Pepperl+Fuchs VAA-2E2A-KE1-S/E2 Instruction Manual

Instruction Manual

AS-Interface Safety at Work
VAA-2E2A-KE1-S/E2

Version 1.0

FACTORY AUTOMATION

With regard to the supply of products, the current issue of the following document is applicable: The General

published by the Ce ntral Association of the "Elektrotechnik und Elektroindustrie (ZVEI) e.V.

in their most recent version as well as the supplementary clause: "Extended reservation of title".

For this reason, this printed matter is produced on paper bleached without the use of chlorine.

Terms of Delivery for Products and Services of the Electrical Industry,

We at Pepperl+Fuchs recognise a duty to make a contribution to the future,

VAA-2E2A-KE1-S/E2

S

Table of contents

1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Symbols used in this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1.1 Non-secure outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1.2 Requirements for the safety monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1.3 Requirements for wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1.4 Switches or sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.3 Transfer time of the safety-relevant information . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 PFD-calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Working principles of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Safety related inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.2 Non-secure outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Connections and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Interface properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.1 AS-Interface, auxiliary energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.2.2 Safety category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.2.3 Cross fault monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.1 Requirements for configuring the safety monitor . . . . . . . . . . . . . . . . . . . . . . 13

7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.3 Addressing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.4 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 Operation of AS-Interface safety modules . . . . . . . . . . . . . . . . . . . . . . 14

9 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

A Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

A.1 Category 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

A.2 Category 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

A.3 Category 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

B Summery of the requirements for categories . . . . . . . . . . . . . . . . . . . 20

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com

1

VAA-2E2A-KE1-S/E2

S

Declaration of conformity

1 Declaration of conformity

The AS-Interface safety module VAA-2E2A-KE1-S/E2 with 2 safety-related inputs for
mechanical switches and 2 non-safety related outputs was developed and manufac­tured in observance of applicable European standards and regulations.

A corresponding declaration of conformity can be requested from the
manufacturer.

The manufacturer of the product, Pepperl+Fuchs GmbH in D-68307 Mannheim, has
a certified quality assurance program in accordance with ISO 9001.

ISO

9001

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

2

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com

S

2 Symbols used in this document

This symbol warns of danger .

In the event the warning is ignored, the consequences may range from
personal injury to death of persons or from damage to destruction of
equipment.

This symbol warns of a possible fault.

Failure to observe may result in damage to the device or systems and
installations connected to it up to and including compete lack of proper
functionality.

This symbol brings important information to your attention.

VAA-2E2A-KE1-S/E2

Symbols used in this document

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com

3

VAA-2E2A-KE1-S/E2

S

Safety

3 Safety

3.1 Intended use

The AS-Interface safety module described here, when used properly in combination
with an AS-Interface safety monitor programmed appropriately, allows for operation
of sensor-controlled devices for protection of persons up to Category 4 according to
EN 954-1 or up to SIL 3 according to EN/IEC 61508.

Protection of operating personnel and the system is not ensured if the
module is not used in accordance with its intended purpose.

3.1.1 Non-secure outputs

The outputs must not be used for safety-related functions.

3.1.2 Requirements for the safety monitor

The module must only be used in a proper manner as a safety-related slave on an
AS-Interface line with the corresponding AS-i safety monitor. The AS-Interface safety
monitor must meet the requirements of the system specification "Specification of safe
AS-Interface transfer" Version 2.01 dated May12, 2000.

All components must be evaluated for functionality according to this safety standard
for the evaluation of a safety-related function.

The correct execution of the desired safety function also depends on the wiring and
programming of the safety monitor. This also applies to the desired safety response
after a code malfuntion or failure. See also the documentation for the safety monitor.
The safety function (including all safety-related sensors) must be tested before it is
placed in service the first time.

3.1.3 Requirements for wiring

The requirements of EN/IEC 60204-1 (or similar standard) must always be observed.
The requirements for external wiring and the selection of sensors that are connected
are based on both the functionality to be provided as well as the required category
(EN 954-1/ISO 13849-1 or EN/IEC 61508). The category can be determined by
means of a risk analysis (for example as described by EN1050) or can be derived
from a C standard. The category or SIL of the safety monitor must at least correspond
to the category or SIL required by the application.

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

4

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com

VAA-2E2A-KE1-S/E2

S

3.1.4 Switches or mechanical contacts

The switches must either be of the forced-opening variety or must have a defined fail­ure behaviour. Combinations of switches that ensure comparable safety (error behav­iour analysis) can be used.

3.2 General safety instructions

Any type of operation other than what is described in the instructions
places the safety and functionality of the module and connected sys­tems in question.

The module can only be operated by trained professionals in accordance with the
available instruction manual (see section 8).

Connecting modules and performing maintenance tasks while the devices are con­nected to a power source must only be performed by trained electrical specialists.

If malfunctions cannot be eliminated, the module must be taken out of operation and
protected from being inadvertently placed back in operation.

Repairs must only be performed directly by the manufacturer.

Making changes to or tampering with the device is not permitted and will render the
warranty void.

When operating the device, care must be taken to ensure that the requirements for
installation of a housing in IP20 are also maintained.

The plant management is responsible for heeding local safety regula­tions.

Safety

3.3 Transfer time of the safety-relevant information

The transfer time depends essentially on the monitor. The corresponding documen­tation and the switch-off times of the actuators must be observed.

3.4 PFD-calculation

To calculate the PFD (probability of failure on demand) of a safety-related function, all
PFD values of all components used in this function must be taken into consideration.
The AS-Interface safety slave does not make any significant contribution to the PFD
or PDH (probability of dangerous failure per hour) of the overall system.

For the PFD or PFH-values of other components, especially of the safety monitor,
please refer to the relevant documentation.

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com

5

VAA-2E2A-KE1-S/E2

S

Working principles of the module

4 Working principles of the module

4.1 Safety related inputs

The module generates a code sequence internally. This code sequence is monitored
by a safety monitor (an additional bus station) for the correct sequence.

.

Figure 4.1: Code generation

The transfer of the code sequence is affected by the status of the externally connect­ed mechanical switch.

Information on the activation of the connected mechanical switches (e. g. for emer­gency stop button activated, code transfer interrupted) is transferred as follows:

Activated input channel Code

DI3 DI2 DI1 DI0

1XX00

200XX

1 and 2 0 0 0 0

none X X X X

Code words 0000, XX00 and 00XX cause the safety monitor to bring the system to a
secure state (for example with the emergency stop button) without reporting a mal­function. If a bit of a code word deviates from the nominal code word, the safety mon­itor switches the system into the secure state and signals a malfunction of the slave.

The two input channels of the safety module are independent of each other. Param­eters can be set in the safety monitor for monitoring the synchronicity of the two inputs
for two-channel applications. For more information, see also the application examples
in Appendix A.

Date of Issue 2003-11-28

ubject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany

6

Pepperl+Fuchs Group • Tel.: Germany [phone] • USA [phone] • Singapore [phone] • Internet http://www.pepperl-fuchs.com