ensure proper use of the MELSEC-

WS safety controller.

Note When mounting, installing and using the MELSEC-WS safety controller, observe the standards and directives applicable in your country.

The national and international rules and regulations apply to the installation and use as well as commissioning 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 and the supplementary Directive 35/63/EC,

–Low-Voltage Directive 2006/95/EC,

–Work safety regulations and 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.

21

	Version, compatibility and features	Chapter 3

3 Version, compatibility and features

Table 2:

Required firmware and software versions

For the MELSEC-WS series several firmware versions and function packages exist that allow different functions. This chapter 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.

				Minimum required version
	Feature			WS0-CPU		WS0-XTIO/		Setting and
						WS0-XTDI		Monitoring Tool
	Logic offline simulation			–*1		–		V1.2.0
	Logic import/export			–		–		V1.3.0
	Online edit			–		–		V1.3.0
	Automatic wiring diagrams			–		–		V1.3.0
	Central tag name editor			–		–		V1.3.0
	Flexi Link (only with WS0-			V2.01		–		V1.3.0
	CPU1/WS0-CPU3)			(Revision 2.xx)
	Flexi Line (only with WS0-CPU3)			V3.02		–		V1.7.0
				(Revision 3.xx)
	Function block documentation
	within the Setting and Monitoring			–		–		V1.3.0
	Tool
	Input/output relation matrix			–		–		V1.3.0
	Invertable inputs for the AND,			V2.01
	OR, RS Flip-Flop and Routing					–		V1.3.0
				(Revision 2.xx)
	N:N function blocks
	Ramp down detection function			V1.11		–		V1.3.0
	block			(Revision 1.xx)
	Adjustable on-delay timer and			V2.01
	adjustable off-delay timer					–		V1.3.0
				(Revision 2.xx)
	function blocks
	Fast Shut Off with Bypass			V2.01		V2.00
	function block (only with WS0-							V1.7.0
				(Revision 2.xx)		(Revision 2.xx)
	XTI0)
	Deactivation of test pulses on					V2.00
	Q1–Q4 on the WS0-XTIO			–				V1.3.0
						(Revision 2.xx)
	possible
	Verification without identical			V2.01		–		V1.3.0
	hardware possible			(Revision 2.xx)
	Status input data and Status			V2.01		V2.00		V1.3.0
	output data in logic			(Revision 2.xx)		(Revision 2.xx)
	Data recorder			V2.01		–		V1.7.0
				(Revision 2.xx)
	Extended cross-circuit detection					V3.10
	time for switching loads with			–				V1.7.0
						(Revision 3.xx)
	high capacitance
	Adjustable filter time for ON-OFF
	filter and OFF-ON filter on the			–		V3.10		V1.7.0
	inputs I1 to I8 of the WS0-					(Revision 3.xx)
	XTIO/WS0-XTDI

22

Chapter 3	Version, compatibility and features

Device	WS0-CPU
Ethernet interface module	V1.11
	(Revision 1.xx)
CC-Link interface module	V1.11
	(Revision 1.xx)
ROHS conformity WS0-XTIO	–

*1 “–” means “any” or “not applicable”.

*2 All other modules from product launch onwards.

WS0-XTIO/	Setting and
WS0-XTDI	Monitoring Tool
–	V1.2.0
–	V1.2.1
V1.01*2
	–

Note  You can find the firmware version on the type label of the MELSEC-WS modules in the field Firmware version.

In order to use modules with a newer firmware version, a new Setting and Monitoring Tool version is required. For CPU0/1 ≥ V2.01 and XTIO/XTDI ≥ V2.00 Setting and Monitoring Tool V1.3.0 or higher is required. This has to be considered when devices are to be replaced in existing systems.

You will find the firmware version of the MELSEC-WS modules in the hardware configuration view of the Setting and Monitoring Tool when the system is online or in the report if the system has been online before.

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).

23

	Installation and removal	Chapter 4

4 Installation and removal

4.1System requirements

Recommended system configuration:

Windows XP (32 Bit/64 Bit), Windows Vista (32 Bit/64 Bit), or Windows 7 (32 Bit/64 Bit)

Microsoft .NET Framework 3.5

1 GHz processor

1 GB RAM

1024 × 768 pixel screen resolution

300 MB free hard disk memory

Note Setting and Monitoring Tool is a .NET Framework application. It requires .NET Framework Version 3.5 or higher.

Information on the current .NET Framework versions, supported operating systems, and Regional and Language Options settings is available on the Internet at

www.microsoft.com

Microsoft .NET Framework Version 3.5 or higher and any other components that may be needed can also be downloaded from www.microsoft.com/downloads.

Note Use a standard user account or higher in Windows Vista or Windows 7.

To display text of Setting and Monitoring Tool in Chinese, use Chinese version of Windows operating systems.

To display text of Setting and Monitoring Tool in Japanese or Chinese in Windows XP (English version), add the language in the Regional and Language Options dialog box. (The dialog box can be accessed from Control Panel.)

4.2Installation and Update

For the acquisition of Setting and Monitoring Tool (including information for installation), please contact your local Mitsubishi representative.

Start the installation by running the setup.exe file and then follow the further instruction.

New software versions may contain new functions and support new MELSEC-WS modules. The version of the Setting and Monitoring Tool can be found in the Extras menu under About.

Remove the old software version before installing a new one. The working directory in which the project data are stored is not overwritten during the new installation and is retained. When an RS232-USB converter (WS0-UC-232A) is used, install a driver from the CD ROM provided with the converter.

When an RS232-USB configuration cable (WS0-C20M8U) is used, please contact your local Mitsubishi representative for a driver of the cable.

24

Chapter 4	Installation and removal

Table 3:

Errors and error elimination

4.3Removal

The Setting and Monitoring Tool can be removed as follows:

In the Windows Start menu, start Uninstall Setting and Monitoring Tool in the Setting and Monitoring Tool program folder.

4.4Troubleshooting

Error/Error message	Cause	Rectification
When Setting and Monitoring	Microsoft .NET Framework is	Install a suitable version of
Tool is started, the following	not installed on the PC.	Microsoft .NET Framework.
or a similar error message is		Ask your system
displayed: “DLL not found –		administrator if
the Dynamic Link Library		appropriate. .NET
mscoree.dll was not found in		Framework is available for
the specified path.		downloading on the internet
Specify the registration key		pages of Microsoft.
HKLM\Software\Microsoft\ N		Note:
ETFramework\InstallRoot so		Install .NET Framework 3.5
that it refers to the
installation location of
the .NET Framework.”

25

	The graphical user interface	Chapter 5

5 The graphical user interface

Note This chapter familiarizes you with the basic elements of the graphical user interface as an introduction. This chapter does not give any information on the configuration of MELSEC-WS modules nor any instructions for logic programming. This chapter is only intended to explain the fundamental functioning of the Setting and Monitoring Tool on the basis of a small section of the functions. Experienced users of Setting and Monitoring Tool can skip this chapter.

5.1Start view

After the Setting and Monitoring Tool has been started, the start view is displayed. The user can specify here with which of the following actions he wants to start:

Open existing project file

Connect to physical device

Create new project

Create new Flexi Link project

Edit com. Interface settings

Figure 1:

Start view with selection of the action

5.2Setting the desired language

Click the flag icon in the menu bar at the far right and select the desired language version.

26

Chapter 5	The graphical user interface

5.3Standard views

The Setting and Monitoring Tool has the following views that can be accessed via buttons below the menu bar.

Figure 2:

The view can be selected below the menu bar

The structure of a MELSEC-WS safety controller consisting of various hardware modules as well as the configuration of the inputs and outputs and the connected elements are specified in the Hardware configuration view.

The function logic can be configured by means of logic function blocks and application-specific function blocks in the Logic editor view. This view is not available unless a CPU module has been selected beforehand in the hardware configuration.

If the project contains at least one network module or if RS-232 communication is enabled, the Network module [13] view is available. Here you can configure the network module and the data that are transferred to and from the network.

Note Do not save the project data while Setting and Monitoring Tool is connected to the MELSEC-WS safety controller.

Before saving the project data, disconnect the PC from the MELSEC-WS safety controller.

Complete information on the currently loaded project and all settings including the logic programming and wiring diagrams is available in the Report view. Furthermore, additional information on the project can be entered here. All information can be saved in standard file formats and printed out. The scope of the report can be compiled individually depending on the selection.

The stored error messages are displayed as a history of a connected MELSEC-WS safety controller in the Diagnostics view.

Input and output signals from a MELSEC-WS safety controller can be recorded and displayed inthe Data recorder view.

27