Siemens Simotion TM 121C Applications Manual

A

pplication manual 06/2003 Edition

simotion

SIMOTION Safety Integrated Safety Unit TM 121C

Preface, Table of Contents

General information on

parameterization software

1

Operating modes

2

Safety components

3

Operating elements

4

Procedural functions of

mechanical presses

5

Procedural functions of hydraulic

presses

6

Procedural functions of press

brakes

7

General functions

8

Operating and fault messages

9

Documentation

10

6AU1900-0DM20-0XA0

SIMOTION

Safety Unit TM 121C

Application manual for presses

06.2003 Edition

Safety instructions

This manual contains instructions that should be observed to ensure your personal safety and to protect the equipment from damage. The instructions are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger:

!

Danger

This warning indicates an imminently hazardous situation which, if appropriate precautions are not taken, will result in death, serious injury or considerable property damage.

!

Warning

This warning indicates an imminently hazardous situation which, if appropriate precautions are not taken, may result in death, serious injury or considerable property damage.

!

Caution

indicates an imminently hazardous situation which, if appropriate precautions are not taken, may result in minor injury or property damage.

Caution

indicates an imminently hazardous situation which, if appropriate precautions are not taken, may result in property damage.

Attention

highlights an important item of information about the product or its use, or indicates a section of the instructions that deserves careful attention.

Qualified personnel

The equipment may be commissioned and operated by qualified personnel only. For the purposes of the safety instructions in this instruction manual, a Qualified Person is one who is authorized to commission, ground and label devices, systems and circuits in accordance with accepted safety standards.

Intended use

Please observe the following information:

!

Warning

The device may only be used in applications as provided for in the catalog and in the technical description, and only in connection with power supply units that have either been recommended or approved by Siemens.

Successful and safe operation of this equipment is dependent on proper transport, storage, erection and installation, as well as careful operation and maintenance.

Trademarks

SIMATIC®, SIMOTION®, SINUMERIK® and SITOP® are registered trademarks of Siemens AG. Other designations in this document may be trademarks whose use by third parties for their own purposes may infringe on the rights of the trademark holder.

Passing this document on to third parties, reproducing this document or using or relating its contents is not permitted without express authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

Siemens AG Automation & Drives Motion Control Systems P.O. Box 3180, D-91050 Erlangen Germany

Liability exclusion

We have checked the contents of this Manual to ensure that they match the hardware and software described herein. However, because deviations cannot be completely ruled out, we cannot guarantee complete conformance. The information contained in this document is checked regularly and any necessary corrections are included in subsequent editions. We are thankful for any recommendations or suggestions.

Siemens AG Safety Unit TM 121C

v

Preface

General information

In the interest of clarity, the information in this Manual does not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation or maintenance.

The contents of this Manual shall neither become a part of nor modify any prior or existing agreement, commitment or legal relationship. The sales contract contains the entire obligation entered into by Siemens. The warranty contained in the contract between the parties is the sole warranty of Siemens. Any statements contained herein do not create new warranties nor modify the existing warranty.

Purpose of this manual

This handbook is a supplement to the equipment manual of the SIMOTION Safety Unit TM 121C with the order number 6AU1900-0CM20-0XA0.

This handbook provides:

• explanatory functional descriptions of mechanical presses, hydraulic presses

and press brakes.

• assistance in the use of the parameterization masks.

For whom is this manual intended?

• Project planners

• Electricians and fitters

• Service and operating personnel

Contact persons

If you should encounter problems or questions when working with the manual, please consult the service center listed on the feedback form at the end of the manual.

Assistance in finding information

To help you get oriented, please turn to the table of contents.



vi SIMOTION Safety Unit (AP) - Edition 06.2003

Notes

vii

Content

1 General information on parameterization software .................... 1-9

2 Operating modes ............................................................................ 2-11

2.1 Selecting the operating mode ....................................................... 2-11

2.2 Operating modes and press cycles .............................................. 2-12

2.2.1 Setup (operating mode 1).......................................................... 2-13

2.2.2 Single stroke (operating mode 2) .............................................. 2-14

2.2.3 Continuous stroke (operating mode 3) ...................................... 2-15

2.2.4 Changeover (operating mode 4) ............................................... 2-16

2.2.5 Automatic continuous stroke (operating mode 5)...................... 2-17

2.2.6 Single-stroke ESPE (operating mode 6) ................................... 2-19

3 Safety components......................................................................... 3-21

3.1 Parameterization of safety components ....................................... 3-22

3.2 Example of safety component wiring............................................ 3-24

4 Control elements............................................................................. 4-27

4.1 Two-hand control .......................................................................... 4-27

4.1.1 Determining the safety distance ................................................ 4-29

4.2 Foot switch.................................................................................... 4-30

4.3 Acknowledge button for group acknowledgement........................ 4-31

4.4 Electro-sensitive protective equipment (ESPE)............................ 4-32

4.4.1 Determining the safety distance with ESPE .............................. 4-33

4.5 Control function with light curtain.................................................. 4-34

4.5.1 Mode selector ............................................................................ 4-34

4.5.2 Modes for clock operation ......................................................... 4-34

4.5.3 Starting the press in clock mode ............................................... 4-34

4.5.4 Restart inhibit of light curtain in clock mode .............................. 4-35

4.5.5 Restart inhibit of light curtain in safety mode............................. 4-36

4.6 EMERGENCY OFF output signal ................................................. 4-37

5 Procedural functions of mechanical presses .............................. 5-39

5.1 Cam evaluation............................................................................. 5-39

5.2 Speed monitor............................................................................... 5-42

5.3 Control of press safety valves....................................................... 5-43

5.4 Valve monitoring ........................................................................... 5-45

6 Procedural functions of hydraulic presses.................................. 6-47

6.1 Control of valves for hydraulic presses......................................... 6-47

6.2 Valve monitoring ........................................................................... 6-48

Inhalt

viii SIMOTION Safety Unit (AP) - Ausgabe 06.2003

7 Procedural functions of press brakes .......................................... 7-51

7.1 Selecting the operating mode ....................................................... 7-51

7.2 Protective features........................................................................ 7-51

7.3 Control elements........................................................................... 7-51

7.4 Generating enables ...................................................................... 7-52

7.4.1 Information on control signals.................................................... 7-52

7.5 Folding function............................................................................. 7-54

7.5.1 Access protection ...................................................................... 7-54

7.5.2 Watchdog timer ......................................................................... 7-55

7.5.3 Dynamic valve monitoring ......................................................... 7-56

7.5.4 Valve control .............................................................................. 7-57

7.6 Information on functionality........................................................ 7-59

7.6.1 Conditions for fast downward movements ................................ 7-59

7.6.2 Tilt monitor ................................................................................. 7-59

7.6.3 "Moving" and "distance" access protection ............................... 7-60

7.7 Application examples and procedural functions ........................... 7-61

7.7.1 Single operator control with foot switch..................................... 7-61

7.7.2 Multiple operator control with foot switch .................................. 7-62

8 General functions ........................................................................... 8-63

8.1 Single operator/multi-operator control .......................................... 8-63

8.2 Single operator control via 2 foot switches and

operating error monitor .............................................................. 8-64

8.3 Output assignment (0.5 A)............................................................ 8-65

9 Operating and fault messages ...................................................... 9-67

10 Documentation.............................................................................. 10-71

10.1 Documentation of inputs (notes)................................................. 10-71

10.2 Documentation of outputs (notes)............................................... 10-72

10.3 Documentation of system data ................................................... 10-72

1-9

1 General information on parameterization software

The parameterization masks are arranged in such a way that it is immediately apparent to the user whether one-channel or two-channel signals are required to achieve the necessary safety level.

• For one-channel signals, the left side of the mask contains a terminal block

field in which block X3 or X4 can be selected. The required pin assignment can also be entered.

• For two-channel signals, terminals X3/X4 are automatically preassigned. The

only data that can be entered is the pin assignment. The pin assignment is identical for blocks X3 and X4!

The entered value is saved by pressing the Accept button. A green dot appears to the left if the entry has been saved properly and completely.



1

General information on parameterization software

1-10 SIMOTION Safety Unit (AP) - Edition 06.2003

Notes

2-11

2 Operating modes

2.1 Selecting the operating mode

Definition

Up to 6 operating modes can be parameterized. A "1 of 6" selection indicates the presence of a short circuit and a faulty multiple selection of operating modes. The use of test voltages, i.e. the selection of clocking via the internal sensor supply, is therefore not required for the mode selector.

Parameterization

The assignment of the connection terminals to the operating mode is shown in Figure 2-1, left section.

Figure 2-1 Operating modes

2

Operating modes

2-12 SIMOTION Safety Unit (AP) - Edition 06.2003

Example of wiring

L+

1

23456

7

123456

-S

X4.3X3.3 X3.4 X4.4 ...

Figure 2-2 Mode selector

2.2 Operating modes and press cycles

The 6 operating modes presented below can be selected in the parameterization mask in the right section of Figure 2-1.

Please note the following rules:

• Each selected operating mode is associated with an enable mask, e.g. for start

and stop conditions, an external start and additional safety devices.

• The entries that are adjustable for a particular operating mode are indicated by

a white field. They have been assigned default parameters and are indicated by a black dot.

• If conditions are being pre-assigned at additional terminals (start enables,

external start, etc.), an additional window for selecting the terminals automatically appears in the mask.

• Irrelevant entries are grayed out and cannot be activated.

• An operating mode type can also have several parameterizations if, for

example, the number of safety devices varies.

• The Setup operating mode (operating mode 1) is predefined and cannot be

modified.

Operating modes

2-13

2.2.1 Setup (operating mode 1)

Definition

The press will only move while the two-hand buttons are being pressed. This is also the case when the ram is moving upward. The press automatically comes to a standstill at the end of each stroke (TDC). The operating elements must be deactivated before a new start can be initiated.

A triple-action stop during a single stroke is not required with this control unit since the Setup operating mode reaches the same level of safety as, for example, the single stroke mode.

Parameterization

Figure 2-3 Enabling of operating mode 1

Note on "Safe motion" parameterization

When parameterizing "Selected safety device can be disabled via terminal", other suitable safety measures must be effective for the specific machine when this parameter is activated.

Operating modes

2-14 SIMOTION Safety Unit (AP) - Edition 06.2003

2.2.2 Single stroke (operating mode 2)

Definition

Pressure must be maintained on the two-hand buttons for activating the ram until the hazardous closing movement is completed (just prior to the BDC). The press then automatically moves back to the TDC and comes to a standstill. The press can also be activated using a foot switch. In this case, however, suitable safety measures (safety gate, light curtain) must be implemented that either make it impossible to reach into the hazardous area with the hands during a closing movement or that cause the machine to come to a standstill in the event of such an action. The same applies if the "Transfer through input terminal" parameter is selected for the "Transfer of START command".

Parameterization

Figure 2-4 Enabling of operating mode 2

Operating modes

2-15

2.2.3 Continuous stroke (operating mode 3)

Definition

This operating mode requires the implementation of suitable safety measures and an automated feed and removal of parts. After a start pulse, the press continues running until it is brought to a standstill by a stop signal.

Depending on the selections made in the enable mask, the press either stops in the TDC or comes to an immediate standstill.

Parameterization

Figure 2-5 Enabling of operating mode 3

Operating modes

2-16 SIMOTION Safety Unit (AP) - Edition 06.2003

2.2.4 Changeover (operating mode 4)

Definition

This is not a production mode type. The production mode is deactivated in this operating mode. In order to carry out an automatic changeover, e.g. to a new production part, a standard control unit can be used to access the clutch and brake (e.g. to adjust the stroke height).

Note

In this operating mode, the machine manufacturer must ensure that it is not possible to initiate a hazardous stroke when the press is controlled by a standard control unit. Safety measures may have to implemented to safeguard the machine.

Parameterization

Figure 2-6 Enabling of operating mode 4

Operating modes

2-17

Figure 2-7 Valve control of mechanical press (mechanical operation)

Figure 2-8 Valve control of hydraulic press (hydraulic operation)

2.2.5 Automatic continuous stroke (operating mode 5)

Definition

This operating mode differs from the continuous mode in that two steps are required to enable the machine for the first time:

• First, the automatic continuous stroke mode is enabled using the two-hand

control.

• Then the machine can be started by an external enable signal via the terminal.

Note

• If at the time of the two-hand activation there is an external enable signal, the

machine starts immediately.

• In this mode, the two-hand control acts as a command device only (not a

safety device). The operator must be protected by additional safety equipment, e.g. ESPE!

Operating modes

2-18 SIMOTION Safety Unit (AP) - Edition 06.2003

Operating instructions

• The machine stops at the next BDC when the external enable signal ceases. It

can be restarted with this signal alone within the next 30 s.

• Two switching steps (see "Definition") are always required when a restart does

not take place within the next 30 s or when a safety device or a continuous stroke stop (BDC or immediate stop) was activated.

Parameterization

Figure 2-9 Enabling of operating mode 5

Operating modes

2-19

2.2.6 Single-stroke ESPE (operating mode 6)

Using a light curtain to control the press is described in the Control Elements chapter.

Parameterization

Figure 2-10 Enabling of operating mode 6



Operating modes

2-20 SIMOTION Safety Unit (AP) - Edition 06.2003

Notes

3-21

3 Safety components

The contacts can be wired directly in the control unit. Additional contactors or relays are not required. The following cyclical monitoring procedures are performed in the program:

• Short circuit monitor between the two mutually isolated signal circuits.

• Discrepancy check of whether both switch-off circuits carry out a signal

change when the button is activated. The change between the two signals is also monitored over time. The only elements that do not adhere to the preset discrepancy time are the safety gate components.

The following components are available and can be combined as required:

• EMERGENCY OFF with restart inhibit (4x)

• EMERGENCY OFF without acknowledge (4x)

• Engaging lock (without acknowledge) (2x)

• Safety guard with restart inhibit (4x)

• Safety guard without acknowledge (4x)

• Safety gate with manual acknowledge (3x)

• Safety gate without manual acknowledge (3x)

Light curtains that are only used in the safety mode can be connected to the existing safety guard components. For a description of their mode of operation, see the Operating Elements chapter.

The parameterization of light curtains that are switched in safety and clock mode is presented in the Operating Elements chapter.

Comments

• The EMERGENCY OFF that is activated in the parameterization is always

active for the entire control unit. It can, however, be deactivated for individual operating modes (e.g. useful when creating different EMERGENCY OFF circuits).

• The same applies to the engaging lock and the safety gate and safety guard

components. In this case, the safety devices can be specifically deselected in the operating modes in which they are to be inactive.

Note

Without the implementation of additional safety measures, safety gates and safety guards without a restart inhibit are not suitable for hazardous areas that

can be walked through.

3

Safety components

3-22 SIMOTION Safety Unit (AP) - Edition 06.2003

3.1 Parameterization of safety components

Figure 3-1 EMERGENCY OFF safety functions

Figure 3-2 Safety guard safety functions

Safety components

3-23

Comment

If the EMERGENCY OFF or the "Safety guard with restart inhibit" is selected, a flashing fault lamp or, optionally, a separate alarm lamp (parameterizable) indicates that the system is ready for acknowledgement.

Figure 3-3 Safety gate safety functions

Note on safety gate with manual acknowledgement

Both contacts must be activated to open the safety gate. If only one contact is activated and reclosed, an alarm is output with a continuous light. In this case, both contacts will then have to be opened and reclosed.

The continuous light goes out after both contacts have been properly opened. When the contacts are closed, a flashing signal indicates that the safety gate is ready for acknowledgement. After the acknowledge button has been activated, the machine is again ready to be started.

For safety gates without acknowledgement, there is no display if only one contact is opened and reclosed due to an operation error. The problem is eliminated by completely opening and reclosing the gate.

Figure 3-4 Engaging lock safety functions

Siemens Simotion TM 121C Applications Manual

Specifications and Main Features

Frequently Asked Questions

User Manual