Pilz PSS SB HYD, Basic license User Manual

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Programmable Safety Systems

PSS-Range

PSS Standard Function Blocks

MBS Hydraulic Presses

Version 3.2

Operating Manual

Item No. 19 203-07

The spirit of safety.

All rights to this manual are reserved by the publishers. Copies may be made for internal purposes.

While every effort has been made to ensure that the information in this manual is accurate, no responsibility can be accepted for errors or omissions contained within it.

We reserve the right to amend specifications without notice. We are grateful for any feedback on the contents of this manual.

The names of products, goods and technologies used in this manual are trademarks of the respective companies.

Introduction 1-1

MBS Modular Block System 1-2 Categories/requirement classes 1-3 Overview of manual 1-4 Definition of symbols 1-5 Terminology 1-6

Overview 2-1

Software package 2-1 Range 2-2

Safety 3-1

Safety guidelines 3-1

Use of qualified personnel 3-1 Warranty and liability 3-1 Application guidelines 3-2 Standards 3-3

Fault detection 3-4 Fault detection techniques 3-5

Feasibility test 3-5 Pulsed input signals 3-6 Self test on the outputs 3-6 Fault prevention 3-6

Intended Use 4-1

System software 4-1 Intended use of the standard function blocks 4-2

SB051: Operating mode selector switch 1 from 8 4-2 SB052: Operating mode selector switch 2 from 6 4-3 SB059: Two-hand monitoring 4-4

Modular Block System: Hydraulic Presses 1

Contents

SB061: Emergency stop monitoring 4-4 SB063: Emergency stop monitoring 4-5 SB064: Safety gate monitoring 4-6 SB065: Feedback loop monitoring 4-7 SB066: Safety gate monitoring 4-8 SB067: Feedback loop monitoring 4-8 SB068: Monitoring ESPE/AOPDs with guarding and control function 4-9 SB069: Monitoring ESPE/AOPDs with guarding function 4-10 SB070: Initialisation of administration data block (DB015) 4-11 SB071: Initialisation of administration data blocks (DB015/DB016/DB017) 4-11 SB072: Temporary suspension of safety functions 4-12 SB075: Controlling and monitoring safety gates with guard locking 4-12 SB086: Overrun control on linear-driven presses 4-13 SB087: Driving/monitoring the position of a single hydraulic valve 4-14 SB088: Driving/monitoring the position of a dual hydraulic valve 4-14 SB089: Driving/monitoring the position of two hydraulic valves 4-16 SB092: Enable switch 4-17 SB097: Monitoring muting lamps 4-18

MBS Basics 5-1

Block design 5-1

Structure 5-1 Formal parameters and actual parameters 5-2

Administration data blocks DB015, DB016 and DB017 5-3

Structure of the administration data blocks 5-3 Blocks contained in the administration data blocks 5-5

Input parameter SSNR 5-7 Fault diagnostics 5-9

Error types 5-9 Fault diagnostics using the administration data blocks 5-10

Temporary flag range in MBS blocks 5-11 Output parameter FG/ENBL 5-11 Assignment of input and output parameters 5-12 Minimum scan time 5-12 Global parameters 5-13

Modular Block System: Hydraulic Presses

Standard Function Blocks 6-1

Guidelines for selecting standard function blocks 6-1 Emergency stop monitoring 6-1

SB061 NA_1 6-1 SB063 E-STOP 6-1

Safety gate monitoring 6-2

SB066 ST-K4 6-2 SB064 S-GATE 6-3

Feedback loop monitoring 6-3

SB067 RFK_K4 6-3 SB065 FBL 6-4

Initialisation of administration data blocks 6-4

SB070 INIT_MBS 6-4 SB071 INIT_MBS 6-5

SB051: Operating mode selector switch 1 from 8 6-6

Block header 6-6 Input parameters 6-6 Output parameters 6-7 Error messages 6-8 Global parameters used in administration data block DB015 6-9 Blocks required 6-10

SB052: Operating mode selector switch 2 from 6 6-10

Block header 6-10 Input parameters 6-10 Output parameters 6-12 Error messages 6-13 Global parameters used in administration data block DB015 6-14 Blocks required 6-14

Modular Block System: Hydraulic Presses 3

Contents

SB059: Two-hand monitoring 6-16

Block header 6-16 Input parameters 6-16 Output parameters 6-20 Error messages 6-20 Global parameters used in administration data block DB015 6-22 Blocks required 6-22

SB061: Emergency stop monitoring Category 4 6-24

Block header 6-24 Input parameters 6-24 Output parameters 6-25 Error messages 6-25 Global parameters used in administration data block DB015 6-27 Blocks required 6-27

SB063: Emergency stop monitoring Category 4 6-28

Block header 6-28 Input parameters 6-28 Output parameters 6-29 Function test 6-29 Error messages 6-30 Global parameters used in the administration data blocks 6-31 Blocks required 6-31

SB064: Safety gate monitoring 6-32

Block header 6-32 Input parameters 6-32 Output parameters 6-34 Functions 6-35 Error messages 6-38 Global parameters used in the administration data blocks 6-39 Blocks required 6-39

SB065: Feedback loop monitoring 6-40

Block header 6-40 Input parameters 6-40 Output parameters 6-41 Functions 6-42 Error messages 6-43 Global parameters used in the administration data blocks 6-45 Blocks required 6-45

Modular Block System: Hydraulic Presses

SB066: Safety gate monitoring 6-46

Block header 6-46 Input parameters 6-46

Input circuitry 6-47 Output parameters 6-48 Functions 6-48 Error messages 6-52 Global parameters used in administration data block DB015 6-53 Blocks required 6-53

SB067: Feedback loop monitoring on contactors 6-54

Block header 6-54 Input parameters 6-54 Output parameters 6-54 Error messages 6-55 Global parameters used in administration data block DB015 6-56 Blocks required 6-56

SB068: Monitoring ESPE/AOPDs with guarding and control function 6-58

Block header 6-58 Input parameters 6-58

Wiring the input parameters 6-62 Output parameters 6-62 Function 6-63 Cycle modes 6-65 Error messages 6-65 Global parameters used in administration data block DB015 6-67 Blocks required 6-67 Diagrams for ESPE/AOPD 6-68

Timing diagram for “guard only” mode of ESPE/AOPD 6-68

Timing diagram for “double break” mode of ESPE/AOPD 6-70

SB069: Monitoring ESPE/AOPDs with guarding and control function 6-72

Block header 6-72 Input parameters 6-72

Wiring the input parameters 6-74 Output parameters 6-74 Function 6-75 Error messages 6-76

Modular Block System: Hydraulic Presses 5

Contents

Global parameters used in administration data block DB015 6-77 Blocks required 6-77 Timing diagram 6-78

SB070: Initialisation of administration data block DB015 6-80

Block header 6-80 Input parameters 6-80 Function 6-80 Error messages 6-82 Blocks required 6-82

SB071: Initialisation of administration data blocks 6-84

Block header 6-84 Input parameters 6-84 Function 6-84 Error messages 6-86 Blocks required 6-86

SB072: Temporary suspension of safety functions (ESPE/AOPD muting) 6-88

Block header 6-88 Input parameters 6-88

Wiring the input parameters 6-91 Output parameters 6-91

Wiring the output parameters 6-92 Operating modes 6-92

Terminology 6-92

Sequential muting mode (muting when entering the danger area) 6-93

Parallel muting mode (muting when leaving the danger area) 6-95

Parallel muting mode (muting when entering and leaving the

danger area) 6-97 Safety guidelines 6-99 Error messages 6-100 Global parameters used in administration data block DB015 6-102 Blocks required 6-102 Cycle diagrams 6-103

Parallel muting cycle 6-103

Sequential muting cycle 6-104

SB075: Controlling and monitoring safety gates with guard locking 6-106

Block header 6-106 Input parameters 6-106 Input circuitry 6-110

Modular Block System: Hydraulic Presses

Output parameters 6-110 Operating modes 6-112 Procedures 6-115 Additional safety guidelines 6-116 Error messages 6-117 Global parameters used in administration data block DB015 6-119 Blocks required 6-119

SB086: Overrun control on linear-driven presses 6-120

Block header 6-120 Input parameters 6-120 Output parameters 6-122 Procedures 6-122 Timing diagram 6-125 Error messages 6-125 Global parameters used in administration data block DB015 6-126 Blocks required 6-126

SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve) 6-128

Block header 6-128 Input parameters 6-128 Output parameters 6-129 Function 6-130 Safety guidelines for input parameters TOn and TOff 6-132 Settings for the parameters TOn and TOff 6-133 Error messages 6-134 Global parameters used in administration data block DB015 6-135 Blocks required 6-135

SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve) 6-136

Block header 6-136 Input parameters 6-136 Output parameters 6-138 Function 6-139 Safety guidelines for input parameters TOn and TOff 6-141 Settings for the parameters TOn and TOff 6-143 Error messages 6-144 Global parameters used in administration data block DB015 6-146 Blocks required 6-146

Modular Block System: Hydraulic Presses 7

Contents

SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet and directional control valves) 6-148

Block header 6-148 Input parameters 6-148 Output parameters 6-150 Function 6-151 Safety guidelines for input parameters TOn and TOff 6-153 Settings for the parameters TOn and TOff 6-154 Error messages 6-155 Global parameters used in administration data block DB015 6-157 Blocks required 6-157

SB092: Enable switch 6-158

Block header 6-158 Input parameters 6-158 Output parameters 6-159 Function 6-160 Switching diagrams 6-161 Error messages 6-163 Global parameters used in administration data block DB015 6-163 Blocks required 6-163

SB097: Monitoring muting lamps 6-164

Block header 6-164 Input parameters 6-164 Output parameters 6-165 Wiring the output parameters 6-166 Wiring diagram 6-166 Function 6-166 Guidelines for the design and layout of muting lamps 6-167 Error messages 6-168 Global parameters used in administration data block DB015 6-169 Blocks required 6-169 Timing diagrams 6-170

Link Blocks 7-1

Check list 7-1

Modular Block System: Hydraulic Presses

Examples 8-1

Application and parameters of individual blocks 8-2

Emergency stop monitoring

with manual start (start-up and operation), category 4 8-2 Emergency stop monitoring

with automatic start-up, manual start (operation)

and function test, category 4 8-4 Feedback loop monitoring

Shutdown with two contactors connected in series,

category 4 8-6 Feedback loop monitoring

Shutdown with two main contactors connected in series and

pulsed outputs, category 4 8-8 Feedback loop monitoring (selective shutdown),

category 4 8-10 Emergency stop monitoring with monitoring of feedback loop,

category 4 8-14 Safety gate monitoring

with manual start and manual restart, category 2 8-16 Safety gate monitoring

with automatic start and manual restart, category 2 8-20 Safety gate monitoring

with manual start and manual restart, category 4 8-24 Safety gate monitoring

with automatic start and manual restart,

category 4 8-28 Safety gate monitoring

with manual start and manual restart, category 4 8-32 Safety sensors PSEN 2.1p-10 and PSEN 2.1p-11

with block SB066 (ST_K4) 8-36 ESPE/AOPD in guard mode with automatic function test

(SB068) 8-40 ESPE/AOPD in single break mode with cycle reset via a pulse at

top dead centre (TDC) 8-42 ESPE/AOPD in guard mode with automatic function test

(SB069) 8-44 Monitoring muting lamps 8-46 Safety gate monitoring with guard locking, automatic start and

manual restart, category 4 8-48

Modular Block System: Hydraulic Presses 9

Contents

Appendix 9-1

Assignment table

Category and requirement class 9-1 Standard function blocks: current versions 9-2 Changes to the standard function blocks 9-3 Changes to the operating manual 9-15 Allocation of safety subroutine numbers enable flags 9-17

Modular Block System: Hydraulic Presses

Modular Block System: Hydraulic Presses 11

Introduction

This manual describes how to manage the standard function blocks in the “MBS Hydraulic Presses” software package in accordance with their intended use. Standard function blocks in the “MBS Hydraulic Presses” package are part of the Pilz MBS Modular Block System. They can be used in the failsafe section of a PSS-range programmable safety system.

To fully understand this manual you will need to be conversant with the information found in the general documentation for the PSS-range (System Manual, Installation Manual for the modular/compact PSS, PSS SW PG Programming Manual/PSS WIN-PRO Programming Manual). In particular you should refer to the following documents from the System Manual:

• Safety Manual

• FS System Description

• Error List

To fully understand the bus-specific requirements and correlations for SafetyBUS p applications you will need some knowledge of the design and management of SafetyBUS p.

Knowledge of the safety regulations for the particular area of application is assumed.

This installation manual is intended for instruction and should be retained for future reference.

1-1Modular Block System: Hydraulic Presses

Introduction

MBS Modular Block System

Safety-related areas can be equipped with a multitude of safety devices such as E-STOPs, safety gates, light barriers etc. Safety devices are required in various quantities and combinations, depending on the object requiring protection. The Pilz MBS Modular Block System was developed to drive the various safety devices and to carry out process engineering functions, helping users to save time and money.

The MBS consists of individual standard function blocks (SBs), which are geared specifically towards the relevant safety device or process engineering function. It allows standard function blocks to be used in any combination. The standard function blocks can be combined in any sequence (max. 600).

Standard function blocks are encoded by an authorised body so that they cannot be modified. If an encoded standard function block is used within an application program, program testing may be restricted to the new parts of the program, considerably reducing the test time.

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Categories / requirement classes

EN 954-1 divides safety devices into categories. All standard function blocks are designed for the highest category permitted for the safety device to be monitored. If safety devices with lower categories are to be monitored, input parameters may be assigned identical inputs (further information can be found in the description for the relevant standard function block).

In process engineering, safety requirements must conform to DIN V 19250 (Basic Safety Requirements for Measurement and Control Protection Devices). Requirement classes in accordance with DIN V 19250 may be referred to the categories as per EN 954-1. The Appendix contains a table showing the assignment of category ↔ requirement class.

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Introduction

Overview of manual

1 Introduction

The chapter you are reading provides an introduction to the Modular Block System (MBS). It is designed to familiarise you with the contents, structure and specific order of this manual and also contains terminology definitions.

2 Overview

This chapter provides information on the most important features of the software package and provides a brief overview of the application range.

3 Safety

This chapter must be read as it contains important information on safety regulations.

4 Intended Use

This chapter must be read as it contains information on intended use.

5 MBS Basics

This chapter explains the basic functions and safety requirements of the MBS.

6 Standard Function Blocks

This chapter explains the function of the standard function blocks in the software package.

7 Link Blocks

This chapter is designed to help you link the standard function blocks into your project and to commission the safety functions.

8 Examples

This chapter is designed to give an overview of how the standard function blocks may be applied and contains typical application examples.

9 Appendix

The Appendix contains a table that explains the relationship between categories and requirement classes, plus a list that documents the current version status of the standard function blocks.

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Modular Block System: Hydraulic Presses

Definition of symbols

Information in this manual that is of particular importance can be identified as follows:

DANGER!

This warning must be heeded! It warns of a hazardous situation that poses an immediate threat of serious injury and death and indicates

preventive measures that can be taken.

WARNING!

This warning must be heeded! It warns of a hazardous situation that could lead to serious injury and death and indicates preventive

measures that can be taken.

CAUTION!

This refers to a hazard that can lead to a less serious or minor injury plus material damage, and also provides information on preventive measures that can be taken.

NOTICE

This describes a situation in which the product or devices in its immediate environment could be damaged. It also provides information on preventive measures that can be taken.

INFORMATION

This gives advice on applications and provides information on special features, as well as highlighting areas within the text that are of particular importance.

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Introduction

Terminology

• The term “input” is frequently abbreviated to “I” (e.g. I-Parameter).

• The term “output” is frequently abbreviated to “O” (e.g. O-Parameter).

• The term “PSS” is always used when the description is valid for all

applicable PSS programmable safety systems. If the description only relates to a specific PSS series, the specific name for that series will be used (e.g. PSS 3000 or PSS SB 3056).

• In this manual, the system software “PSS SW PG” and “PSS WIN-PRO”

is referred to as “programming device” or “PG”.

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Modular Block System: Hydraulic Presses

Overview

Software package

The “MBS Hydraulic Presses” software package is part of the Pilz MBS Modular Block System. The software package contains all the standard function blocks necessary for electronically-monitored safety devices on distributed automation plants. This includes:

• Monitoring the position of operating mode selector switches for safe

mode selection (automatic, manual, cycle mode etc.)

• Monitoring two-hand circuits for simultaneity

• Evaluation of E-STOP buttons, grab wires etc.

• Monitoring safety, maintenance and supply gates

• Monitoring of power contactors through control of the feedback loop

• Controlling and monitoring electrosensitive protective equipment

• Safe, temporary suspension of safety functions (muting mode)

• Driving and monitoring a press safety valve

• Monitoring enable switches

Standard function blocks in the “MBS Hydraulic Presses” software package are used in the failsafe section of a PSS-range programmable safety system.

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Overview

Range

The software package consists of:

• The files for the software package on CD and

• An operating manual:

PSS Standard Function Blocks MBS Hydraulic Presses, Version 3.2

The software package on the CD contains the following standard function blocks:

• SB051 BA_1AUS8

Operating mode selector switch 1 from 8 (approved safety block)

• SB052 BA_2AUS6

Operating mode selector switch 2 from 6 (approved safety block)

• SB059 2_HAND

Two-hand monitoring (approved safety block)

• SB061 NA_1

Monitoring E-STOP button up to category 4 in accordance with EN 954-1, 03/97 and AK 6 in accordance with DIN V 19 250, 05/94 (approved safety block)

• SB063 E-STOP

Monitoring E-STOP button up to category 4 in accordance with EN 954-1, 03/97 and AK 6 in accordance with DIN V 19 250, 05/94 (approved safety block)

• SB064 S-GATE

Safety gate monitoring (approved safety block)

• SB065 FBL

Feedback loop monitoring (approved safety block)

2-2

• SB066 ST-K4

Safety gate monitoring (approved safety block)

Modular Block System: Hydraulic Presses

• SB067 RFK_K4

Feedback loop monitoring (approved safety block)

• SB068 BWS_AOS

Monitoring ESPE/AOPD with guarding and control function (approved safety block)

• SB069 AOPD_GDO

Monitoring ESPE/AOPD with guarding function (approved safety block)

• SB070 INIT_MBS

Initialisation of the administration data block (DB015) (approved safety block)

• SB071 INIT_MBS

Initialisation of the administration data blocks (DB015/DB016/ DB017) (approved safety block)

• SB072 MUTING

Temporary suspension of safety functions (approved safety block)

• SB075 GRD_LCK

Control and monitoring of safety gates with guard locking (approved safety block)

• SB086 OVERRUN

Overrun control on linear-driven presses (approved safety block)

• SB087 H_VALV_S

Control and position monitoring of single hydraulic valves (poppet valve and directional control valve) (approved safety block)

• SB088 H_VALV_D

Control and position monitoring of dual hydraulic valves (poppet valve and directional control valve) (approved safety block)

• SB089 H_VALV_P

Sequential control and position monitoring of two hydraulic valves (poppet valve and directional control valve) (approved safety block)

2-3Modular Block System: Hydraulic Presses

Overview

• SB092 ENBL_DEV

Enable switch (approved safety block)

• SB097 MUT_LAMP

Monitoring muting lamps (approved safety block)

• SB255 System block

SB255 is described in the PSS System Description

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Modular Block System: Hydraulic Presses

Safety

Safety guidelines

These safety guidelines are an important part of this manual. Failure to keep to these guidelines will render all warranty, guarantee and liability claims invalid.

• All health and safety / accident prevention regulations for the particular

area of application must be observed.

• Before using one or more of the standard function blocks in this software

package, you must perform a safety assessment in accordance with the Machinery Directive.

Use of qualified personnel

The package may only be assembled, installed, commissioned, operated, maintained and decommissioned by qualified personnel who, because they are

• Qualified electrical engineers and/or

• Have received training from qualified electrical engineers are suitably experienced to operate devices, systems, plant and machinery

in accordance with the general standards and guidelines for safety technology.

Warranty and liability

All claims to warranty and liability will be rendered invalid if:

• Standard function blocks are used contrary to the purpose for which they

were intended

• Damage can be attributed to not having followed the guidelines in the

manual

• Operating personnel are not suitably qualified.

3-1Modular Block System: Hydraulic Presses

Safety

Application guidelines

• The instructions given in the “Safety Manual” and in the “Installation

Manual” must be followed.

• Please read the information in Chapter 4 regarding the intended use of

these blocks.

• The use of Pilz SBs does not detract from the fact that it is the

responsibility of the user to design appropriate safety systems for plant, machinery and software.

• It is the users' responsibility to determine their application requirements

by carrying out a detailed risk analysis, which should take into account relevant regulations and standards, etc.

WARNING!

Please note: To achieve the corresponding category or requirement class, the whole system including all safety-related components (parts, devices, user program etc.) must be included in the assessment. For this reason, Pilz cannot accept liability for the correct classification into a category or requirement class.

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Modular Block System: Hydraulic Presses

Standards

To use the SBs correctly you will need to have a good knowledge of the relevant standards and directives. The following gives an overview of the most important standards:

• E-STOP circuits EN 418

• Safety of machinery -

Two-hand controls EN 574

• Mechanical presses EN 692

• Hydraulic presses EN 693

• Hydraulic stamping and bending presses EN 12 622

• Machinery directive- basic terminology EN 292-1 and EN 292-2

• Printing and paper machinery prEN 1010

• Safety gates EN 1088

• Electrosensitive protective equipment EN 61 496-1

• Electrical equipment EN 60 204-1

• Machinery safety EN 954-1

• Basic Safety Requirements for Mea-

surement and Control Protection Devices DIN V 19 250

• Electrical equipment on firing plants prEN 50 156-1

Please note this is not an exhaustive list of safety standards and directives.

3-3Modular Block System: Hydraulic Presses

Safety

Fault detection

The detection of errors and defects is an important function of the PSS, in addition to pure control tasks.

Potential faults are subdivided into:

• Errors in the system hardware and wiring errors in the periphery units:

• Feasibility errors and functional errors in the process periphery units

- Errors in the system hardware are automatically detected and managed by the PSS

- If test signals are used, wiring errors in the periphery units will automatically be detected and managed by the PSS.

Users do not need to take this type of error into account within the application program (additional information can be found in the PSS “System Description”).

(input devices, actuators, wiring etc.). These errors must be detected and managed through the PSS control

program.

WARNING!

It is particularly important to detect open circuits and shorts within the safety circuits (e.g. two-hand, E-STOP etc.)

It is the responsibility of the user to select and apply an appropriate fault detection system.

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Modular Block System: Hydraulic Presses

Fault detection techniques

Various options are available to the user to help detect and rectify errors in the process periphery units:

• Errors can be detected via the feasibility checks in the application program, e.g. by using redundant input devices.

• Errors can be detected by pulsing the signal lines using the test pulses from the PSS DI2O T module.

• Errors can be detected by using the automatic tests in the output modules.

• Avoid potential errors by using appropriate wiring.

Additional information on how to exclude potential errors can be found in the directive VDI 2854 (safety requirements on automated manufacturing systems).

Feasibility test

Redundant input devices for safety functions must undergo a feasibility test within the application program.

Example: A two-hand button has a N/C and a N/O contact. Once the application program has detected the open N/C contact, it must check that the N/O contact closes within an appropriate period of time. The function test must be carried out for all possible combinations of the two contacts.

The plant must be stopped immediately if a feasibility error occurs. Similar tests will also be required for other input devices. If safety valves have feedback contacts, these must be evaluated accordingly.

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Safety

Pulsed input signals

Input devices for inputs with infrequent operation (e.g. E-STOP, off buttons, etc.) must be pulsed using test signals. The connection of test pulses to input devices is described in the “Installation Manual”. Test pulses should also be used for input devices which have an important safety function and frequent operation (e.g. two-hand, camshaft etc.).

Self test on the outputs

PSS output modules regularly carry out function tests. Using these tests, dual-pole switching output modules on the PSS are automatically able to detect and deal with open circuits, short circuits and external power sources in the periphery wiring. Single-pole switching output modules can detect short circuits but not open circuits.

Fault prevention

Not all potential faults can be detected and managed. Such faults must be excluded by suitable wiring.

Example: If the feed to the input device and the feedback from the input device to the input use the same multicore cable, a short circuit between the two wires could short out the input device. Such a fault would go undetected.

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Modular Block System: Hydraulic Presses

Intended Use

The software package “MBS Hydraulic Presses” is designed for use within the failsafe section of the PSS-range of programmable safety systems.

INFORMATION

Use of standard function blocks outside the specifications described here will be deemed improper use.

INFORMATION Always use the current version of the relevant standard function block.

Please ensure you refer to the Appendix, sections entitled “Standard function blocks: current versions” and “Changes to the standard function blocks”.

System software

The software package “MBS Hydraulic Presses” can be used with the following system software:

• PSS SW PG

• PSS WIN-PRO

INFORMATION

Depending on the programming language selected on PSS WIN-PRO, designations for formal parameters and operands may differ from those found on PSS SW PG. Any designations that are different will automatically be replaced by PSS WIN-PRO.

Further information is available in the programming manual for “PSS SWPG” or “PSS WIN-PRO”.

4-1Modular Block System: Hydraulic Presses

Intended Use

Intended use of the standard function blocks

SB051: Operating mode selector switch 1 from 8

SB051 is a standard function block designed to monitor the position of lockable standard operating mode selector switches.

Safe coding is achieved by means of the selection process “1 from 8”.

Features:

• Maximum of 8 operating modes are possible

• Break-free switchover within the adjustable contact switchover time

Input circuitry:

• 1 input is required per operating mode

INFORMATION

If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses.

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Modular Block System: Hydraulic Presses

SB052: Operating mode selector switch 2 from 6

SB052 is a standard function block designed to monitor the position of lockable standard operating mode selector switches.

Safe coding is achieved by means of the selection process “2 from 6”. Coding reduces the number of inputs required.

Operating modes:

• Maximum 15 switch positions possible when 6 inputs are used

• Break-free switchover within the adjustable contact switchover time

Input circuitry:

• Output signals (contacts) from the mechanical operating mode selector switch

INFORMATION

If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses.

4-3Modular Block System: Hydraulic Presses

Intended Use

SB059: Two-hand monitoring

The function of standard function block SB059 is determined in accordance with EN 574, 02/97. It fulfils all the requirements of category 4, in accordance with EN 954-1, 03/97.

Operating modes:

• Monitoring two buttons (N/C and N/O) in accordance with EN 954-1, 03/97

• Monitoring the synchronisation time of two buttons (<0.5 s)

• Can also be used to monitor foot switches

INFORMATION

Input circuitry:

• Two-hand buttons must use test pulses.

SB061: Emergency stop monitoring

SB061 is a standard function block for monitoring E-STOP buttons up to category 4, in accordance with EN 954-1, 03/97 and AK 6, in accordance with DIN V 19 250, 05/94. It is also possible to use SB061 to monitor safety gates up to category 4, in accordance with EN 954-1, 03/97.

Operating modes:

• With or without start-up reset on cold-start

• With or without automatic reset when E-STOP is released

INFORMATION

Input circuitry:

• Use E-STOP button with test pulses

• When using SB061 for category 4 applications:

- use dual-channel elements

• When using SB061 for category 2 applications:

- use single-channel elements

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Modular Block System: Hydraulic Presses

SB063: Emergency stop monitoring

SB063 is a standard function block for monitoring E-STOP buttons up to category 4, in accordance with EN 954-1, 03/97 and AK 6, in accordance with DIN V 19 250, 05/94. It is also possible to use SB063 to monitor safety gates up to category 4, in accordance with EN 954-1, 03/97.

INFORMATION

On SB063, the SSNR may lie in the range of 1 to 600.

Operating modes:

• With or without start-up reset on cold start or on a SafetyBUS p group start

• With or without automatic reset when E-STOP is released

• With or without prompt for function test after a synchronisation error when the E-STOP is released

INFORMATION

Input circuitry:

• Use E-STOP button with test pulses

• When using SB063 for category 4 applications:

- use dual-channel elements

• When using SB063 for category 2 applications:

- use single-channel elements

SB064: Safety gate monitoring

SB064 is designed for monitoring a safety gate. It can monitor a safety gate with one or two switches. SB064 meets all the requirements up to category 4, in accordance with EN 954-1, 03/97. The block is designed in such a way that it can be used generally to monitor the synchronisation of two signals and contact welding.

INFORMATION

On SB064, the SSNR may lie in the range of 1 to 600.

4-5Modular Block System: Hydraulic Presses

Intended Use

Operating modes:

• Automatic start when PSS starts up or when starting I/O-Groups (SafetyBUS p)/start-up reset when PSS is cold-started or when starting I/O-Groups (SafetyBUS p) (start-up disabler)

• No function test/function test on the gate during start-up (function test = opening and closing the gate)

• Automatic restart/reset to start (reset lock)

• Restart without function test/start only after function test on the gate (reset lock) (function test = opening and closing the gate)

• Synchronisation time is selectable

INFORMATION

Input circuitry:

• Inputs should have pulsed outputs

SB065: Feedback loop monitoring

SB065 is a standard function block for the direct control and monitoring of 1 or 2 contactors up to category 4, in accordance with EN 954-1, 03/97.

INFORMATION

On SB065, the SSNR may lie in the range of 1 to 600.

Features and application areas:

• Feedback loop is monitored during the change in the switch signal and while the contactors are in a static condition.

• Feedback loop can be monitored on two separate feedback loops of contactors connected in series

• Feedback loop can be monitored on two separate feedback loops of contactors connected in parallel

• Feedback loop can be monitored on group contactors

• Selectable time for feedback loop monitoring

• Parameter to suppress error messages when an I/O-Group stops (SafetyBUS p)

4-6

Modular Block System: Hydraulic Presses

INFORMATION

Input circuitry:

• To achieve category 4, two independent shutdown routes must be provided within the current path of the potentially dangerous drive

• If wiring is to be laid outside the control cabinet, feedback loops must use test pulses.

• Feedback loops must use test pulses if the possibility of a short-circuit cannot be excluded.

• If only one contactor is used to switch a potentially dangerous drive, it must be possible to switch this off via a group contactor within the current path (selective shutdown).

• The group contactor must also be monitored through a feedback loop.

SB066: Safety gate monitoring

SB066 is designed for monitoring a safety gate. It can monitor a safety gate with one or two switches. SB066 meets all the requirements of category 4, in accordance with EN 954-1, 03/97.

Operating modes:

• Automatic restart

• Automatic start when PSS starts up Start-up reset when PSS is cold-started

• No function test on the gate (function test = opening and closing the gate)

INFORMATION

Input circuitry:

• Inputs should have pulsed outputs

4-7Modular Block System: Hydraulic Presses

Intended Use

SB067: Feedback loop monitoring

SB067 is a standard function block for the direct control and monitoring of contactors up to category 4, in accordance with EN 954-1, 03/97.

Features and application areas:

• Feedback loop is monitored during the change in the enable flag and while the contactor is in a static condition

• Feedback loop can be monitored on two separate feedback loops of main contactors connected in series

• Feedback loop can be monitored on group contactors

INFORMATION

Input circuitry:

• To achieve category 4, two independent shutdown routes must be provided within the current path of the potentially dangerous drive

• If wiring is to be laid outside the control cabinet, feedback loops must use test pulses.

• Feedback loops must use test pulses if the possibility of a short-circuit cannot be excluded.

• If only one contactor is used to switch a potentially dangerous drive, it must be possible to switch this off via a group contactor within the current path (selective shutdown).

• The group contactor must also be monitored through a feedback loop.

4-8

Modular Block System: Hydraulic Presses

SB068: Monitoring ESPE/AOPDs with guarding and control function

SB068 is a standard function block which is designed to monitor ESPE/ AOPDs up to category 4, in accordance with EN 954-1, 03/97, with guarding and control function.

Features:

• Monitors the ESPE/AOPD outputs: feasibility check on the contact switchover time of the two N/O contacts

• Start-up disabler

• Reset lock

• Test mode

• Cycle mode (control): enabled via single or double break of the ESPE/ AOPD.

• Cycle time monitoring

Operating modes

• AUS (OFF): Guard function of ESPE/AOPD is deactivated

• Safety (GdO): ESPE/AOPD as guarding device with reset lock

• 1-Break (SBrK): Enabled via single break of ESPE/AOPD

• 2-Break (DBrK): Enabled via double break of ESPE/AOPD

INFORMATION

This block performs safety functions. When using this block you must comply with the relevant standards and regulations, in particular:

• EN 61 496-1, 06/98

• Regulations laid down by the manufacturer of your ESPE/AOPD

INFORMATION

Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4.

4-9Modular Block System: Hydraulic Presses

Intended Use

SB069: Monitoring ESPE/AOPDs with guarding function

SB069 is a standard function block which is designed to monitor ESPE/ AOPDs up to category 4, in accordance with EN 954-1, 03/97, with guarding function.

INFORMATION

On SB069, the SSNR may lie in the range of 1 to 600.

Features:

• Monitors the ESPE/AOPD outputs: feasibility check on the contact switchover time of the two N/O contacts

• Start-up disabler

• Reset lock

• Test mode

• Parameter to suppress error messages when an I/O-Group stops (SafetyBUS p)

Operating modes

• Guard function of ESPE/AOPD is deactivated (ESPE/AOPD switched off)

• ESPE/AOPD as guarding device with reset lock

INFORMATION

This block performs safety functions. When using this block you must comply with the relevant standards and regulations, in particular:

• EN 61 496-1, 06/98

• Regulations laid down by the manufacturer of your ESPE/AOPD

INFORMATION

Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4.

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Modular Block System: Hydraulic Presses

SB070: Initialisation of administration data block (DB015)

SB070 is used to calculate the global parameters, depending on the set minimum scan time (see also under “Minimum Scan Time” in Chapter 5). The global parameters in administration data block DB015/DW1001 ... DW 1023 are initialised using SB070.

Function:

• Reads in the set minimum scan time from DB002 (configurator)

• Calculates the cycles based on the times transferred in the parameters

• Enters the calculated values into the administration DB.

SB071: Initialisation of administration data blocks (DB015/DB016/DB017)

SB071 is used to calculate the global parameters, depending on the set minimum scan time (see also under “Minimum Scan Time” in Chapter 5). Global parameters DW1001 ... DW1023 in administration data blocks DB015, DB016 and DB017 are initialised using SB071.

Function:

• Reads in the set minimum scan time from DB002 (configurator)

• Calculates the cycles based on the times transferred in the parameters

• Enters the calculated values into the administration data blocks

NOTICE

It is absolutely essential that SB071 is called in OB120 when using the following standard function blocks:

• SB063 E-STOP

• SB064 S-GATE

• SB065 FBL

4-11Modular Block System: Hydraulic Presses

Intended Use

SB072: Temporary suspension of safety functions

SB072 is a standard function block designed to temporarily suspend the safety functions (ESPE/AOPD) without interrupting the process (muting). SB072 was approved in accordance with the requirements of EN 61 496-1 Appendix A7.1, 06/98 (requirement of the function) and A7.2, 06/98 (requirement in case of failure). For a limited period of time, and for a specific operational phase (e.g. for feeding materials), it will suspend the effect of safety devices during the working process. Once completed, it will reset the safety function.

Function:

• Muting via light barriers or limit switches

• Sequential and parallel muting mode

• Muting time is adjustable

• Muting timer can be interrupted

• Time monitoring of the muting limit switch

• Monitoring of ESPE/AOPD with two N/O contacts

INFORMATION

Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4.

SB075: Controlling and monitoring safety gates with guard locking

SB075 is designed for controlling and monitoring a safety gate with guard locking. SB075 meets the requirements of category 4, in accordance with EN 954-1, 03/97. It can monitor a safety gate with one or two switches and control and monitor a guard locking device. The safety gate is monitored in almost exactly the same way as on blocks SB064 and SB066.

INFORMATION

On SB075, the SSNR may lie in the range of 1 to 600.

4-12

Modular Block System: Hydraulic Presses

Features:

• Synchronisation time of the gate switches is monitored

• The guard locking device is controlled

• Feasibility of the guard locking device is monitored

• Status display for safety gate and guard locking

Operating modes:

• Automatic start when PSS starts up or when starting I/O-Groups (SafetyBUS p)/start-up reset when PSS is cold-started or when starting I/ O-Groups (SafetyBUS p) (start-up disabler)

• No function test/function test on the gate during start-up and each time the gate is unlocked (function test = opening and closing the gate)

• Automatic restart/reset to start (reset lock)

SB086: Overrun control on linear-driven presses

SB086 is designed to perform overrun control on linear-driven hydraulic presses in accordance with VBG 7n5.2 §11.

Function

• Check performed via the overrun cam TLS (Test Limit Switch)

• Overrun measurement can only be started from the extreme top position (ETP) of the press.

• Ability to set the overrun measuring period

• Overrun errors and hardware errors can only be reset when the press is in the extreme top position

• Reset via 0/1 pulse edge at RSET input

• Can be used for overrun measurement on AKAS systems (Fiessler)

4-13Modular Block System: Hydraulic Presses

Intended Use

SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve)

SB087 is a standard function block which is designed to control and monitor the position of a single hydraulic valve. The position of the valve is acknowledged via an input.

Features:

• Input for selecting the valve type (poppet valve/directional control valve)

• Valves switched on in start position only

• Operation with or without reaction time monitoring

• An error message is issued if the valve is in the wrong position

• Valve is immediately switched off if an error occurs

• Reset latch when an error is detected

WARNING!

The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB087 description (see Chapter 6) must be adhered to at all times.

SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve)

SB088 is a standard function block which is designed to control and monitor the position of a dual hydraulic valve. The position of each valve is acknowledged via a separate input. Valves can be switched off individually for external overrun measurement.

Features:

• Input for selecting the valve type (poppet valve/directional control valve)

• Two valves controlled and monitored simultaneously

4-14

Modular Block System: Hydraulic Presses

• Valves switched on in start position only

• Operation with or without reaction time monitoring

• An error message is issued if the valve is in the wrong position

• Valve is immediately switched off if an error occurs

• Reset latch when an error is detected

INFORMATION

• If both valve signals are acknowledged via switches, the supply to these switches must be from test pulses.

• If both valve signals are acknowledged via proximity switches which cannot be pulsed, the signal lines of the proximity switches must be laid in different multicore cables within the duct. This will ensure that a short cannot occur between the two signal lines. This safety precaution will not be necessary if you use proximity switches with diverse signals.

• This block is designed for dual valves. You can assume that these will have a similar switching characteristic. This means that the switch- on and switch-off times for both valves can be monitored through a single time parameter for each function. Please note that when driving structurally separated valves, these will also show a similar switching characteristic.

WARNING!

The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB088 description (see Chapter 6) must be adhered to at all times.

4-15Modular Block System: Hydraulic Presses

Intended Use

SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet valve and directional control valves)

SB089 is a standard function block which is designed for the sequential drive and position monitoring of two hydraulic valves. The two valves may be driven individually. However, only one valve may be switched on at a time. Each valve is interlocked with respect to the other. The position of each valve is acknowledged via a separate input.

Features:

• Input for selecting the valve type (poppet valve/directional control valve)

• Controls and monitors two valves (structurally separated valves also)

• Valves switched on in start position only

• Operation with or without reaction time monitoring

• An error message is issued if the valve is in the wrong position

• Valve is immediately switched off if an error occurs

• Reset latch when an error is detected

INFORMATION

• If both valve signals are acknowledged via switches, the supply to these switches must be from test pulses.

• Both valves are monitored via a single time parameter for switch-on and switch-off. If you are using structurally separated valves, make sure that these have a similar switching characteristic.

4-16

Modular Block System: Hydraulic Presses

WARNING!

The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB089 description (see Chapter 6) must be adhered to at all times.

SB092: Enable switch

SB092 monitors three-position enable switches designed to protect personnel where operating modes have safety devices suspended.

Application and use: SB092 can be used for the following applications:

• For enable switches conforming to prEN 1921, 10/95 and VDE 2853, 07/87

• For three-position switches conforming to EN 692 section 5.3.19.4, 08/ 96, and EN 693 section 5.3.17.4, 1995, with automatic reset and slow closing speed (10 mm/s)

• For the documented switching diagrams

INFORMATION

Please bear in mind the following points (EN 1921, 10/95):

• An enable switch approves a dangerous movement but does not actually trigger it.

• A potentially hazardous situation may not be initiated by the enable switch alone.

• If an enable device is required, it must be connected to either a category 0 or category 1 stop

• If the switching device is fed back from stage 3 through stage 2 to stage 1, the enable function in stage 2 will not occur.

• It is possible to set a start-up and reset lock after feedback from stage 3.

4-17Modular Block System: Hydraulic Presses

Intended Use

SB097: Monitoring muting lamps

SB097 is a standard function block for controlling and monitoring two redundant muting lamps, up to and including category 4 in accordance with EN 954-1, 03/97.

Application and use: SB097 can be used for the following applications:

• Displaying muting status in accordance with EN 61496-1, 06/98.

• Connecting muting lamps to single-pole outputs.

• Controlling two redundant muting lamps (24 V incandescent lamps).

• Monitoring muting lamps for a break in the filament.

• Defective muting lamps can be exchanged while the plant is running.

• Removing the enable when the second filament blows.

• Can be used with just one output. Positive-switching: 1 output. Negative-switching: 2 outputs.

INFORMATION

This block undertakes muting safety functions in conjunction with the block SB072. When using this block you must comply with the relevant standards and regulations, in particular EN 61496-1, 06/98.

4-18

Modular Block System: Hydraulic Presses

MBS Basics

Block design

Structure

Safety-related areas can be equipped with a multitude of safety devices such as (e.g. E-STOPs, safety gates, light barriers). These safety devices are used in various quantities and combinations, depending on the object requiring protection.

The Modular Block System (MBS) is made up of individual standard function blocks. A standard function block is geared towards the requirements of specific safety devices (e.g. monitoring an E-STOP button, safety gate monitoring).

A standard function block must be assigned to each safety device in order for it to be evaluated and monitored using the MBS. This procedure enables any combination of individual safety devices to be evaluated and monitored. The standard function blocks can be combined in any sequence within the user program (max. 600).

One exception to this are standard function blocks used to drive and monitor contactors or valves. For control engineering reasons, these should be called up at the end of the user program.

5-1Modular Block System: Hydraulic Presses

MBS Basics

Formal parameters and actual parameters

Parameters can be set on the MBS standard function blocks. Formal parameters are established in the block header. The user must assign a corresponding actual parameter to each formal parameter. When the standard function block is called up in the user program, the formal parameters will be replaced by the user-specific actual parameters.

Formal parameter

PSS SW PG PSS WIN-PRO: Pilz IL

D Z

INFORMATION

Actual parameter

PSS SW PG PSS WIN-PRO: Pilz IL

Input bit E Output bit A Flag bit M

Input byte EB Output byte AB Flag byte MB Constant KB

Input word EW Output word AW Flag byte MW Constant KW

Data block DB Timer or counter

5-2

Further information is available in the programming manual for “PSS SWPG” or “PSS WIN-PRO”.

Modular Block System: Hydraulic Presses

Administration data blocks DB015, DB016 and DB017

Data blocks DB015, DB016 and DB017 are permanently specified within the Modular Block System (MBS).

These data blocks are common administration blocks for fault and diagnostic data from the MBS standard function blocks and for block and parameter data that is required internally.

The administration data block DB015 must always be installed when using MBS standard function blocks. Administration data blocks DB016 and DB017 are installed when necessary. The administration data blocks must always be installed with their full length of 1024 data words and they must always have read/write status.

NOTICE

Data blocks DB015, DB016 and DB017 should only be used as MBS administration data blocks and not for other data.

Structure of the administration data blocks

The administration data blocks DB015, DB016 and DB017 have the same structure.

Each standard function block in the user program has 5 data words available in one of the administration data blocks. These data words are used to back up the temporary flags from the standard function block (see section entitled “Temporary flag range in MBS blocks”).

In each of the administration data blocks, the range DW0001 to DW1000 is divided into 5 blocks, each with 200 data words (see Fig. 5-1).

5-3Modular Block System: Hydraulic Presses

MBS Basics

DB017

DB016

DB015

DW0000

Block 1

200 data words

Block 2

200 data words

Block 3

200 data words

Block 4

200 data words

Block 5

200 data words

Block 6 Global parameters

DW 0001

DW 0200

DW 0201

DW 0400

DW 0401

DW 0600

DW 0601

DW 0800

DW 0801

DW 1000

DW 1001

DW 1023

5-4

Fig. 5-1: Structure of the administration data blocks

Modular Block System: Hydraulic Presses

Blocks contained in the administration data blocks

Each standard function block occupies 1 data word per block (see Fig. 5-2). This means a max. of 200 safety devices (e.g. E-STOP 1, ESTOP 2, safety gate 1) can be managed per administration data block.

The PSS uses a standard function block’s SSNR to automatically generate the corresponding data words (see section entitled “Input parameter SSNR”).

DB017

DB016

DB015

DW0000

Block 1

Data word 1

Block 2

Data word 2

Block 3

Data word 3

Block 4

Data word 4

Block 5

Data word 5

Block 6 Global parameters

Fig. 5-2: Contents of the administration data blocks

Data words 1 to 5 of an MBS standard function block

5-5Modular Block System: Hydraulic Presses

MBS Basics

DW0000 (DB015)

1st data block (DB015/DB016/DB017): DW 0001 ... DW0200 Bits for hardware and operator errors

2nd data block ... 5th data block (DB015/DB016/DB017):

If parameters for a standard function block’s input parameter SSNR are not within the permitted range, DW0000 of DB015 will contain the incorrect SSNR parameter. The standard function block will not be enabled (output parameter FG/ ENBL= 0). If the SSNR=0, DW0000 of DB015 will contain the decimal value -1 or KH FFFF.

The significance of the individual bits can be found in the description for the relevant standard function block (see section entitled “Fault diagnostics”). If a data word contains the value 0, no error has been found

DW0201 ... DW1000

Data blocks 2 ... 5 are used for internal block data.

6th data block (DB015/DB016/DB017) DW1001 ... DW1023

Data block 6 contains the global parameters (see section entitled “Global parameters”).

5-6

Modular Block System: Hydraulic Presses

Input parameter SSNR

MBS standard function blocks have input and output parameters which can be adapted to suit the respective control configuration. The input parameter SSNR (safety subroutine number) is available on all MBS standard function blocks. It is required to manage the administration data blocks DB015, DB016 and DB017.

INFORMATION

MBS standard function blocks may differ in terms of the permitted value range for the SSNR. The following value ranges are possible for the SSNR:

• Value range of input parameter SSNR: 1 ... 200 (byte constant type: KB001 ... KB200)

• Value range of input parameter SSNR: 1 ... 600 (word constant type: KF000001 ... KF000600)

The valid value range for the SSNR of a standard function block is documented in the standard function block description.

The input parameter SSNR determines the administration data block plus the 5 data words assigned in the administration data block of the corresponding safety device (1 DW per block). The administration data blocks are assigned the following SSNR ranges:

• SSNR 001 ... 200: DB015

• SSNR 201 ... 400: DB016

• SSNR 401 ... 600: DB017

The one data word per block is generated automatically internally (SSNR + offset).

5-7Modular Block System: Hydraulic Presses

MBS Basics

NOTICE

• One MBS standard function block must be used for each safety device.

• Each standard function block should be assigned its own SSNR.

• Make sure that each SSNR is assigned once only. If two SB calls have the same value for the SSNR, they will access the same data word in the administration data block. This can lead to malfunctions.

• Document the assignment of the safety device to the respective SSNR of the standard function block.

Example

Safety device 2 (E-STOP button) is monitored using SB061. The value KB002 is assigned to input parameter SSNR of SB061.

The following DWs in DB015 are therefore assigned to safety device 2: Block 1: DW0002

Block 2: DW0202 Block 3: DW0402 Block 4: DW0602 Block 5: DW0802

The user program has read-only access to these data words.

INFORMATION

On some blocks (e.g. SB061), the input parameter SSNR is monitored. These blocks must be run through as part of each PSS cycle. The following commands should therefore be entered once only at the end of OB 101:

A DB015

I DW1015

Effect: The counter for monitoring the SSNR in DB015/DW1015 (global parameters) will be incremented.

5-8

Modular Block System: Hydraulic Presses

Fault diagnostics

Error types

On programmable safety systems from the PSS-range, a distinction is made between two types of errors. On the one hand there are errors which are detected and evaluated through the PSS operating system, and on the other there are errors which are detected and evaluated through the user program. The reaction to these two types of errors is different.

Where errors are detected through the operating system, the FS section of the PSS will switch to a STOP condition and all outputs will be switched off safely.

Where errors are detected through the user program, only the configured error reaction will occur. Errors that are detected via an MBS standard function block belong to this second type of error.

5-9Modular Block System: Hydraulic Presses

MBS Basics

Fault diagnostics using the administration data blocks

Data words DW0001 ... DW0200 of an administration data block contain the error messages from the individual MBS standard function blocks (see Fig 5-3). 1 data word is reserved for each standard function block used. The assignment is made using the SSNR.

SB061

KB001

KB005

KF000205

KF000427

SSNR

SB061

SSNR

SB065

SSNR

SB065

SSNR

ENBL

DB015

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

DB016

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

DB017

DW0000

DW0001

...

DW0005

...

DW0027

...

DW0200

...

DW1023

Fig. 5-3: Managing the MBS error messages using the administration data blocks (example)

5-10

Modular Block System: Hydraulic Presses

Temporary flag range in MBS blocks

Internally, MBS blocks use the flags in the range M 64.00 ... M69.31 as temporary flags.

NOTICE

We recommend the following:

• Do not use flags from the temporary flag range for your own applications. Malfunctions may occur if you use the temporary flag range M64.00 ... M69.31 for your own applications.

• If it is absolutely necessary to use this flag range, under no circumstances should you use the flags:

- in alarm OBs

- as input parameters for standard function blocks

- as output parameters for standard function blocks

- as global parameters

Output parameter FG/ENBL

Many standard function blocks have an enable output FG/ENBL. This output parameter indicates the enable status of a standard function block. The enable status results from the standard function block’s check of the inputs.

FG / ENBL = 1: No error found,

FG / ENBL = 0: An error has been found,

INFORMATION

If you are using a Pilz evaluation package we recommend that you use flags M70.00 ... M88.23 for the output parameter FG/ENBL. You will need to note the allocation of the flags to the safety subroutine numbers (input parameter SSNR): SSNR = 1 should use flag M70.00; SSNR = 600 should use flag M88.23. The Appendix contains a table showing the allocation of safety subroutine numbers to enable flags.

function is enabled

function is not enabled.

5-11Modular Block System: Hydraulic Presses

MBS Basics

Assignment of input and output parameters

Input and output parameters should be assigned in accordance with the details given in the operating manual.

WARNING!

If several unused output parameters are connected to the same flag, malfunctions may occur in the standard function blocks. If an unused output has to be assigned a flag, make sure the output is assigned to a flag that is not used anywhere else in the program.

Minimum scan time

Most of the timer functions required within the blocks are performed using cycle counters. This means that almost all the timers are available for use in applications.

WARNING!

• If MBS blocks are used, a minimum scan time must always be entered in the configurator. Empirical values should be used.

The empirical value can be determined by reading the maximum program processing time values from DB000: DB000 DW10 -> max. scan time of FS section DB000 DW12 -> max. scan time of ST section The sum of these values plus 10 ms for the operating system test times plus a tolerance time of 1 ... 5 ms, for example, will provide an initial value for the “Minimum scan time”. Once the program is loaded, special monitoring of the “Minimum scan time” is automatically activated in the CPU. This will put the FS section into STOP (with the error display F-20/

06) if the “Minimum scan time” is exceeded several times. With this particular STOP, the error message will read: “F-0C/04 Minimum scan time exceeded too often”. The value for the “Minimum scan time” will therefore need to be increased. This automatic monitoring is implemented from the “CPU3” generation, with operating system version V39. On earlier versions the FS section does not stop, but the error message F20/06 does appear.

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Modular Block System: Hydraulic Presses

• If the error message F-20/06 (error category/error number) appears on the CPU display, you must amend the minimum scan time appropriately. This error message indicates that the minimum scan time has been exceeded. The PSS must not be operated while this error message is present. If you continue to operate the PSS despite this error message, the monitoring times may be increased and the planned safety functions may be adversely affected.

• Further guidelines for setting the minimum scan time are given in the PSS operating manual (e.g. FS System Description, item no. 18645-08, page 6-11).

SB070 and SB071 automatically enter the minimum scan time in DW1022 of the administration data blocks. In this way it is automatically available to the MBS.

INFORMATION

Please note that the times are imprecise. The lack of precision on times is due to the cyclical processing of the user program. It is determined by the scan time of the respective user program. The following is generally valid: The greater the ratio of time value to scan time, the greater accuracy you will have with the required times.

Global parameters

Block 6 (DW1001 ... DW1023) of the administration data blocks contains global parameters. These are parameters that are valid for several blocks. For details of which global parameters a standard function block uses, please refer to the description of the individual standard function blocks. The data words in block 6 must be initialised when the program is started (OB120) using SB070/SB071 (INIT_MBS). The abbreviations in brackets {... : ...} at the end of each data word correspond to the parameters in SB071. The times that are also specified within the brackets are empirical values, unless stated otherwise.

5-13Modular Block System: Hydraulic Presses

MBS Basics

DW1001 Number of cycles in the contact synchronisation time between

DW1002 Number of cycles in the feedback loop’s reaction time to a

DW1003 Number of cycles in the contact switchover time between a

DW1004 Number of cycles in the contact switchover time between a

DW1005 Number of cycles in the machine clock time

2 N/O contacts or 2 N/C contacts (e.g. E-STOP button, reset key, etc.) {CoSy : 50 ms}

change in the PSS output connected to the main contactor {RFbL : 100 ms}

N/O and N/C contact (pushbutton) {CS_B : 100 ms}

N/O and N/C contact (relay) {CS_R: 50 ms}

{MaCy : max. 30 s in accordance with EN 61496-1 section A.8.4, 06/98}

DW1006 Number of cycles in the permitted ESPE reaction time

{ESPE : max. 150 ms in accordance with EN 61496-1 section

5.2.4, 06/98}

DW1007 Reserved DW1009 Reserved DW1010 Reserved DW1011 Reserved DW1012 Reserved DW1013 Reserved DW1014 Reserved DW1015 Counter for monitoring the SSNR DW1016 Reserved DW1017 Reserved DW1018 Reserved DW1019 Reserved for administration DW1020 Reserved

5-14

DW1021 Reserved for burner management DW1022 Min. scan time from DB002/DW0002 DW1023 Reserved

Modular Block System: Hydraulic Presses

Standard Function Blocks

Guidelines for selecting standard function blocks

Several standard function blocks are available for the following safety devices:

• E-STOP button

• Safety gate

• Feedback loop and

• Initialisation of the administration data blocks

The following information is designed to help you select the standard function block that is most appropriate for your application.

Emergency stop monitoring

SB061 NA_1

SB061 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p).

INFORMATION

Do not use SB061 in applications with SafetyBUS p.

SB061 cannot be used to monitor whether contacts switch synchronously when releasing an E-STOP button that has been operated. The additional commands for monitoring the SSNR are required (A DB015, I DW1015). Further information is available in Chapter 5, in the section entitled “Input parameter SSNR”.

SB063 E-STOP

SB063 is used in applications up to category 4. This standard function block is suitable for applications with SafetyBUS p. It has an input parameter to evaluate the status of the I/O-Group (SafetyBUS p), for which parameters are set on the E-STOP button contacts.

6-1Modular Block System: Hydraulic Presses

Standard Function Blocks

It is possible to monitor whether contacts switch synchronously when releasing an E-STOP button that has been operated. SB063 provides an additional input parameter for this task.

The value range for the safety subroutine number SSNR has been expanded to 1...600 (see Chapter 5, section entitled “Input parameter SSNR”).

The use of SB063 is preferred in very extensive applications (> 200 standard function blocks). In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable.

The additional commands for monitoring the SSNR are not required.

Safety gate monitoring

SB066 ST_K4

SB066 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p).

INFORMATION

Do not use SB066 in applications with SafetyBUS p.

6-2

Modular Block System: Hydraulic Presses

SB064 S-GATE

SB064 is used in applications up to category 4. The function range of SB064 corresponds largely to that of SB066. However, the value range for the safety subroutine number SSNR has been expanded to 1...600 (see Chapter 5, section entitled “Input parameter SSNR”).

This standard function block is suitable for applications with SafetyBUS p. It has an input parameter to evaluate the status of the I/O-Group (SafetyBUS p), for which parameters are set on the safety gate contacts.

The use of SB064 is preferred in the following applications:

• Applications with SafetyBUS p

• Very extensive applications (> 200 standard function blocks) with/without SafetyBUS p

In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable.

Feedback loop monitoring

SB067 RFK_K4

SB067 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p).

INFORMATION

Do not use SB067 in applications with SafetyBUS p.

6-3Modular Block System: Hydraulic Presses

Standard Function Blocks

SB065 FBL

SB065 is used in applications up to category 4. The function range of SB065 corresponds largely to that of SB067. However, the value range for the safety subroutine number SSNR has been expanded to 1...600 (see Chapter 5, section entitled “Input parameter SSNR”).

Other changes compared with SB067:

• Additional input parameter to set the time for monitoring the feedback loop individually

• Additional output parameter to drive 2 contactors

• Improved error message output

The use of SB065 is preferred in the following applications:

• Applications with SafetyBUS p

• Very extensive applications (> 200 standard function blocks) with/without SafetyBUS p

In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable.

Initialising the administration data blocks

SB070 INIT_MBS

SB070 exclusively initialises administration data block DB015 with global parameters. For this reason it can only be used in applications which:

• Comprise a maximum of 200 standard function blocks

• Do not use standard function blocks SB063, SB064, SB065, SB069 and SB075

6-4

Modular Block System: Hydraulic Presses

SB071 INIT_MBS

SB071 initialises all three administration data blocks (DB015, DB016 and DB017) with global parameters. It can be used for all applications.

NOTICE

SB071 is essential if you are using any one of the following standard function blocks:

• SB063

• SB064

• SB065

• SB069

• SB075

In this case, the use of SB071 is firmly specified.

6-5Modular Block System: Hydraulic Presses

Standard Function Blocks

SB051: Operating mode selector switch, 1 from 8

SB051

Block header

Input parameters

•

SSNR

SB 051

BA_1AUS8

B - SSNR X- S1 X- S2 X- S3 X- S4 X- S5 X- S6 X- S7 X- S8 X - RSet X - LOCK W - TIME

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte constants KB001 ... KB200 (see sections in Chapter 5 entitled “Administration data blocks DB015, DB016 and DB017” and “Input parameter SSNR”).

FG - X BA - B RSET - X

6-6

•S1 ... S8: Switch levels from operating mode selector switch

On each position of the selector switch, a 1-signal must be present at one switch contact only. Unused inputs should be assigned RLO-0 (M 110.00)

Input coding of selector switch (mode 1 from 8):

Position S8 S7 S6 S5 S4 S3 S2 S1 Dec.Value

S1 1 00000001 1

2 00000010 2 3 00000100 4 4 00001000 8 5 00010000 16 6 00100000 32

7 01000000 64 8 10000000 128

Modular Block System: Hydraulic Presses

•

RSet

•

LOCK

•

TIME

INFORMATION

If possible you should use the PSS(1) DI2 as input module. If this is not possbible, the inputs must use test pulses.

Output parameters

•

: Reset input for error acknowledgement

RSet

= 0/1 signal edge: Reset occurs

: Lock switch position

LOCK LOCK

= 0: Switch position unlocked = 1: Switch position locked

If the switch position changes, an error will be triggered immediately

The parameter

LOCK

can be allocated the flag “Machine

running” or “press safety valve: on”, for example.

: Maximum permitted contact switchover time between two

correct switch positions Permitted time range: 1 ... 2047 ms

: Enable flag bit

= 1: Enabled (no errors)

i.e. existing errors were reset via

RSet

and

only one input (S1... S8) = 1.

•

: Operating mode,

Output parameter: Byte format (8 Bit) If the input signal is faulty, no bit will be set in output byte BA.

Output coding of selector switch (mode 1 from 8):

Position Output Parameter BA (Byte Format) Dec. Value

Bit: 07 06 05 04 03 02 01 00 1 000 00001 1 2 000 00010 2 3 000 00100 4 4 000 01000 8 5 000 10000 16 6 001 00000 32

7 010 00000 64 8 100 00000 128

Modular Block System: Hydraulic Presses 6-7

Standard Function Blocks

•

RSET

Error messages

Any fault that is detected will be stored in the corresponding error data word ( with.

• Error messages in DB015

- Bit 00: Incorrect input signal

: Reset output

RSET

SSNR

More than one input (S1 ... S8) is high. Remedy: Check switch, cable and input card, then reset (input parameter

= 1: The operating mode has been changed.

If the operating mode has been changed (e.g. “reset ESPE/AOPD”), the high for one cycle.

) of DB015 (1st data block), until the fault has been fully dealt

RSet

SB051

RSET

)

output will be

- Bit 01: No input signal (S1 ... S8) is high, all inputs are low (cable break) Remedy: Check switch, cable and input card, then reset (input parameter

- Bit 08: Switch changed when Remedy: If switch has not changed: Check switch, cable and input card, then reset (input parameter If switch has changed: Check switch position and then reset (input parameter

- Bit 14:

INFORMATION

Error bits 00, 01 and 08 can only be reset in “Setup” mode.

RSet

input constantly high or set too early Remedy: If

RSet

input was not set too early and is constantly high:

Check switch, cable and input card, then reset (input parameter If

RSet

input was set too early: reset again

(input parameter

RSet

)

LOCK

)

= 1

RSet

)

6-8

Modular Block System: Hydraulic Presses

• Error messages on the CPU-display

- None

Global parameters used in administration data block DB015

Global parameters may be set in OB120 using SB070.

• DW1022: Minimum scan time from DB002/DW002

Blocks required

• DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access.

• SB070 Initialisation of global parameters in DB015

Modular Block System: Hydraulic Presses 6-9

Standard Function Blocks

SB052: Operating mode selector switch, 2 from 6

SB052

Block header

Input parameters

•

SSNR

SB052

BA_2AUS6

B - SSNR X - S1 X - S2 X - S3 X - S4 X - S5 X - S6 X - RSet X - LOCK W- TIME

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte constants KB 001 ... KB 200 (see sections in Chapter 5 entitled “Administration data blocks DB015, DB016 and DB017” and “Input parameter SSNR”).

FG - X BA - W RSET - X

6-10

•S1 ... S6: Switch levels from coded operating mode selector switch On each position of the selector switch, a 1-signal must be present at two switch contacts only.

If a maximum of 6 switch settings (operating modes) are used, switch contacts S5 and S6 may be omitted (see table overleaf: “Input coding of selector switch”). If a maximum of 10 switch settings are used, switch contact S6 may be omitted (see table overleaf: “Input coding of selector switch”).

Unused inputs should be assigned RLO-0 (M 110.00).

Modular Block System: Hydraulic Presses

Input coding of selector switch (mode 2 from 6):

Position S6 S5 S4 S3 S2 S1 Dec. Value

1 000 011 3 2 000 101 5 3 000 110 6 4 001 001 9 5 001 010 10 6 001 100 12 7 010 001 17 8 010 010 18

9 010 100 20 10 011 000 24 11 100 001 33 12 100 010 34 13 100 100 36 14 101 000 40 15 110 000 48

•

RSet

: Reset input for error acknowledgement

RSet

= 0/1 signal edge: Reset occurs

•

LOCK

: Lock switch position

LOCK LOCK

= 0: Switch position unlocked = 1: Switch position locked

If the switch position changes, an error will be triggered immediately. The parameter be allocated the flag “Machine running” or “Press safety valve: on” (input parameter SB 080), for example.

•

TIME

: Maximum permitted contact switchover time between two

correct switch settings. Permitted time range: 1 ... 1023 ms

INFORMATION

If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses.

EIN

LOCK

from

can

Modular Block System: Hydraulic Presses 6-11

Standard Function Blocks

Output parameters

: Enable flag bit

•

= 1: Enabled (no errors)

i.e. existing errors were reset via input parameter

RSet

•

: Operating mode

Output parameter: Word format (16 Bit) Bit 00 represents no switch position. If the input code is faulty, no bit will be set.

Output coding of selector switch (mode 2 from 6):

and two inputs (

... S6) = 1.

SB052

Position Output Parameter

HIGH-Byte LOW-Byte

15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 1 0000000000 00001 2 2 0000000000 00010 4 3 0000000000 00100 8 4 0000000000 01000 16 5 0000000000 10000 32 6 0000000001 00000 64

7 0000000010 00000 128 8 0000000100 00000 256 9 0000001000 00000 512

10 0000010000 00000 1024 11 0000100000 00000 2048 12 0001000000 00000 4096 13 0010000000 00000 8192 14 0100000000 00000 16384 15 1000000000 00000 32768

(Word Format) Dec.

Value

6-12

Modular Block System: Hydraulic Presses

Error messages

•

RSET

Any fault that is detected will be stored in the corresponding error data word ( with.

• Error messages in DB015

- Bit 00: Incorrect code from switch

- Bit 01: No signal from operating mode selector switch, both signals

: Reset output

RSET

SSNR

Remedy: Check switch position Otherwise: Check switch, cable and input card, then reset (input parameter

interrupted Remedy: Check switch Otherwise: Check cable and input card, then reset (input parameter

= 1: The operating mode has been changed.

If the operating mode has been changed (e.g. “reset ESPE/AOPD”), the high for one cycle.

) of DB015 (1st data block), until the fault has been fully dealt

RSet

)

RSet

)

RSET

output will be

- Bit 14:

INFORMATION

Error bits 00, 01 and 08 can only be reset in “Setup” mode.

• Error messages on the CPU-display

- None

RSet

input constantly high or set too early Remedy: If

RSet

input was not set too early and is constantly high:

Check switch, cable and input card, then reset (input parameter If

RSet

input was set too early: reset again

(input parameter

RSet

LOCK

)

= 1

RSet

)

Modular Block System: Hydraulic Presses 6-13

Standard Function Blocks

Global parameters used in administration data block DB015

Global parameters may be set in OB120 using SB070.

• DW1022: Minimum scan time from DB002/DW002

Blocks required

• DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access.

• SB070 Initialisation of global parameters in DB015

SB052

6-14

Modular Block System: Hydraulic Presses

Notes

Modular Block System: Hydraulic Presses 6-15

Standard Function Blocks

SB059: Two-hand monitoring

SB059

Block header

Input parameters

•

SSNR

SB 059

2_HAND

B - SSNR X - STFG X - MEin X - T1.2 X - T1.4 X - T2.2 X - T2.4 W- KU_S X - RSET X - Tipp X - Auf X - Off

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte constants KB001 ... KB200 (see sections in Chapter 5 entitled “Administration data blocks DB015, DB016 and DB017” and “Input parameter SSNR”).

FG - X GST - X AUF - X OFF - X

6-16

•

STFG

•

MEin

: Static enable

STFG STFG

The two-hand control can only be enabled (FG = 1) if high. The must be present to operate the press are linked (e.g. FG from the E-STOP, FG from the operating mode selector switch etc.)

: Machine “On”

A 1/0-pulse edge on the stroke protection), which will only be lifted when the start position is achieved (both buttons T1 and T2 released).

MEin MEin

= 0: Function disabled = 1: Function enabled

STFG

= e.g. “Safety valve on” flag: Activation of lock required

= RLO-0 (M 110.00): Activation of lock not required.

signal is the result when all the signals that

MEin

signal activates a lock (single-

Modular Block System: Hydraulic Presses

STFG

•

T1.2

: N/C button 1

•

T1.4

: N/O button 1

•

T2.2

: N/C button 2

•

T2.4

: N/O button 2

•

KU_S

: Contact switchover time between N/O and N/C contact on

pushbuttons Permitted time range: 1 ... 1000 ms Format: Constant fixed point number KF00001 … KF01000 Suggested value: KF00100

INFORMATION

If your plant does not run stably using the suggested value, you can work out the value that suits your plant as follows:

- Select the suggested value as a starting point.

- Increase this value by appropriate time intervals until your plant runs stably.

Please note:

Entering an excessively high time value for monitoring will reduce the level of safety on your plant.

•

RSET

: Reset input

RSET

= 0/1-signal edge: Trigger reset

WARNING!

The input parameter

Tipp

is not intended for use on presses and therefore must not be activated on presses. On presses, this input should be assigned RLO-0 (M110.00).

•

Tipp

: Mode: “Jog mode using one button and setup speed”

Tipp

= 0: Mode: “Jog mode using one button” is blocked.

To disable jog mode using one button, the input should be assigned RLO-0 (M110.00).

Modular Block System: Hydraulic Presses 6-17

Standard Function Blocks

Tipp

= 1: Mode: “Jog mode using one button” is permitted.

The input should be assigned the flag “Setup mode”. The input parameter normal two-hand operation. However, jog mode using one button, where the other button is constantly operated, is additionally permitted.

Procedure: To start jog mode, press both two-hand buttons simultaneously, then release one button while the keeping the other pressed down. Operate jog mode using the two-hand button that was released.

WARNING!

The input parameter presses. It must not be activated on eccentric presses. On eccentric presses, this input should be assigned RLO-0 (M110.00).

Auf

SB059

Tipp

= 1 has no effect on

is intended exclusively for use on hydraulic

•

Auf

: Activate upward movement with one button (output parameter

AUF

)

Auf

= 0: Output parameter

Assign the input RLO-0 (M110.00) if you want to use both buttons to activate the upward movement.

Auf

= 1: Output parameter

button is operated for longer than 0.5 s Assign the input RLO-1 (M110.01) if you want to use one button to activate the upward movement.

•

Off

: Deselect two-hand control circuit

Where plug-in two-hand devices/consoles are being monitored, there is the option to deselect a two-hand device/ console (e.g. re-tooling to two-man operation from 4-man).

Off

= 0: Two-hand control circuit/console is selected

Off

= 1: Two-hand control circuit/console is deselected

AUF

is inactive (

AUF

is set (

AUF

= 1), if one

= 0)

6-18

Modular Block System: Hydraulic Presses

INFORMATION

The two-hand device/console is correctly disconnected and deselected when:

Input parameter T1.2 and T1.4 = 0

T2.2 and T2.4 = 0

Output parameter FG, GST, AUF = 0

OFF = 1

In all cases, an error message will be issued when a two-hand device/ console is disconnected. You will need to take one of the following actions:

• The two-hand device/console is disconnected, but still selected via the key switch: Deselect the console via the key switch and then reset. The two-hand device/console is now correctly deselected and disconnected (please refer to “Error messages” under “Bit 04”).

• The two-hand device/console is deselected via the key switch, but is still connected: Disconnect the console and then reset. The two-hand device/console is now correctly deselected and disconnected (please refer to “Error messages” under “Bit 05”).

A dummy connector is not required to act as a buffer when unplugging a two-hand device/console.

DANGER!

If a two-hand circuit is deselected using the input parameter

Off

, a diffe-

rent safety device must be employed in its place.

Remember that the two-hand circuit has a safety function in addition to its operator function.

Modular Block System: Hydraulic Presses 6-19

Standard Function Blocks

INFORMATION

• All two-hand buttons must use test pulses. These pulses should be entered in the configurator (DB 002) accordingly.

SB059

• Ensure the selector switch contact for input parameter pulse output and enter this output in the configurator (DB 002) accordingly

• If the block is to be used to monitor a foot switch, the inputs of the N/O and N/C contacts on the foot switch must be connected to or

• In accordance with EN 574 section 3.5, 02/97, monitoring of the synchronisation time between the two buttons is set at < 0.5 s.

Output parameters

•FG

•

GST

T1.4

and

T2.4

respectively.

: Enable flag bit

= 0: Not enabled

= 1: Two-hand operation is enabled

: Start position

GST

= 0: T1 and T2 not in start position

GST

= 1: Both buttons (T1 and T2) are released.

Off

has a test

T1.2

and

T2.2

Two-hand operation is enabled provided the output parameter T2) are operated within 0.5 s and any errors have been rectified and reset.

STFG

= 1, both buttons (T1 and

6-20

•

AUF

: (for use only with hydraulic presses)

AUF

= 0: “Upward movement with one button” is inactive

AUF

= 1: Only one button needs to be operated for longer

than 0.5 s to trigger an upward movement. This output may only move the press slide upwards. Ejectors and die cushions may only be moved to TDC using a separate button.

OFF

: Two-hand control circuit/console is selected/deselected

(input parameter

OFF

= 0: Two-hand control circuit/console selected (

OFF

= 1: Two-hand control circuit is correctly deselected

Off

)

(

Off

= 1) and disconnected.

Modular Block System: Hydraulic Presses

Off

= 0)

Error messages

Any fault that is detected will be stored in the corresponding error data word ( with.

• Error messages in DB 015

SSNR

- Bit 00: T1 N/O and N/C contact open

- Bit 01: T1 N/O and N/C contact closed

- Bit 02: T2 N/O and N/C contact open

- Bit 03: T2 N/O and N/C contact closed

) of DB 015 (1st data block), until the fault has been fully dealt

Remedy: Check input button, cable, input card and all conditions, then reset (input parameter

RSET

)

- Bit 04: Two-hand control circuit/console selected, but the console is disconnected Remedy: Check switch, cable, input card and all conditions, then reset (input parameter

- Bit 05: Two-hand control circuit/console is deselected, but the console is connected Remedy: Check switch, cable, input card and all conditions, then reset (input parameter

- Bit 08: Reset (input parameter pressed Remedy: If

RSET

Check switch, cable and input card, then reset (input parameter If

RSET

parameter

input has not been set too early and is contantly high:

RSET

input has been set too early: reset again (input

RSET

)

RSET

)

) pressed too soon or constantly

Modular Block System: Hydraulic Presses 6-21

Standard Function Blocks

- Bit 09: Button pressed without start enable Remedy: Check enable input, cable, input card and all conditions, then reset (input parameter

- Bit 10: Synchronisation time error, T1 missing (no “Auf” mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter

- Bit 11: Synchronisation time error, T2 missing (no “Auf” mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter

RSET

SB059

)

- Bit 12: Two-hand control RESET via Remedy: Check switch, cable, input card and all conditions, then reset (input parameter

- Bit 14: T1 not released (no “Jog” mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter

- Bit 15: T2 not released (no “Jog” mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter

• Error messages on the CPU-display

- None

Global parameters used in administration data block DB015

Global parameters may be set in OB120 using SB070.

• DW1022: Minimum scan time

MEin

RSET

)

(button released)

RSET

)

Blocks required

6-22

• DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access.

Modular Block System: Hydraulic Presses

Notes

Modular Block System: Hydraulic Presses 6-23

Standard Function Blocks

SB061: Emergency stop monitoring, category 4

SB061

Block header

Input parameters

•

B - SSNR X - EIN X - S1_Ö X - S2_Ö X - QAnf X - QAut

SSNR

EIN

: Safety subroutine number

Permitted value range: 1 ... 200 Format: Byte constants KB001 ... KB200 (see sections in Chapter 5 entitled “Administration data blocks DB015, DB016 and DB017” and “Input parameter SSNR”).

: Reset button (N/O contact)

EIN

= 0/1-pulse edge: Reset occurs

SB 061

NA_1

FG - X

6-24

•

S1_Ö

•

S2_Ö

•

QAnf

•

QAut

: E-STOP N/C contact 1 : E-STOP N/C contact 2

: Automatic reset (PSS cold start)

QAnf

= RLO-0 (M 110.00): No reset required.

Cycle: When the PSS is started up or cold started, the enable is triggered without an additional reset.

QAnf

= RLO-1 (M 110.01): Reset required.

Cycle: When the PSS is started up or cold started, a reset is required through the input parameter

: Automatic reset when E-STOP button is released

QAut

= 0: Reset through input parameter

EIN

in order to trigger the enable.

EIN

is required.

Modular Block System: Hydraulic Presses

Output parameters

•

QAut EIN QAnf

INFORMATION

Automatic reset is only possible in conjunction with:

EIN QAnf

This means that an automatic reset ( (

: Enable flag bit

FG FG

= 1: Automatic reset when = 1: E-STOP-button is released = 0:

= RLO-1 (M 110.01) and

= RLO-0 (M 110.00).

QAut

= 1) and a reset on PSS start-up

QAnf

= 1) are mutually exclusive.

= 0: Not enabled = 1: Function enabled when no errors are present

Error messages

Any fault that is detected will be stored in the corresponding error data word ( with.

• Error messages in DB 015

SSNR

- Bit 00: E-STOP button operated

- Bit 01: Contact synchronisation time exceeded for N/C contact

- Bit 02: Contact synchronisation time exceeded for N/C contact

) of DB 015 (1st data block), until the fault has been fully dealt

Remedy: Check button, cable and input card, release E-STOP button and reset (input parameter

EIN

)

S1_Ö

S2_Ö

Modular Block System: Hydraulic Presses 6-25

Standard Function Blocks

- Bit 03: With: “Automatic reset (PSS cold start)”: E-STOP button operated and reset button pressed Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter

With: “Automatic reset when E-STOP button is released”: E-STOP button operated Remedy: Release E-STOP button

- Bit 08: E-STOP released, ready for reset Remedy: Press reset button (input parameter

- Bit 09: Reset button pressed constantly (i.e. stuck in) Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter

- Bit 10: Reset successful, but N/C contact S1_Ö failed to open when the E-STOP button was operated. Remedy: Press E-STOP button again to ensure that contacts open correctly and then reset; otherwise: check cable and input card, release the E-STOP button and reset (input parameter

EIN

SB061

EIN

)

EIN

)

- Bit 11: Reset successful, but N/C contact S2_Ö failed to open when the E-STOP button was operated. Remedy: Press E-STOP button again to ensure that contacts open correctly and then reset; otherwise: check cable and input card, release the E-STOP button and reset (input parameter

• Error messages on the CPU-display

- E 001: Parameter error

SSNR

- E 002: Parameter error

SSNR

DW1015 in DB015 was not incremented

EIN

)

does not lie within the limits of 1 ... 200

assigned more than once OR

6-26

Modular Block System: Hydraulic Presses

Global parameters used in administration data block DB015

Global parameters may be set with SB070 in OB120.

• DW1001: Number of cycles in the contact synchronisation time between the 2 N/C contacts on the E-STOP button

Blocks required

• DW1015: Counter for monitoring the

SSNR

INFORMATION

On some blocks (e.g. E-STOP) the input parameter

SSNR

is monitored.

These blocks must be run through as part of each PSS-cycle. The following commands should therefore be entered once only at the end of OB101:

A DB015

I DW1015

Effect: The counter for monitoring the

SSNR

in DB015/DW1015 (global

parameters) will be incremented.

• DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access.

• SB070 Initialisation of global parameters in DB015

• SB255: To call up the operating system

Modular Block System: Hydraulic Presses 6-27

Standard Function Blocks

SB063: Emergency stop monitoring, category 4

SB063

Block header

Input parameters

•

SSNR

SB063

E-STOP

W - SSNR X - GRP X - NC_1 X - NC_2 X - AuSt X - ARSt X - FTST X - RSET

: Safety subroutine number

Permitted value range: 1 ... 600 Format: Word constants KF000001 ... KF000600 (see sections in Chapter 5 entitled “Administration data blocks DB015, DB016 and DB017” and “Input parameter SSNR”).

ENBL - X

•

GRP:

•

NC_1:

•

NC_2:

•

AuSt:

I/O-Group status flag (SafetyBUS p) containing the inputs

NC_1

I/O-Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1.

E-STOP N/C contact 1 E-STOP N/C contact 2 Reset on start-up (PSS cold start) or when I/O-Group is started

(SafetyBUS p)

AuSt

Sequence: When the PSS is cold/warm started or the I/OGroup is started ( required through input parameter enable.

and

NC_2

= 0: Initial reset required.

(M116.00 for I/O-Group 0 to M116.31 for

GRP

= 0/1-pulse edge), an initial reset is

RSET

, in order to trigger the

6-28 Modular Block System: Hydraulic Presses

•

ARSt:

•

FTST

•

RSET:

AuSt

= 1: No initial reset required Sequence: When the PSS is cold/warm started or the I/OGroup is started (GRP = 0/1-pulse edge), the enable is triggered without a further initial reset. is also required in order to set the enable.

Automatic reset when E-STOP button is released

ARSt

= 0: Reset through input parameter

ARSt

= 1: Automatic reset required when E-STOP button is

released Function test

FTST FTST

synchronisation error occurs when the E-STOP button is released.

Reset button (N/O contact)

RSET

RSET should be assigned RLO-0 if you do not need a reset button (e.g. with automatic reset).

= 0: No function test required = 1: A function test must be performed if a

= 0/1-pulse edge: Reset occurs

NC_1

RSET

= 1 und

is required

NC_2

= 1

Output parameters

•

ENBL:

Function test

The function test will check whether both contacts on the E-STOP button are switching synchronously. A function test must always be performed if a synchronisation error occurs when the E-STOP button is operated. Input parameter test is required if a synchronisation error occurs when the E-STOP button is released.

Enable bit

ENBL ENBL

= 0: Enable is blocked = 1: This function is error-free, the E-STOP button

FTST

has not been operated

can be used to establish whether or not a function

Modular Block System: Hydraulic Presses 6-29

Standard Function Blocks

Sequence of function test:

• Press E-STOP button

• Release E-STOP button

SB063

Error messages

• Press reset button (input parameter

Any fault that is detected will be stored in the corresponding error data word ( fault has been fully dealt with.

• Error messages in the administration data block

SSNR

- Bit 00: E-STOP button operated

- Bit 01: Reset required

- Bit 03: Function test required due to a synchronisation error

- Bit 04: E-STOP button operated and reset button pressed

) of the administration data block (1st data block), until the

Remedy: Release E-STOP button and reset (input parameter

Remedy: Reset (input parameter

Remedy: Perform function test (press E-STOP button, release it and reset (input parameter

Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter

RSET

)

RSET

)

RSET

))

)

RSET

)

- Bit 05: Reset button pressed too soon or constantly pressed Remedy: Check reset button, cable and input card and reset again (input parameter

- Bit 06: Initial reset required Remedy: Reset (input parameter

- Bit 07: Synchronisation error N/C contact 1 Remedy: Check button, cable and input card, release the ESTOP button and perform a function test (press E-STOP button, release it and reset (input parameter

6-30 Modular Block System: Hydraulic Presses

RSET

)

RSET

)

RSET

))

- Bit 08: Synchronisation error N/C contact 2 Remedy: Check button, cable and input card, release the ESTOP button and perform a function test (press E-STOP button, release it and reset (input parameter

- Bit 09: I/O-Group stop triggered while PSS is in RUN mode Remedy: Start I/O-Group

• Error messages on the CPU-display

- E003 Administration data block has not been initialised Remedy: Call SB071 in OB120

Global parameters used in the administration data blocks

The global parameter may be set in OB120 using SB071.

• DW1001: Number of cycles in the contact synchronisation time between the 2 N/C contacts on the E-STOP button

Blocks required

RSET

))

• DB015, DB016, DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words and have READ/WRITE access (see Chapter 5, section entitled “Administration data blocks...”).

• SB071: Initialisation of global parameters in DB015, DB016 and DB017

Modular Block System: Hydraulic Presses 6-31

Standard Function Blocks

SB064: Safety gate monitoring

SB064

Block header

Input parameters

•

SSNR

SB064

ST_K4

W - SSNR X - GRP X - S1 X - S2 W - SyTi X - MRun X - AuSt X - ARSt X - NoFT X - RSET

: Safety subroutine number

ENBL - X

•

GRP

: I/O-Group status flag (SafetyBUS p) containing the inputs

and S2 (M116.00 for I/O-Group 0 to M116.31 for I/O-Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1

•S1: Gate switch: Signal 1 If the gate is closed, both gate

•S2: Gate switch: Signal 2 switches must supply a 1-signal

•

SyTi

: Synchronisation time between S1 and

Value in ms [0...32767]; 0 = infinite; format: word constants

6-32 Modular Block System: Hydraulic Presses

•

MRun

•

AuSt

•

ARSt

•

NoFT

: Machine is running

MEin

= 0: Machine standing

MEin

= 1: Machine is running

MEin

= 1/0-pulse edge: Activate reset lock. This parameter can force the operator to carry out a function test of the gate (gate open/closed). The reset lock is lifted by carrying out a function test on the gate followed by the

: Automatic start/start-up disabler

AuSt = 0: Start-up disabler (initial reset is required)

AuSt

= 1: Automatic start/no start-up disabler on PSS cold/

warm start or when starting the I/O-Group; only effective in conjunction with under “Operating modes”)

: Automatic restart/reset lock

ARSt = 0: Reset lock (reset is required)

ARSt

= 1: Automatic restart/no reset lock

(see also under “Operating modes”)

: Function test on the gate

NoFT = 0: Function test required on the gate

NoFT

(see also under “Operating modes”)

= 1: Cold/warm start without function test on the gate

RSET

signal.

NoFT

= 1 (see also

•

RSET

: Reset input

RSET = 0/1 pulse edge:

- Reset errors or

- Reset start-up disabler or

- Reset reset lock

Modular Block System: Hydraulic Presses 6-33

Standard Function Blocks

Input circuitry

• Inputs S1 and S2 must use test pulses. These pulses should be entered in the configurator (DB002) accordingly.

• Using SB064 for safety gate monitoring:

- Category 2

CAUTION!

This can only be used on safety gates which are regularly opened and closed as part of the machine cycle.

If you are only using one switch/contact, S1 and S2 will have the same input address. The switch must close when the safety gate is closed.

If you only use one switch/contact, malfunctions such as a button plunger sticking or the gate failing to actuate cannot be detected. A function test must therefore be carried out on the gate as part of each cycle, i.e. the gate must be opened and closed regularly.

SB064

- Category 4:

Output parameters

•

ENBL

This requirement is met if the reset lock is activated each cycle by a 1/0 pulse edge at the so that it is only possible to restart the machine after the gate has been opened and closed.

Use two separate switches/contacts, which must be operated independently. Both switches must close when the safety gate is closed. A cyclical function test on the gate is not required.

: Enable bit

ENBL ENBL

= 0: Enable is blocked = 1: Enable occurs if

MRun

the safety gate is closed (S1 = 1 and S2 = 1), any errors have been rectified and confirmation has been given via the

input (e.g. each time the machine stops),

RSET

signal.

6-34 Modular Block System: Hydraulic Presses

Functions

The operation of SB064 is established via the following input parameters:

•

ARSt

: No reset lock (Automatic Restart)

•

AuSt

: No start-up disabler (Automatic Start) on PSS cold/warm start

or when starting the I/O-Group

•

NoFT

: No function test on the gate

Please note that a combination of various settings is possible with these input parameters (e.g. start-up disabler activated/reset lock activated or start-up disabler activated/reset lock disabled etc.). These input parameters are also used to establish what the operator needs to do should an error occur (function test and error acknowledgement/reset). The individual options can be found in the following tables.

Tables for setting the functions:

Procedure for achieving the enable (output parameter

ENBL

) on PSS cold/

warm start

Op. mode

Start disabler AuSt 0001 *101

Parameter ARSt 010011

NoFT 001111 Func- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x *2- x *2-x-x-x-x test Open and close

gate

x *2xx *2x----- x

RSET - - - -

Table 1: Function: “Start-up disabler”

Modular Block System: Hydraulic Presses 6-35

Standard Function Blocks

SB064

Procedure for achieving the enable (output parameter

ENBL

) when PSS is

in RUN mode (subsequent statuses only after enable is issued)

Op. mode

Reset ARSt 0 1 0 0 1 1 lock

Parameter AuSt 0 0 0 1

NoFT 0 0 1 1 1 1 Func- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x - x - x - x - x - x test Open and close

gate

-- -- -- -- -- --

RSET - - -

Table 2: Function: “Reset lock”

Required reaction from operator in the case of a fault

Parameter ARSt 0 1 0 0 1 1

AuSt 0 0 0 1

NoFT 0 0 1 1 1 1 Funk- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x - x - x - x - x - x test Open and close

gate

x*4xx*4xx4xx*4xx*4xx*4x

RSET - - -

Table 3: Reaction in the case of a fault

x Function activated or

operator reaction required

- Function not activated or no operator reaction required or reset not required

Reset required via the reset input

The function “No start-up disabler on PSS cold/warm start” is only possible when no function test is set (

First close the gate, then open it and close it again.

The enable can be set by opening/closing the gate or by a pulse at the

NoFT

= 1).

reset input.

When synchronisation time S1-S2 is exceeded (error bit 09)

6-36 Modular Block System: Hydraulic Presses

Example 1: Parameters These settings mean that the “start-up disabler” and “reset lock” functions are activated; a function test of the gate is required.

• With PSS cold or warm start (start-up disabler), proceed as follows:

- If the gate is open, close, open and then close the gate again, then reset via the reset button (

- If the gate is closed, open and close the gate and reset via the reset button (

• Subsequent statuses only after enable is issued (reset lock):

- If the gate is open, close the gate and reset via the reset button (

RSET

ARSt, AuSt

RSET

and

NoFT

RSET

= 0

- If the gate is closed, reset via the reset button (

• If there has been a fault, this must first be rectified before proceeding as follows:

- If the gate is open, close the gate and reset via the reset button

(

RSET

open and then close the gate again, then reset via the reset button (

RSET

- If the gate is closed, open and close the gate and reset via the reset

button (

Example 2: Parameters These settings mean that the “start-up disabler” and “reset lock” functions are activated and a function test of the gate is not required.

• With PSS cold or warm start (start-up disabler), proceed as follows:

- If the gate is open, close the gate and reset via the reset button

(

RSET

- If the gate is closed, reset via the reset button (

• Subsequent statuses only after enable is issued (reset lock):

- If the gate is open, close the gate and reset via the reset button

(

RSET

). If error bit 09 occurs (synchronisation time exceeded), close,

RSET

ARST

and

AuST

= 0,

NoFT

= 1

RSET

- If the gate is closed, reset via the reset button (

Modular Block System: Hydraulic Presses 6-37

RSET

Standard Function Blocks

• If there has been a fault, this must first be rectified before proceeding as follows:

- If the gate is open, close the gate and reset via the reset button

(

Error messages

RSET

open and then close the gate again, then reset via the reset button (

RSET

- If the gate is closed, open and close the gate and reset via the reset

button (

Any fault that is detected will be stored in the corresponding error data word ( has been fully dealt with.

• Error messages in the administration data block

- Bit 06: I/O-Group stop triggered while the PSS is in RUN mode

). If error bit 09 occurs (synchronisation time exceeded), close,

RSET

SSNR

) of administration data block (1st data block), until the fault

Remedy: Start I/O-Group

SB064

- Bit 07: Gate open (S1 and S2 open)

Remedy: Close gate and then reset (input parameter

- Bit 08: Function test not carried out (gate open/closed)

Remedy: Carry out function test and/or check switch, cable and input card and then reset (input parameter

- Bit 09: S1 and S2 synchronisation time exceeded

Remedy: Check switch, cable and input card, carry out a function test and then reset (input parameter

- Bit 10: Gate open (S1 open)

Remedy: Close gate, check switch, cable and input card and then reset (input parameter

- Bit 11: Gate open (S2 open)

Remedy: Close gate, check switch, cable and input card and then reset (input parameter

RSET

)

RSET

)

RSET

)

6-38 Modular Block System: Hydraulic Presses

Pilz PSS SB HYD, Basic license User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

MBS Modular Block System

Categories / requirement classes

Overview of manual

Definition of symbols

Terminology

Overview

Software package

Range

Safety

Safety guidelines

Use of qualified personnel

Warranty and liability

Application guidelines

Standards

Fault detection

Fault detection techniques

Feasibility test

Pulsed input signals

Self test on the outputs

Fault prevention

Intended Use

System software

Intended use of the standard function blocks

SB051: Operating mode selector switch 1 from 8

SB052: Operating mode selector switch 2 from 6

SB059: Two-hand monitoring

SB061: Emergency stop monitoring

SB063: Emergency stop monitoring

SB064: Safety gate monitoring

SB065: Feedback loop monitoring

SB066: Safety gate monitoring

SB067: Feedback loop monitoring

SB068: Monitoring ESPE/AOPDs with guarding and control function

SB069: Monitoring ESPE/AOPDs with guarding function

SB070: Initialisation of administration data block (DB015)

SB071: Initialisation of administration data blocks (DB015/DB016/DB017)

SB072: Temporary suspension of safety functions

SB075: Controlling and monitoring safety gates with guard locking

SB086: Overrun control on linear-driven presses

SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve)

SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve)

SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet valve and directional control valves)

SB092: Enable switch

SB097: Monitoring muting lamps

MBS Basics

Block design

Structure

Formal parameters and actual parameters

Administration data blocks DB015, DB016 and DB017

Structure of the administration data blocks

Blocks contained in the administration data blocks

Input parameter SSNR

Example

Fault diagnostics

Error types

Fault diagnostics using the administration data blocks

Temporary flag range in MBS blocks

Output parameter FG/ENBL

Assignment of input and output parameters

Minimum scan time

Global parameters

Standard Function Blocks

Guidelines for selecting standard function blocks

Emergency stop monitoring

SB061 NA_1

SB063 E-STOP

Safety gate monitoring

SB064 S-GATE

Feedback loop monitoring

SB065 FBL

SB051: Operating mode selector switch, 1 from 8

Block header

Input parameters

Output parameters