Wieland Electric samos User Manual

BA000256 12/2012 (Rev. I)

Multifunctional Safety Switching Device

Modular Electronic Safety System with Coding

Contents

1 Contents

samos

Safety System

3 About this Manual

41 Terminal Assignment

Assignment of outputs to inputs

Safety-related information, Conditions of installation

5 Safety Function Blocks

Features of the Safety System

6 samos Overview

System and components

7 Coding of modules 9 Summary Analysis and samos

Guide

Risk assessment and risk minimization

11 System Functions

Overview of system functions

Relay Output Modules SA-OR

42 Relay Output Module Data

Connection diagram, Notes, Technical data

44 Interfaces and Operation

Interfaces, Meaning of LEDs

Glossary

45 System Functions

Safety inputs, OR, Muting, Bypass, Reset, Feedback circuit monitoring, Enable, Output, Communication, Diagnosis

Base Modules SA-BM

13 Base Module Data

Connection diagram, Notes, Technical data, Function diagrams

17 Interfaces and Operation

samos

and IEC/EN 61508/EN 62061

Definition of safety integrity level and demand rate

50 Characteristic safety values 52 Applications and Pictograms

Interfaces, Meaning of LEDs, First installation and Accepting configuration, Handling errors

19 Input Circuit Functions

Overview of applications, Evaluating input circuits, General structure and signal flow, OR function, Muting

Logic Functions

53 AND Links

of safety inputs, function groups, function blocks

55 OR Links

of safety inputs

function, Special functions

24 Control Circuit Functions

Starting inhibit, Restarting inhibit, Reset function, Off delay,

Applications

58 Application Examples

A253, A254, A267, A258, A259, A268

Retriggering, Control inputs

28 Function Blocks

Applications, Terminal assignment, Overview

Annex

63 Anti-Manipulation Measures,

Error Codes

64 Installing / Removing

Input Module SA-IN

32 Input Module Data

Connection diagram, Notes, Technical data, Function diagrams

35 Interfaces and Operation

Interfaces, Meaning of LEDs

36 Input Circuit Functions

Evaluating inputs, Standard functions, Logic functions, Expansion function

Screw terminals pluggable, Spring force terminals pluggable, Switch cover SA-COVER

66 Dimensions 67 General Technical Data

Data, Approvals

69 Overview of Devices / Order

Numbers 71 Index 74 Configuration List

___________________________________________________________________________

Validity of the manual as from module revision:

 SA-BM : F-01  SA-IN : F-01  SA-OR : D-01

bout this manual

2 About this manual

About this manual

What Does This Manual Describe?

This manual provides an overview of the functionalities of the modular samos safety system as a safety processing unit for plant and machines. It describes the individual modules and the way they function together in the system as a whole with safety sensors, switches and actuators.. As well as the specific configurations of switches and terminals, the fundamental methods by which the functions work are also explained in detail. Relevant application examples help you to use samos in practice, especially in hierarchical safety zones. The manual also includes installation information, instructions and rules that must be observed, technical data and interface descriptions, error information, error handling and instructions for risk analysis.

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Who Is This Manual For?

This manual contains the information required for proper use of the devices described in it. The system and its modules must only be installed by properly qualified personnel. The applicable national norms and regulations must be observed (in Germany VDE). For that reason this manual is aimed at technically qualified personnel such as mechanical and electrical engineers, safety reps, PLC programmers, enclosure makers, electrical fitters, machine and plant operators, setup staff, and service and maintenance personnel.

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Safety-related Information

The “Caution” symbol is used at various places in this manual.

“Caution” indicates a potentially dangerous situation or state that could – if not avoided – lead to minor or medium injury. “Caution” is also used to warn against uncertain operation and potential misuse. “Caution” is also used to indicate situations where property damage could occur without causing personal injury.

Please observe the following safety rules:  Only trained professional electricians may install, startup, modify, and retrofit this

equipment!

 Disconnect supply voltage to the equipment / system prior to starting any work! If

installation or system errors occur, line voltage may be present at the control circuit in devices without DC isolation!

 Observe all electrical safety regulations issued by the appropriate technical authorities or

the trade association.

 Opening the housing or any other manipulation will void the warranty.  If the device has been subjected to improper or incorrect use it must no longer be used,

and the guarantee loses its validity. Impermissible conditions include: strong mechanical stress, for example through a fall, or voltages, currents, temperatures or humidity outside of the specifications.

 Before starting up your machine/plant for the first time, please be sure to check all the

safety functions according to valid regulations, and observe the specified test cycles for safety equipment.

 Take the following safety measures prior to installation, assembly, or disassembly:



Disconnect supply voltage to the equipment / system prior to starting any work!



Lockout/tag the equipment/system to prevent accidental activation!



Confirm that no voltage is present!



Ground the phases and short to ground!



Protect against adjacent live components using guards and barriers!

bout this manual

Protection type according to EN 60529. Limited contact protection! Housing/terminals: IP 40 / IP 20. Finger-proof (DIN EN 50274).

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Proper Use

The samos safety system described in this manual serves to protect people, the environment, the machine and the material according to the valid EU occupational health and safety directive 89/391/EEC, the machinery directive 2006/42/EC, the use of work equipment directive 89/655/EEC as well as the statutory regulations and standards applicable in other countries (e.g. USA with OSHA 29 CFR 1910.xxx safety standards, OSHA 3067 concepts and technologies for machine safety and NPFA 70, NFPA 79, ANSI B11 product liability).

If the safety system is properly maintained and used for its intended purpose it will not normally cause damage to property or present health hazards. However, improper configuration, installation, maintenance or operation of the system or machine, ignoring the instructions in this manual, or intervention by insufficiently qualified personnel may result in connected actuators (such as motors, hydraulic units, etc.) becoming a source of danger.

The safety system is a state-of-the-art product and is manufactured to recognized safety requirements. All the same, its use can cause danger to the health and safety of operators and others, or damage machines, systems or other property.

The safety system must only be used in perfect technical condition for its intended purpose, with attention given to safety and danger, and observing the information and instructions given in this manual and the operating instructions supplied with the devices. Correct transport, storage, installation, operation and maintenance of the system are all prerequisites for smooth and safe operation of the control system. Malfunctions, in particular those which may affect safety, must be immediately resolved.

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Conditions of Installation

 The devices must be installed in an enclosure with at least IP54 protection.  The devices must be installed on a mounting rail (EN 50022-35).  The mounting rail must be connected to protective earth (PE).  The system and the system inputs must always be powered by a common power supply

unit.

 The external power supply unit must comply with the regulations for safety and

protection extra low voltage systems (SELV, PELV acc. to IEC 60536) and DIN EN 50178 (Electronic Equipment for Use in Power Installations).

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Exclusion of Liability

The application examples and circuitry suggestions have been developed to the state of the art and our best knowledge. Nonetheless, Wieland cannot accept liability for the correctness and completeness of the information. The information does not have the legal status of guarantees or guaranteed qualities.

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samos Safety System

3 samos Safety System

Safety Function Blocks

The

samos

safety system consists of a small number of multifunctional modules and an

optional field bus coupler. This you add modules as the safety task grows. Sensibly coordinated, combinable function blocks take the place of singular solutions and isolated specialists.

samos

 combines all the safety sensors that monitor your machine/plant safety singly, in

combination or all together.

 replaces special devices for monitoring – for example – emergency stop, position

switches, two-hand switches and light barriers.

 allows you to create dependent/independent safety zones.

fety modular system is, as the name suggests, modular –

Even a single 22.5 mm base module can operate independently and replace two safety switching devices. Two

samos

modules replace up to 6 safety switching devices. In the maximum configuration you can monitor up to 50 dual-channel safety sensors – up to EN ISO 13849-1 PL e / category 4 or EN 61508/EN 62061 SIL 3.

Handling and function will be familiar from conventional safety switching devices. You can set all the safety functions simply using a screwdriver – no programming software – and read them off on the device. If required, you can expand the inputs or outputs using additional modules.

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Functions

 Emergency stop, with or without cross-circuit monitoring  Safety door monitoring, also with coded electromagnetic switches  Controlled stopping with settable off delay up to 5 minutes, with or without retriggering  Light barrier monitoring with testable/self-testing sensors (non-contact safety device type 2

and 4)

 Position monitoring with testable inductive sensors (PDF)  Static valve monitoring  Two-hand applications to EN 574, type IIIA and IIIC  Jog mode  4-wire switching mat monitoring  Muting and bypass  Enabling function for cascading and grouping  Automatic or manual Reset, starting and restarting inhibit

samos Safety System



The samos System









Configuration

The samos modular safety system is a programmable electronics PE) element of an electrical/ electronic/programmable electronic system (E/E/PES) as described in IEC/EN 61508/EN 62061. The system comprises base modules, input and output modules, and bus coupler modules.

The minimum configuration is one SA-BM master base module. You can connect other active safety modules, passive safety modules and bus coupler modules to the master to create a system.

 Up to 12 active safety modules (SA-IN input modules)  Additionally up to 4 SA-OR passive relay output modules  Additionally 1 bus coupler module

All SA-BM base modules can be expanded with SA-IN inputs and SA-OR relay outputs. The system groups formed in this way are functionally autonomous and can be wired together as required.

Structure

In a system the master base module is at the left-hand end, the optional bus coupler module at the right-hand end. The modules are connected by means of a connector with proper coding, integrated in the housing. The 24 V power supply is fed in through the master base module.



The coded modules of the samos system

samos Safety System

Accordingly to the applications in a samos overall system hard-coded system groups can be assembled, whose codings are different and whose logical functions are independent from each other. Every system group of the overall system consists of a distinctly coded basic module, which can be amended with input modules of the same coding.

Example of one system group

Basic module

Master (SA-BM-S1)

Input module

(SA-IN-S1)

Input module

(SA-IN-S1)

Output module

Bus interconnection

System group 1

More safety via coding

In our enhanced

samos

IN) is hard-coded according to its system group (1-3) and cannot be applied in other system groups. Equally coded basic modules cannot be stuck together. Modules SA-BM, and/or SA-IN in combination with Germany in an overall system with two or more basic modules of the same coding and at least one input module, prior to the 17th of April in 2012 (till construction level E-01) mustn't be applied without approval of the patentee of the German patent 100 20 075. (more information at http://register.dpma.de/DPMAregister/pat/einsteiger?lang=en)

module

system, every basic module (SA-BM) and every input module (SA-

samos

system modules, which have been delivered in

Coding

samos Safety System

Master base module (Coding 1)



The master base module is the obligatory basic element of the samos system. On its own it functions as a complete safety switching device for monitoring up to 2 safety circuits. It offers 8 function blocks for inputs and logic functions (set on rotary switch on front), 8 inputs and 4 wear-free semiconductor safety outputs. The system configuration is saved in the master. Errors and unauthorized alterations cause safety shutdown of the whole system.

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Input module (Coding 1)



The input module adds additional input circuits or logic functions to a base module on its left. The module has two function groups, A and B, each with 4 inputs. You have to set one of 10 functions for each group using the rotary switch.

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Relay output module



The output module adds potential-free output safety circuits with positively driven relay contacts to expand the base module outputs. The module does not function as a slave on the internal safety bus of the samos system. Instead it is integrated in the functions via external wiring. It can therefore be positioned anywhere between the master base module and the (optional) bus coupler module.

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Bus coupler module



The bus coupler module for the Profibus-DP field bus allows system information for diagnosis purposes (input levels, error and status information) to be sent to other bus stations (e.g. higher-order controller). There is a separate manual for the bus coupler modules (see page 70).

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

samos Safety System

Summary Analysis

Risk assessment and risk minimization for plant and machines

This simplified description outlines the basics of risk analysis for planners and designers. For more detailed information please consult the relevant norms.

Determining the limits of a machine



 Proper use  Spatial limits (transport, assembly, installation, power supply, material feed)  Temporal limits (working life, servicing intervals, ...)

Identifying dangers



 Crushing, shearing, electric shock, poisoning, burns, ...

Assessment of all danger situations



 Operator-machine relationship  Operating states  Servicing, maintenance, disassembly, disposal  Wear  Predictable misuse, ...

Risk assessment



 Extent of damage  Persons in danger zone  Probability of danger occurring  Possibilities of avoiding/limiting damage

Select measures for risk minimization



 Design measures  Technical measures  User information, warnings, operating hints, ...

Determine residual risks



 Test effectiveness of safety measures  Validate acc. to EN ISO 13849-2

If necessary introduce additional measures



to reduce residual risk to an acceptable level.

Risk analysis e.g. as per EN ISO 12100

Risk assessment and minimization e.g. as per EN ISO 14121

samos Safety System

You can find examples for logic functions on page 53ff.

You can find an overview of applications on page 19 and 36.

You can find descriptions of input modules on page 32ff.

You can find descriptions of base modules on page 13ff, relay output modules on page 42ff.

You can find examples for logic functions on page 53ff.

You can find the descriptions of reset behavior on page 24ff.

Bus coupler modules are described in a separate manual. You can find the order numbers on page

70.

samos

Guide

The technical measures for reducing the risk of dangerous states and damage to the machine or material include the electrical equipment. The required level of risk minimization and consequently the requirements of the safety-related parts on the controller are determined for example according to EN ISO 13849-1 (here controller category.

Creating safety zones In risk analysis the machine is often divided into different safety zones, which may have different risk potentials. The zones are linked by safety logic functions so that only the necessary parts of the machine are shut down when a safety event occurs.

Selecting safety devices and safety functions

for monitoring the safety equipment and safety zones. Selection of stop category 0 and/or 1 (EN 60204-1).  Select function blocks and input circuit functions for the application on the samos

base module.

How many safety sensors and safety circuits must also be monitored?

 Select input expansions.

How many additional safety outputs are needed?

 Select outputs on base module (semiconductor)

or output expansion (relay contacts)

Link safety zones

and function blocks in the samos system.

Select Reset behavior

for powering up and after safety event.

Select optional field bus function as diagnosis function.

samos Safety System

System Functions

The samos safety system is for monitoring sensors as part of the safety equipment of machines. The safety function (e.g. an emergency stop function) is implemented by switching outputs Q on or off safely in relation to the state of the sensors on inputs I, EN (enable) and S (Reset condition). Switching these outputs on/off prevents dangerous states occurring in the plant/ machine.

The safety function is made up of a chain of logically linked functions. The input modules communicate with the associated base module (on the left) via the internal safety bus (SBus). The relay output modules are not integrated directly via the SBus in the samos safety communication system. However, indirect monitoring is possible via the feedback circuits.

Input circuit function



The input circuit function logically links input signals for further processing. There are different methods for activation:

 Input circuit function single-channel via NC contact  Input circuit function with dual-channel equivalent activation,

with/without cross-circuit monitoring, with/without synchronous time monitoring

 Input circuit function with dual-channel non-equivalent activation,

with/without cross-circuit monitoring, with/without synchronous time monitoring

 Two-hand function with activation by one NO contact per hand (EN 574, IIIA)  Two-hand function with activation by NO/NC combination for each hand (EN 574, IIIC)  Dual-channel equivalent activation by semiconductor

Safety inputs

samos Safety System

Muting

Bypass

Reset

Enable

Safety outputs

Diagnosis

OR function and muting function



The off signal of an input function can be bridged with an OR signal. For example, in setup mode a safety function can be bridged using an enabling button; an OR operation can also link two safety functions.

The muting function is a special case of the OR function. For example, muting sensors allow a conveyor belt to transport material through a light curtain by briefly bridging the light curtain function.

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Bypass function



With a bypass signal the OFF signal of a Reset function (see page 47) can be changed into an ON signal in the base module. Bypass is used when the system is to be switched on after a power shutdown but a light barrier is obstructed by material. Bypass cancels the safety function of the safety device, allowing the blockage to be cleared. In normal operation the muting function bridges automatically (see above).

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Reset function



The Reset function defines which (Reset) conditions must be fulfilled if, for example, an ON signal is to be passed on to the Reset function output. All input and muting signals from the base module and the associated input modules, and the bypass/OR signals from the input modules are logically linked (AND/OR). The terminal configuration with bridges and feedback circuits is also evaluated.

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Enable function



The enable function enables the ON signal in the Reset function if there is H-level on the EN input. The H-level for enabling can be generated, for example, by a semiconductor output Q applications (EN ISO 13849-1) the module that generates the enabling signal must be in the same enclosure. If the EN input is open or on L-level the following Q outputs are locked.

on the base module for logic operations or a PLC output. For category 4

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Output function



The time behavior of the safety ON/OFF signal is defined in the output function. Depending on the function, you can set a off delay for outputs Q3 or Q3/Q4 between 0 and 5 minutes (depending on module version).

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Communication

With the communication function system data is exchanged between the different modules in a system via the internal safety bus (SBus).

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Diagnosis and display function

The diagnosis function allows internal system data to be provided to external systems via a diagnosis module or bus coupler module.

semiconductor

NOTE

For detailed explanations of system functions and other hints and examples please refer to the glossary on page 45ff.

4 SA-BM Base Module

Base Module Data

 SA-BM-S1

SA-BM-S1

 The controller category (EN ISO 13849-1) or SIL (EN 61508/EN 62061) depends on the

external circuitry, the wiring, the choice of control devices and their location on the machine.

 In the event of single-channel control of a contact extension (e.g. SA-OR) through a base

module (SA-BM), category 4 according to EN ISO 13849-1 can be achieved if both devices are installed in the same enclosure.

 The SA-BM must be protected with a 6 A fuse of utilization category gG or a 6 A (4 A)

circuit-breaker (tripping characteristic B or C).

 The rotary switches for selecting function and time must only be adjusted when power is

off.

 Never connect or disconnect modules while the operating voltage is switched on.  If external contactors or relays are connected, the feedback circuits (NC contacts) must

be connected to the base module.

 When inductive loads are connected (e.g. valves, contactors) a suppressor circuit must

be set up (e.g. RC combination).

 Internal samos module addresses are assigned automatically when the system starts up.

Manual addressing is unnecessary (and not possible).

 The safety system must be installed in an enclosure with at least IP 54 protection.  Each base module forms a system group within the overall system (sometimes together

with associated input expansion modules; see diagram on page 8).

Master base module

The SA-BM master base module is the obligatory module of the samos system. On its own it functions as a complete safety switching device for monitoring up to 2 safety circuits.

Connection diagram

Notes

SA-BM Base Module

SA-BM technical data

* For the times, see the function diagram at the end of the table

The sum of currents, which are drained from the outputs X1, X2 of all Base modules to supply external sensors, may not exceed 600 mA!

-BM-S1

Function Function display 11 green LEDs, 1 red LED Controls 2 10-position switches, 1 1-position button Terminals Plug-in terminals with screws / spring force Max. number of modules / status in system 1 / SBus master Max. number of parallel-connected module inputs

that can be controlled from one module

In or S

output X

or Qn

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Power circuitry (

Operating voltage U Residual ripple V Rated power, DC Peak current I Ready time t Device fuse

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Input circuit (I1..I4, EN, S1..S3) Min. Typical Max.

Input voltage, U (LOW) Input current, I (LOW) Cyclical peak input current, I Input capacitance, C Input resistance, R ON period* t OFF period* t Break time of U Break time period Synchronous time t Synchronous time t Duration of operation Reset inuts S1, S2

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Output circuit (

Output voltage Output current Wire capacitance, C Wire resistance, R Type of outputs / short-circuit behavior Semiconductor / absolutely short-circuit-proof

Base module in the samos system

A1, A2

) Min. Typical Max.

, DC 19.2 V 24 V 30.0 V

3.0 V

1.8 W

(after connecting UB) 10 s

25 A

6 A (gG)

(HIGH)

13.0 V

30.0 V

–0.5 V

(HIGH)

2.4 mA

–2.5 mA

E,Peak

(test pulses) 1.0 ms

15 mA 200 nF

70 ms

> tAN

3.0 mA

8 k

20 ms

(Function 2)

(Functions 4, 5.2)

1500 ms

500 ms

50 ms 5 s

X1, X2

) Min. Typical Max.

18.0 V 30.0 V 150 mA

500 nF

100 

5.0 V

3.8 mA

2.1 mA

Output circuit (

Output voltage Output current (with U Total current (see diagram)

Q1..Q4

) Min. Typical Max.

= DC 24 V) res./ind. 2.0 A

SA-BM Base Module

18.0 V 30.0 V

4.0 A

SA-BM technical data

Diagram "Total current vs. Temperature"

Inductive switching off energy E (E=0,5*L*I²) Settable off delay Q3/Q4 or Q4, t

(depending on device version) Test pulse width, t Test pulse period, t Load capacitance, C

TI,HL

TP,HL

Conductor length (single,  1.5 mm

370 mJ 0 / 0.5 / 1 /1.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 s 0 / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 50 s 0 / 0.5 / 1 / 1.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 min

500 μs

32 ms 80 ms

)

500 nF

100 m

Type of outputs / short-circuit behavior Semiconductor / absolutely short-circuit-proof Parallel connection of outputs not allowed

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Input test tTI, typ. tTD, typ. tTP, typ.

Test pulse width* t Test duration** t Test pulse period t

;

Function 3.1, 7, 8 Function 3.2 (BWS type 2) Function 3.2 (PDF sensors) Functions 1, 2, 4, 5, 6, 9

no test pulses 12 ms 52 ms 12 ms

20 ms 70 ms 20 ms

40 ms

384 ms

40 ms

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Response times Min. Typical Max.

Response time*** t Functions 3.1, 7, 8 Function 3.2 (BWS type 2) Function 3.2 (PDF sensors) Functions 1 (except safety mat), 2, 4, 5.1, 6, 9 Function 1 (safety mat) Function 5.2 DISABLE (via EN input) OR off to Qx off Function 3 (MUTING off to Qx off) EN off to Qx off

(normal operation)

13 ms 32 ms 79 ms 20 ms 38 ms

29 ms 13 ms 9 ms 65 ms 13 ms

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Safety parameters at ambient temperature TB +55 °C

PFD 1.7 x 10 PFH 7.9 x 10-9 h SFF 96 % DC 93 % MTTFd 158 years

-5

-1

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General data Min. Typical Max.

Enter button ON period Isolation Power circuitry – input circuit Power circuitry – output circuit Input circuit – output circuit Weight 0.16 kg General technical data See page 65. Order numbers See page 69.

3 s

no no no

* Signal changes are not detected during the test pulse.

** Signal changes from HIGH to LOW are not detected during the test pulse.

For the times see the function diagrams at the end of the table.

*** The response time tAN is the time between the OFF signal arriving at the input terminals and the outputs actually being shut down (in normal operation).

The response times of any assigned input modules must also be taken into consideration. See input module data, page 33.

For information on safety-related parameters, see glossary p. 49

SA-BM Base Module









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Function diagrams

tTI : Test pulse width tTD : Test duration tTP : Test pulse period

tE : ON period tA : OFF period QIN: see page 47

Input test function diagram (with cross circuit monitoring)

Output X1

Output X2

Input I1/I3

Input I2/I4

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Input circuit function diagram (equivalent activation)

Input I1

Input I2

QIN (good state)

  



approx. 0.5

 t



 t





approx. 0.5







Interfaces and Operation

SA-BM Base Module

Clamps

A1, A2

X1, X2

EN S1, S2, S3

I1, I2, I3

Q1, Q2, Q3 SBus

Voltage supply of the basic module and the corresponding extension module (Plus voltage at A1) Outputs only for voltage supply of inputs of the module or rather the control of the sensors Input for enabling the outputs Control inputs for the configuration of mode of operation and the connection of reset buttons / feedback circuits Inputs for the connection of signal transmitters / sensors Outputs for the controlling of actuators 10-pin connector for safety bus

- SA-BM: just nut (coded)

Push-buttons

FUNCTION

Q3/4 DELAY

ENTER S1, S2, S3

LEDs EN, S1 .. S3, I1.. I4

(green) PWR (green) Q1/2, Q3/4 (green)

FLT (red)

8-staged torque switch for adjustment of an input circuit function 10-staged torque switch for adjustment of the fall-back delay time Button for the assumption of system configuration (just SA-BM)

Indicators of according inputs

Voltage supply Switching status of the semiconductor outputs Indicator of flawed operating modes (see FLT error codes page 63)

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 PWR on  I1-I4 on  I1, I2 flash simultaneously  I3, I4 flash simultaneously  I1, I2 flash alternately  I3, I4 flash alternately  I1 oder I2 flashes

 I3 oder I4 flashes

 EN, S1..S3 on  S1..S3 flashes  Q1/2, Q3/4 on

 FLT off

Power supply to module electronics is on H-level on corresponding input Cross-circuit between I1 and I2 Cross-circuit between I3 and I4 Sequence error on I1, I2 Sequence error on I3, I4 Synchronous time error. The input that flashes is the one that achieves good state too late. Synchronous time error. The input that flashes is the one that achieves good state too late. H-level on corresponding input Feedback circuit open H-level on corresponding outputs, Q3/4 flashes during off delay time No fault states

Interfaces

Meaning of LEDs

SA-BM Base Module

Interfaces and Operation

Accepting configuration

NOTES

Handling errors

NOTES

There is a blank configuration list for copying inside the back cover.

Notes on downloading an online version on page 74.

First installation and Accepting the system configuration

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Manipulation, handling errors and operating errors during operation

Configurations can only be set or altered using the switches and terminals when the whole system is switched off, i.e. when there is no operating voltage on terminals A1/A2 on any base module. After the required functions and control circuit functions have been set on all the modules in the system (using the rotary switches and external circuitry on terminals S1, S2, S3 respectively), operating voltage must be connected while the ENTER button on the SA-BM base module is pressed and held. As soon as the FLT indicator starts blinking the ENTER button must be released within 3 seconds. Then the selected mode is saved in non-volatile form and active. If the ENTER button is pressed for longer than 5 seconds after the LED has started blinking, the FLT display will indicate a fault (blinking light).

 Terminals S1, S2, S3 serve not only to set the mode; they

can also be used for feedback-circuit monitoring of connected relays and contactors. This means that the terminal signals change during operation (opened contact). The set mode remains unaffected because it is only detected, checked and saved when the system is switched on or restarted.

 Because the relay expansion modules are not directly inte-

grated in the communication or diagnosis of the samos system via the internal safety bus, changes in their input/output circuitry are registered only indirectly via the feedback circuits.

 Manipulating the system configuration (e.g. operating a

rotary switch or adding or removing modules causes immediate canceling of enabling. To assist in setting the valid configuration the green PWR LED on the module changes from blinking to continuous when the respective switch position has been restored. A restart (switch off and on again) under the set Reset condition is possible when the former configuration has been restored. The ENTER key has no effect during operation.

 If the new configuration is to be adopted you have to go

through the “accept configuration” procedure described above.

We recommend keeping a record of the configuration with the documentation or in a clearly visible place in the enclosure. One way to check the system configuration is to output a checksum of the configuration data via a connected bus coupler module.

There is a separate manual for the bus coupler modules (see page 70).

Input Circuit Functions

Overview of possible applications and corresponding sensor connections

Sensor connection

Emergency stop / safety door

Single-channel NC

Emergency stop / safety door

Dual-channel equivalent NC

Cross-circuit monitoring

Emergency stop / safety door

Dual-channel three-wire equivalent NC

Safety door or valve

Dual-channel equivalent NC/NO

Coded electromagnetic switch on safety door

Dual-channel non-equivalent NC/NO

Access monitoring with self-testing sensors (e.g. outputs from light curtain type 4)

dual-channel single-ended positive switching

semiconductor

Access monitoring with testable sensors (e.g. type 2 light barriers) or potential-free contacts

Single-channel NC/semiconductor outputs

Position monitoring with testable inductive sensors (PDF)

Single-channel NC/semiconductor outputs

Two-hand control acc. to EN 574 IIIC or safety door

2x dual-channel non-equivalent NO/NC

Two-hand control acc. to EN 574 IIIA (not for press control)

2x single-channel NO

Jog mode max. 5 s (e.g. setup mode)

2x single-channel NO

Access monitoring with short-circuiting switching mats

Four-wire

AND operation

Enabling input for cascading and grouping

OR operation

Muting, OR, bypass for bridging safety functions for setup mode, clearing, alternative safety function

Application e.g. Module/

group *

3AB 7A/7B 8A/8B

1AB 5A 6A/6B 3AB 7A/7B 8A/8B 2AB 4

2AB 4

3AB 7A/7B 8A/8B

3AB 2

3AB 4

4AB 4

5B 2

1AB 3

In base module:

Sensor inputs:

Muting:

Bypass:

all function blocks input module

3AB

OR:

1AB, 2AB, input module input module

SA-BM Base Module

Overview of applications

Category

up to **

* Availability of applications/sensor connections in function blocks (1 to 8) and function groups (A, B).

See page 20.

** Maximum control category (depends on sensor, wiring and installation

Please also note the information on page 13.

SA-BM Base Module

Input Circuit Functions

Using the rotary FUNCTION switch on the front you can set 8 function blocks as single, combination or dual functions. On their own or in appropriate combinations these function blocks cover the main fields of safety application. Using terminal combinations you can set Reset behavior for manual/automatic Reset (page 24), off delay retriggering (page 25) and special functions (page 23). Switch positions 0 and 9 are without function and must not be used.

 Single functions 1 to 4

The input circuits of function groups A and B act jointly on output circuits Q1 to Q4 (exception: function 3 with Q3 as muting lamp / Reset required output). In functions 1 and 2 settable off delay and retriggering act jointly on outputs Q3 and Q4; in function 3 only on Q4; in function 4 no off delay can be set.

 Combination functions 5 to 7

The input circuits of function group A act directly on all output circuits Q1 to Q4; the input circuits of function group B act on output circuits Q3 and Q4.

They are AND-linked via the internal logic with input circuits A. This allows the safety concept found on many machines (two safety zones, one group subordinate) to be reproduced within the device. With the exception of function 5 (for which no off delay is settable) the settable off delay and retriggering act only on output Q4.

 Dual function

The input circuits of function groups A and B act separately on output circuits Q1, Q2 or Q3, Q4. This means that with one base module you can monitor two independent safety groups on a machine or system. Settable off delay and retriggering act only on output Q4.

Evaluating input circuits / function blocks

The diagram shows three different types of evaluation and the signal flows between inputs and outputs for single function 1, combination function 6 and dual function 8. The diagram is an excerpt from the function overview (see page 30).

together linked separate

General structure and signal flow using the example of function block 6

Select function block with

FUNCTION switch Function groups A and B

Applications for ... (e.g. emergency stop)

Controlled stopping possible via off delay

Sensor connection to input terminals I1/I2 (group A) or I3/I4 (group B) and supply terminals (clock outputs) X1/X2 With cross-circuit monitoring

OR link with input expansion

via SBus

AND link with input expansion internal safety bus (SBus)

Reset function configuring (starting/restarting inhibit) for function group

via terminal S1++ (Reset button, bridge or

feedback circuit)

Internal logic module, AND link between function group B and function group A

Reset function configuring (starting/restarting inhibit) for function group B via terminal S2

(Reset button, bridge or

feedback circuit)

OR link with input expansion

function via SBus

AND operation with ENABLE input EN for external group formation and cascading

Settable off delay for output Q4

Configuring of retriggering via terminal

(bridge or feedback circuit)

Safe semiconductor outputs Q1, Q2, Q3, Q4

SA-BM Base Module

Structure and signal flow

OR function

signals via

BYPASS

For input module

functions see page 32ff.

See control circuit

functions, page 24.

SA-BM Base Module

Input Circuit Functions

OR function

NOTE

OR function of function blocks 1 and 2

The off signal of an input function can be bridged with a OR signal, for example with an enabling button for setup mode. All the function blocks offer the possibility to link OR function signals on the SA-IN input modules (function 7, see page 39) with base module input signals by logical OR via the SBus.

Additionally, the single function blocks 1 and 2 offer use of the OR function on the base module itself via the two inputs I3 and I4. U

is expected as the signal. Generation of an ON

signal (H-level) depends on several functions (see "System Functions", page 46).

The OR function corresponds to an input circuit function with dual-channel equivalent activation without cross-circuit monitoring.

With a constant Ux signal+ on I3 and I4 and outputs Q1 to Q4 switched on, the outputs remain switched on regardless of the condition of the monitored safety sensors.

Muting function

NOTE

___________________________________________________________________________

Muting function of function block 3

The muting function is a conditional OR function, with which for example muting sensors can briefly bridge a light curtain function to allow material to be transported through a light curtain.

Muting is only possible on base modules with single function block 3, via inputs I3 and I4. U

is expected as the

signal. Generation of an ON signal (H-level) depends on several functions (see “System Functions”, page 46).

Output Q3 controls the corresponding muting lamp. If manual Reset is configured, the Q3 output additionally indicates via periodical ON/OFF (0.5 s/0.5 s) that Reset is expected at input S1 (Reset-Required).

The muting function in the base device corresponds to an input circuit function with dual-channel equivalent activation without cross-circuit monitoring.

With a constant Ux signal+ on I3 and I4 and outputs Q1, Q2 and Q4 switched on, the outputs remain switched on regardless of the condition of the monitored safety sensors. Muting of a safety function must not be dependent on a single signal!

The Ux signal can come from



supply voltage +UB,



the Qx semiconductor outputs on the base modules,



the OSSD outputs of muting light barriers (muting function only).

SA-BM Base Module

Special functions

Single function 3 and combination function 5 allow the use of special functions that are activated via a corresponding configuration on control circuit terminal S2.

 Single function 3

This function block offers the possibility of monitoring with an external test not only emergency stop, safety door and non-contact safety device type 4 applications (acc. to EN 61496-x) but also sensors (e.g. non-contact safety device type 2) and potential-free contacts. When the inputs are activated in this way the test function is activated by leaving terminal S2 unactivated. Otherwise S2 is bridged with the supply voltage (functions 3.1 and 3.2, see the “Control circuit functions” table on page 26 and the “Function blocks” table on page 28).



Testable sensors on X1-I1 (terminal S2 open): If time conditions are observed several sensors can be cascaded. Testable sensors such as non-contact safety device type 2 light barriers (EN 61496-x) have separate activation inputs on the transmitters. The activation inputs are used to test the sensor function with a low signal; the base module analyses the response signal generated by the receiver.



Testable sensors on X2-I2 (terminal S2 open): If time conditions are observed up to four sensors can be cascaded. The time conditions are matched specially for the GM 504S and GM 505S non-contact inductive sensors (PDF acc. to EN 60947-5-3) made by ifm. The connection is only available on base

modules, not on input modules. If one of the inputs I1 or I2 in not used a bridge must be installed to the respective control output.

Inputs I3/I4 can be used as muting inputs specially for use with light curtains. They are AND-linked to one another and OR-linked to the other inputs. The muting inputs only act if the corresponding internal output signals of the Reset function Q module were previously high (see also pages 22 and 46).

Output Q3 functions as a muting lamp output and as sigalling output „ResetRequired“. In this single function off delay for controlled stopping and retriggering act only on output Q4.

___________________________________________________________________________

 Combination function 5

Function group B can be used to monitor normal two-hand operation (synchronous operation of two buttons within 0.5 s, function 5.1*) or two-hand operation in jog mode (function 5.2*), e.g. for clearing a system. Here an output signal is only generated while the controls are being pressed. Jog mode is restricted to 5 s. Releasing both controls resets the time; repeated Reset is possible.

To activate jog mode terminal S2 remains unactivated. For other two-hand and safety door applications S2 is bridged with the supply voltage +U

The two-hand function with two NO contacts cannot be used for operating presses, because the safety level usually required (category 4) is not achieved. Function block 4 should be selected for press operation (EN 574 Type IIIC).

on the base

START

Special function type 2

Special function Testable PDF

Special function two-hand

* For the functions see also the "Control circuit function" table on page 26 and the "Function block overview" table on page 30).

___________________________________________________________________________

Single function 3.2 Combination

function 5.2

S2 and supply voltage unbridged

___________________________________________________________________________

Single function 3.1 Combination

function 5.1

Bridge between S2 and supply voltage

Configuration

+ 53 hidden pages

Wieland Electric samos User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual