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

49

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

2

A

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.

___________________________________________________________________________

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.

___________________________________________________________________________

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!

3

A

bout this manual

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

___________________________________________________________________________

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.

___________________________________________________________________________

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).

___________________________________________________________________________

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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4

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.

sa

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.

___________________________________________________________________________

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

5

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.



6

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

7

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.

___________________________________________________________________________

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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

8

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

9

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.

10

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

11

samos Safety System

OR

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

n

___________________________________________________________________________

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

n

NOTE

12

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

13

SA-BM Base Module

A

S

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

n

output X

or Qn

n

___________________________________________________________________________

Power circuitry (

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

___________________________________________________________________________

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

8

A1, A2

) Min. Typical Max.

, DC 19.2 V 24 V 30.0 V

B

3.0 V

SS

1.8 W

P

(after connecting UB) 10 s

ON

25 A

6 A (gG)

(HIGH)

E

13.0 V

30.0 V

–0.5 V

(HIGH)

E

2.4 mA

–2.5 mA

E,Peak

IN

E

A

(test pulses) 1.0 ms

E

15 mA 200 nF

70 ms

> tAN

3.0 mA

8 k

20 ms

(Function 2)

S

(Functions 4, 5.2)

S

1500 ms

500 ms

50 ms 5 s

X1, X2

) Min. Typical Max.

18.0 V 30.0 V 150 mA

L

500 nF

100 

5.0 V

3.8 mA

2.1 mA

14

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

N

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

RV

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

TI,HL

TP,HL

L

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

2

)

500 nF

100 m

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

___________________________________________________________________________

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

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

;

TI

;

TD

TP

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

___________________________________________________________________________

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)

AN

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

___________________________________________________________________________

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

15

SA-BM Base Module









A

___________________________________________________________________________

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

___________________________________________________________________________

Input circuit function diagram (equivalent activation)

Input I1

Input I2

QIN (good state)

  

t



TI

t

TD

approx. 0.5

 t

E



t

TP

 t



t



TI

t

TD

approx. 0.5



t

TP

t





TI

16

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)

___________________________________________________________________________

 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

17

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

___________________________________________________________________________

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).

18

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 **

2

4

3

4

* 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.

19

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

20

A

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

++

S3

(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.

21

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

x

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

x

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).

22

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).

.

B

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

23

SA-BM Base Module

Control Circuit Functions

You can set the Reset behavior of the base modules by configuring terminals S1/S2 and connecting Reset buttons, bridges or feedback circuits from external contactors/relays.

___________________________________________________________________________

Starting lockout

 ON

When power is switched on and the inputs are in safe state the base module expects a Reset (if restarting inhibit ON) or actuation on at least one input circuit (if restarting inhibit OFF).

NOTE

Restarting lockout

NOTE

Reset function

The enabling input does not act as an input circuit on the monitored sensors, i.e. the starting inhibit is not canceled by switching the EN signal off and on again. In combination functions 5, 6, 7 the starting inhibit in group B is not canceled by a signal change on the Reset function in group A; the signal change must occur in group B.

 OFF

The outputs switch on immediately after power is switched on and the inputs are in safe state.

___________________________________________________________________________

 ON

For resetting the safety function after a safety event the base module expects the Reset button to be operated. This realizes the required manual Reset after emergency stop (or switching back on after the safety zone has been entered and left again).

The Reset button must be operated for between 50 ms and 5 s. In combination functions 5, 6, 7 the restarting inhibit in group B must always be canceled by the Reset button.

In function 3, the expected Reset signal is indicated via blinking output Q3 (ResetRequired).

 OFF

Automatic Reset after safety event and restoration of safe state of inputs.

Elimination of a cross circuit is also immediately defined as restoration of safe state of inputs.

___________________________________________________________________________

The Reset function of manual and automatic Reset is defined by connecting terminals S1/S2 with supply voltage +U

or the module’s own clock output X1. (Here terminal S1 is

B

shown; in functions with separate evaluation of function groups A and B terminal S2 and clock output X2 are used equivalently for group B; see the table on page 26).

Starting inhibit Restarting inhibit  Manual reset

Reset button and feedback circuit between S1 and supply voltage

___________________________________________________________________________

 Automatic reset

Bridge or feedback circuit between S1 and clock output

NOTE

24

During the configuration phase (after power on) of manual Reset (with Reset button) the corresponding S output must be open or connected to a high-ohm output (e.g. a PLC). High or low potential will result in incorrect configuration.

SA-BM Base Module

pag

On the front of the base modules you can set a off delay of 0..5 s, 0..50 s or 0..5 min, depending on the device version. In position 0 release time = t Technical Data, page 15). Depending on the selected function block, the off delay acts on outputs Q3 and Q4, only on Q4, or on none of the outputs.

for undelayed outputs (see

R

Release delay

In functions without off delay (4 and 5) the delay switch must be set to 0 s, otherwise a fault will be indicated. Contactors and/or relay output modules connected to the delayed outputs are monitored separately via the feedback circuits (see “Control Circuit Functions”,

e 26).

___________________________________________________________________________

The behavior of off delay (retriggering) can be influenced by configuring terminal S3.



Bridge or feedback circuit between S3 and clock output X1

Auto mode (restarting inhibit OFF)



Manual mode (restarting inhibit ON)



Bridge or feedback circuit between S3 and supply voltage

Manual mode (restarting inhibit ON)



).

Auto mode (restarting inhibit OFF)



Auto mode (restarting inhibit OFF)



 ON

If the safe input state (“good state”) of the input circuits is reached again before the delay has expired, the delayed output circuits do not alter and the delay time is reset (

In restarting inhibit mode the Reset button has to be actuated additionally during retriggering time (

Example: In automatic mode the safety door is opened and the off delay starts for the corresponding enabling paths. If the door is closed again before the time has expired the enabling paths do not shut down and the machine continues to operate without interruption.

 OFF

Regardless of the state of the input circuits, the delayed output circuits open after expiry of the off delay time (

and ).



With automatic Reset and “good state” before expiry of the off delay time, the delayed output circuits shut down for 400 ms and then switch on again (

Example: In manual mode the emergency stop button is operated and the off delay starts for the corresponding enabling paths. If the emergency stop button is released before the time has expired and the Reset button operated, the enabling paths shut down anyway. The delay time must expire before enabling via the Reset input is possible again.





).

NOTE

Retriggering

EXAMPLE

25

SA-BM Base Module

Control Circuit Functions

Control inputs

The table provides an overview of the use of control circuit terminals in connection with the selected function block:

 S1 – Reset function (RESET), feedback circuit monitoring (FEEDBACK)  S2 – Reset function, special functions, feedback circuit monitoring  S3 – Retriggering (RETRIGGER), feedback circuit monitoring

NOTE

Control inputs S1 and S3 must always be connected.

Reset, feedback and retrigger

S1 S2 S3

FUNCTION RESET FEEDBACK* RESET FEEDBACK* RETRIGGER FEEDBACK*

Switch position not allowed

Man. /

Auto

Q1 / Q2 unactivated Q3 / Q4 Q3 / Q4

Man. /

Auto

Man. /

Auto

Man. /

Auto

Q1 / Q2 unactivated Q3 / Q4 Q3 / Q4

Q1 / Q2

Q1 / Q2 unactivated

+U

 FUNCTION 3.1**

B

open  FUNCTION 3.2**

Q4 Q4

No function

Q3 / Q4

NOTE

Man. /

Auto

Q1 / Q2

Man. /

Auto

Man. /

Q1 / Q2

Auto

Man. /

Q1 / Q2

Auto

Man. /

Q1 / Q2

Auto

 FUNCTION 5.1**

+U

B

open  FUNCTION 5.2**

Man. / Auto

Q3 Q4 Q4

No function

Q3 / Q4

* With off delay 0 s all the associated outputs of the group do not switch back on until all feedback circuits in the group are closed.

** For special functions see page 23.

26

Reset and feedback – activation of control inputs

S1 S2

S1

and

S2

SA-BM Base Module

Feedback via S1, S2

Without

FEEDBACK

With

FEEDBACK

Bridge or

feedback circuit

Q1/Q2

Without

FEEDBACK

With

FEEDBACK

Bridge or

feedback circuit

Q3

Manual reset (restarting inhibit)

Automatic reset without starting inhibit

___________________________________________________________________________

Retrigger and feedback – activation of control input

Retrigger OFF

Without

FEEDBACK

S3

With

FEEDBACK

Bridge or

feedback circuit

Q1/Q2 resp. Q4

S3

Feedback via

S3

Retrigger ON

In functions without cross-circuit monitoring (see “Function Blocks – Overview”, page 30) dynamic signals on outputs X1 and X2 are generated only during the configuring phase after power on.

During the configuration phase (after power on) of manual Reset (with Reset button) the corresponding S output must be open or connected to a high-ohm output (e.g. a PLC). High or low potential will result in incorrect configuration.

___________________________________________________________________________

In order to monitor external contactors (FEEDBACK) that may be connected to outputs Q1 Q4 the NC contacts of the respective contactors or output expansions must be connected in series with the associated control inputs (see the tables here and page 47).

NOTE

Feedback circuit monitoring

27

SA-BM Base Module

y

A

Function blocks

FUNCTION

Function

group

Application e.g.

Switch position not allowed

Emergency stop, safety door, 4-wire switching mat Dual-channel NC/NC with cross monitoring, stop category 0

OR

Safety door monitoring with electromagnetic switches, valve position monitoring Dual-channel NC/NO with cross monitoring, stop category 0 and 1

OR

3.1* Non-contact safety device type 4, emergency stop, safety door Dual-channel NC/NC, single-channel NC, stop category 0 and 1

3.2* PDF, Stop category 0 and 1 Non-contact safet

device type 2, Stop category 0 and 1

Muting

* For special functions see page 23.

Two-hand function EN 574 Type IIIC, safety door 2x dual-channel NC/NO with cross monitoring

Emergency stop, safety door Dual-channel NC/NC with cross monitoring

5.1* Two-hand function EN 574 Type III NO/NO with cross monitoring

5.2* Jog mode with 5 s operating time restriction NO/NO with cross monitoring

Emergency stop, safety door Dual-channel NC / NC with cross monitoring, stop category 0 and 1

Emergency stop, safety door, non-contact safety device type 4 Dual-channel NC/NC, single-channel NC, stop category 0 and 1

Emergency stop, safety door, non-contact safety device type 4 Dual-channel NC/NC, single-channel NC, stop category 0

Emergency stop, safety door, non-contact safety device type 4 Dual-channel NC/NC, single-channel NC, stop category 0 and 1

Emergency stop, safety door Dual-channel NC / NC with cross monitoring, stop category 0 and 1 Emergency stop, safety door, non-contact safety device type 4 Dual-channel NC/NC, single-channel NC, stop category 0 and 1

28

Function block terminal assignment

Terminal

assignment

Q1 Q2 Q3 Q4

X1 – I1 X2 – I2

U U

– I3

x

– I4

x

NO

DELAY

X1 – I1 X2 – I2

U U

– I3

x

– I4

x

– I1

x

– I2

x

(PDF) X1 – I1 (Type 2) X2 – I2

U U

– I3

x

– I4

x

NO

DELAY

NO

DELAY

**X1 – I1 (NO contact) X1 – I2 (NC contact) X2 – I3 (NO contact)

NO

DELAY

X2 – I4 (NC contact) X1 – I1

X2 – I2

NO

DELAY

X1 – I3 X2 – I4

X1 – I1 X2 – I2

X1 – I3 X2 – I4

U U

– I1

x

– I2

x

– I3

x

– I4

x

– I1

x

– I2

x

– I3

x

– I4

x

X1 – I1 X2 – I2

U U

Ux – Signal from Qx or UB or semiconductor outputs from sensors QE – Cross-circuit monitoring

– I3

B

– I4

B

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

Output function / off delay

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

Muting lamp/

Reset-Required

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

NO

DELAY

SA-BM Base Module

** not actuated

NO

DELAY

NO

DELAY

In combination functions 5 to 7 the signals on I1, I2 shut down all outputs Q1 to Q4, the signals on I3, I4 shut down only the outputs Q3 and Q4.

NOTE

29

SA-BM Base Module

Function Blocks – Overview

Function block

FUNCTION

Function group

Application example Cat. acc. to EN 954-1

Stop category. 1 (Controlled Stop)

Input circuit functions

Sensor connection

Synchronous time monitoring

Cross-circuit monitoring

4

5

6

3

2

7

1

8

9

0

4

or

3

or

2

SINGLE

1

X1

X2

X1

X2

AB

n

t

I1

I2

I1

I2

CROSSMON

MUTING**

by I3/ I4, Output Q3 for indicator Muting/ Reset required

OR**

by I3/I4 or input expansion

INPUT A INPUT B

7

I4

I3

+

>

1

AND

Input expansion

RESET FB Q1/2AB,

RESET switch

or

INPUT A INPUT B

*K1/2

+U

B

*K1/2

X1

1-6

S1

Startup

inhibit

ON

OFF

&

Restart

inhibit

ON

OFF

AND

Internal logic

Special function

S2

+U

B

or

S2

+U

BYPASS****

Input expansion

ENABLE***

B

INPUT A

INPUT B

8

Q

START

SBus AB

>

1

EN

&

Off-delay

Retriggering, FB Q3/4

*K3/4

X2

S3

or

*K3/4

+UB

S3

Outputs

SAFE

Q1

Internal safety bus for function group A or B or AB *K1/2 Bridge or feedback circuit Q1/2 *K3/4 Bridge or feedback circuit Q3/4 *K3 Bridge or feedback circuit Q3 *K4 Bridge or feedback circuit Q4

OFF-DELAY

ON

OFF

SAFE

Q2

Q4

Q3

SINGLE

2

X1

X2

X1

X2

AB

n

t

I1

I2

CH1

t

sync

CH2

I1

I2

CROSSMON

3

AB

SAFE

POSITION

TYPE 4

n

t

I1

X1

I2

I1

Ux

X2

I2

I1

I2

I4

I3

+

>

1

I4

I3

SBus AB SBus AB SBusABSBus AB

+

>

1

SBus AB SBus AB SBusABSBus AB

&

Restart

Startup

inhibit

ON

OFF

Q

START

SBus AB SBus AB SBusAB

>

1

EN

&

OFF-DELAY

ON

SAFE

Q1

OFF

SAFE

Q2

Q4

Q3

>

1

&

Restart

Startup

inhibit

ON

OFF

TEST

3.2

3.1

OFF

Q

START

>

1

EN

&

SAFE

Q1

MUTING

SAFE

Q2

**For signal supply to MUTING and OR inputs I3/I4 see page 22.

**For signal supply to ENABLE input EN see page 48.

SINGLE

4

AB

TEST

TYPE 2

n

t

TEST

or

TEST

ER

or

I1

I2

I1

X1

I2

I3

X2

I4

>

1

CH1

t

sync

CH2

CROSSMON

X1

X2

&

Startup

inhibit

ON

OFF

Q

ON

Restart

Startup

inhibit

OFF

ON

fix fix

*K1/2

+U

B

S1

Q

START

>

1

EN

&

OFF-DELAY

ON

OFF

SAFE

Q4

Q3

SAFE

Q1

****BYPASS limited to max. 60 s.

Signal Ux from supply voltage +UB or the Qx semiconductor outputs on the base module or the OSSD of light barriers/light

*K3/4

+U

B

S3

SAFE

Q4

Q2

Q3

Q1

A

>

&

START

>

&

5

CROSSMON

1

Restart

inhibit

SBus A

1

SAFE

Q2

COMBI

I1

I2

ON

OFF

EN

X1

X2

CH1

t

sync

CH2

Startup inhibit

ON

5.1

OFF

Q

+U

B

Q3

B

>

&

tmax

5s

START

>

&

*K3/4

MAX. 5s

CROSSMON

SBus BSBus A

1

SBus BSBus A

Restart

inhibit

OFF

5.2

ON

SBus B

1

S3

SAFESAFE

Q4

I3

I4

30

A

t t

Function block

FUNCTION

Function group

Application example Cat. acc. to EN 954-1

Stop category 1 (Controlled Stop)

Input circuit functions

Sensor connection

Cross-circuit monitoring

2 1

SA-BM Base Module

4

5

6

3

7

8

9

0

4

or

3

or

2

X1

X2

A

6

CROSSMON

COMBI

I1

I2

COMBI

7

B

n

t

I3

X1

I4

X2

CROSSMON

A

TYPE 4 TYPE 4 TYPE 4

I1

I2

I1

Ux

I2

I1

Ux

I2

B B

TYPE 4 TYPE 4

n

t

I3

I4

I3

Ux

I4

I3

Ux

I4

DUO

8

A

I1

I2

I1

I2

I1

I2

B

n

t

I3

X1

I4

X2

I3

Ux

I4

I3

Ux

I4

A

9

CROSSMON

COMBI

I1

I2

n

t

I3

I4

I3

Ux

I4

I3

Ux

I4

OR**

by input expansion

INPUT A INPUT B

AND

Input expansion

INPUT A INPUT B

RESET FB Q1/2A,

RESET switch

*K1/2

+U

B

or

*K1/2

X1

AND

Internal logic

RESET FB Q3B,

RESET switch

*K3

+U

B

or

*K3

X2

BYPASS****

Input expansion

INPUT A INPUT B

ENABLE***

Off-delay Q4

Retriggering, FB Q4

SBus A

7

>

1

SBus A SBus ASBus B SBus B SBusSBus A SBus B

&

1-6

Restart

Startup

inhibit

S1

ON

S1

OFF

>

1

&

Startup

inhibit

ON

OFF

>

&

1

Restart

inhibit

ON

OFF

>

1

& &

Startup

inhibit

ON

OFF

>

&

1

Restart

inhibit

ON

OFF

>

1

&

Startup

inhibit

ON

OFF

>

&

SBus ASBus ASBus B SBus B SBusSBus A SBus B

1

SBus A

Restart inhibit

ON

OFF

>

1

& & &

Restart

Startup

inhibit

S2

Q

START

8

>

1

&

ON

OFF

Q

SBus A SBus ASBus B SBus B SBusSBus A SBus B

START

>

1

EN ENEN EN

&

OFF-DELAY

Q

START

>

1

&

Restart

Startup

inhibit

ON ON

OFF OFF

Q

START

>

1

& &

OFF-DELAY OFF-DEL

Q

START

>

1

&

Startup

inhibit

ON

OFF

Q

Restart

inhibit

START

>

1

&

OFF-DELAY

ON

OFF

Restar

Startup

inhibi

inhibit

Q

START

SBus A

>

1

&

START

>

1

*K4

X2

S3

or

*K4

+U

B

S3

SAFE

Q1

SAFE

Q2

Outputs

Starting inhibit ON: Manual Reset after supply ON. Starting inhibit OFF: Automatic Reset after supply ON. Restarting inhibit ON: Manual Reset after safety event. Restarting inhibit OFF: Automatic Reset after safety event (see page 24).

Q3

SAFESAFE

ON

OFF

Q4

SAFE

Q1

SAFE

Q2

Q3

SAFESAFE

ON

OFF

Q4

SAFE

Q1

Q2

Q3

Q4

ON ON

OFF OFF

Q4

SAFE

Q1

SAFE

Q2

SAFE SAFESAFE SAFE

Retriggering ON: Delayed outputs remain in ON condition if safe state of inputs has been restored when the delay has expired.

Retriggering OFF: Unconditional time delay period (see page 25).

31

SA-IN Input Module

Y

5 SA-IN Input Module

Input Module Data

 SA-IN-S1,

SA-IN-S1

Input Module

The input module adds additional input circuits or logic functions to a base module on its left (SA-BM master).

ou can operate several input modules on one base

module.

There are two function groups, A and B, each with four inputs and four sensor supplies. You can set one of 10 functions for each group independently, using the rotary switches on the front. The configuration will be permanently saved in the master base module. The device operates as a slave on the internal safety bus.

Connection diagram

Notes

Accepting configuration

SA-IN

 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.

 The rotary switches for selecting function must only be adjusted when power is off.  Never connect or disconnect modules while the operating voltage is switched on.  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.  Input modules are always assigned functionally to the next connected base module to

the left. Each base module forms a system group within the overall system (sometimes together with associated input expansion modules; see diagram on page 8).

 Base modules and input modules are uniquely coded depending on their system system

group (see diagram on page 8).

Accepting the system configuration

For accepting the system configuration see page 18.

32

SA-IN Input Module

Function Function display 11 green LEDs, 1 red LED Controls 2 10-position switches Terminals Plug-in terminals with screws / spring force Max. number of modules / status in system 12 / slave on SBus

___________________________________________________________________________

Power circuitry (internal) Min. Typical Max.

Operating voltage U Residual ripple V Rated power, DC

, DC 19.2 V 24.0 V 30.0 V

B

3.0 V

SS

___________________________________________________________________________

Input circuit (

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

I1..I8

) Min. Typical Max.

(HIGH) 13.0 V 30.0 V

E

(HIGH) 2.4 mA 3.0 mA 3.8 V

E

E,PEAK

IN

E

A

(HIGH) 1.0 ms

E

(Functions 3, 5) 1500 ms

S

___________________________________________________________________________

Output circuit

Output voltage Output current in sum Wire capacitance, C Wire resistance, R Short-circuit behavior Absolutely short-circuit-proof

(X1.. X8

L

) Min. Typical Max.

___________________________________________________________________________

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

Test pulse width* t Test pulse period, t

;Test duration**, tTD;

TI

TP

Functions 1, 2, 3, 4, 5, 8

___________________________________________________________________________

Response times Min. Typical Max.

Response time*** t Function 1 Functions 6, 7 Functions 2 (without safety mat), 3, 4, 5, 8 Function 2 (safety mat)

(normal operation)

AN

Input module in the samos system

1.2 W

–5.0 V 5.0 V

–2.5 mA 2.1 mA

15 mA 200 nF

8 k

70 ms

> tAN

20 ms

18.0 V 30.0 V 150 mA 1000 nF

12 ms

20 ms

100 

40 ms

33 ms 16 ms 24 ms 42 ms

Technical data SA-IN

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

The sum of currents, which are drained from all input modules of one system to supply external sensors, may not exceed 600 mA!

* Signal changes are not detected during the test pulse.

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

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

*** The response time tAN is the time between the output signal arriving at the input terminals and the semiconductor outputs of the associated base module actually being shut down. The time is independent of the number of input modules connected to the base module.

33

SA-IN Input Module

Y









A

Input Module Data

Technical data

Function diagrams

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

tE : ON period tA : OFF period

QIN: see page 47

Safety parameters at ambient temperature TB +55 °C

PFD 9.2 x 10 PFH 6.1 x 10-9 h SFF 96 % DC 93 % MTTFd 204 years

___________________________________________________________________________

General data

Isolation Power circuitry – input circuit Power circuitry – output circuit Input circuit – output circuit Connection diagram KS 260-1-3 Weight 0.13 kg General technical data See page 65 Order numbers See page 69

___________________________________________________________________________

Input test function diagram (with cross-circuit monitoring)

Output X

X

Output X

Input I

X

Input I

___________________________________________________________________________

Input circuit function diagram (equivalent activation)

Input I1

Input I2

QIN (good state)

-6

-1

no no no

  

t



TI

t

TD

approx. 0.5

 t

E



t

TP

 t



t



TI

t

TD

approx. 0.5



t

TP

t





TI

34

SA-IN Input Module

Interfaces and Operation

Clamps

I1, I2, I3, I4 Inputs for connection of signal transmitters /

X1, X2, X3, X4 Outputs only for input circuit voltage or

I5, I6, I7, I8

X5, X6, X7, X8 Outputs just for the input circuit voltage or

SBus 10-pin connector for safety bus (plug and

Push-buttons

INPUT A INPUT B

LEDs I1.. I8 (green)

PWR (green) QA (green)

QB (green)

FLT (red)

___________________________________________________________________________

 PWR on  I1-I8 on  I1, I2 flash simultaneously  I3, I4 flash simultaneously  I5, I6 flash simultaneously  I7, I8 flash simultaneously  I1, I2 flash alternately  I3, I4 flash alternately  I5, I6 flash alternately  I7, I8 flash alternately  I1 or I2 flashes

 I3 or I4 flashes

 I5 or I6 flashes

 I7 or I8 flashes

 QA on

 QB 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 Cross-circuit between I5 and I6 Cross-circuit between I7 and I8 Sequence error on I1, I2 Sequence error on I3, I4 Sequence error on I5, I6 Sequence error on I7, I8 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. 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. Good state of AND-linked input pairs I1/I2 and I3/I4 (function group A) Good state of AND-linked input pairs I5/I6 and I7/I8 (function group B) No fault states

sensors (functional group A)

rather control sensors of the module (functional group A) Inputs for connection of signal transmitters / sensors (functional group B)

rather control sensors of the module (functional group B)

nut)

10-staged torque switch for adjustment of an input circuit function (functional group A or rather B)

Indicators of according inputs Voltage supply Overall indicator of inputs I1..I4 (functional group A) Overall indicator of inputs I5..I8 (functional group ) Indicator of flawed operating modes (see FLT error codes page 63)

Meaning of LEDs

35

SA-IN Input Module

Input Circuit Functions

You can set one of 10 input functions (0–9) for each function group using the INPUT A and INPUT B rotary switches on the front. The input signals are evaluated internally (depending

on switch position, for example for cross-circuit and simultaneity) and passed in groups on the safety bus to the base module to the left. There they are linked logically with the corresponding function group A or B. Several input modules can be assigned to one base module. The effect of the input module groups on the associated base module depends on the function block set there.  Function blocks 1 - 4: the inputs of both function groups on the input module (A + B) will

act together on the selected base module function (AND operation).

 Function blocks 5 - 8: the inputs of both function groups on the input module A resp. B

will act separately on the respective group on the base module function.

___________________________________________________________________________

Evaluating inputs

* Maximum control category (depends on sensor, wiring and installation). Please also note the information on page 13.

** Pairs of inputs Group A: I1/I2 and I3/I4, Group B: I5/I6 and I7/I8.

Sensor connection

Evaluation Application

Single-channel

All four inputs of each function group (A, B) are single-channel and linked by a logical AND. The inputs In expect test pulses, which are generated on the associated outputs Xn.

Single-channel testable sensors Type 2 non-contact safety devices (light barriers)

Testable sensors (e.g. type 2 non-contact safety devices) are monitored. All four inputs of each function group (A, B) are single-channel and linked by a logical AND. The inputs I

n

expect test pulses, which are generated on the associated outputs X

. You can also cascade

n

several light barriers. Also observe the test pulse data for the sensors (non-contact safety device, PDF, ...) and the samos module!

Dual-channel equivalent (with cross-circuit monitoring, with/without synchronous time monitoring 1 s)

Two pairs are formed from the four inputs of a function group (e.g. group A: I1/I2 and I3/I4)**. A valid ON signal is only generated if ON state is present at both inputs of a pair and both were previously in OFF state (L-level) (flipflop). Both pairs are then linked by a logical AND.

Dual-channel equivalent (without cross-circuit monitoring)

As above, but without cross-circuit monitoring. Can also be operated as dual-channel threewire circuit.

e.g.

INPUT A INPUT B

1 2

3 / 2 4

6 3

Cat. up

36

A

u

Sensor connection

Evaluation

Dual-channel non-equivalent (with cross-circuit monitoring, with/without synchronous time monitoring 1 s)

Two pairs are formed from the four inputs of a function group (e.g. group A: I1/I2 and I3/I4)**. A valid ON signal is only generated if ON state (H/L-level) is present at both inputs of a pair and both were previously in OFF state (L/Hlevel) (flipflop). Both pairs are then linked by a logical AND.

Dual-channel equivalent, Semiconductor activation, positive switching

Two pairs are formed from the four inputs of a function group (e.g. group A: I1/I2 and I3/I4)**. A valid ON signal is only generated if ON state is present at both inputs of a pair and both were previously in OFF state (L-level) (flipflop). Both pairs are then linked by a logical AND.

OR (without cross-circuit monitoring)

Two pairs are formed from the four inputs of a function group (e.g. group A: I1/I2 and I3/I4)**. A valid ON signal is only generated if ON state (H-level) is present at both inputs of a pair and both were previously in OFF state (L-level) (flipflop). Both pairs are then linked by a logical OR. The result of this function is used in the base module to suppress an OFF signal. For the OR function see page 46.

BYPASS

(with cross-circuit monitoring)

A pair is formed from the first two inputs of a function group (e.g. group A: I1/I2)**. A valid ON signal is only generated if ON state (Hlevel) is present at both inputs of the pair and both were previously in OFF state (L-level) (flipflop). The result of this function is used in the base module to force an ON signal of duration limited to 60 s. For the BYPASS function see page 46.

pplication

e.g.

INPUT A INPUT B

5 / 4 4

6 4

7 3

8 4

SA-IN Input Module

Cat. up to*

When cross-circuit is detected the whole group (A or B) is shut down.

NOTE

37

SA-IN Input Module



























Input Circuit Functions

Standard functions

Standard functions 1 to 6

Functions 1 to 6 allow input expansion for standard functions such as emergency stop, light curtain, valve position monitoring, etc. The signals are AND-linked with the base module function blocks. The configuration of input terminals I1 to I4 (function group A) and I5 to I8 (function group B) can be set separately. In switch position 0 unused inputs do not need to be connected. In all other switch positions any unused inputs must be connected in such a way as to correspond to the indicated good state of the selected input circuit function of the respective function group on the input module.

The output signal Q linked inputs. The exception is function 1, where all inputs are AND-linked. See also "Evaluating inputs", page 36.

Output signal Output signal

Connection

* & : AND-linked input pairs + : Combination of flipflop + AND link; see "Evaluating inputs", page 36.

Terminal assignment see page 41.

or QB from function group A or B is generated from paired AND-

A

INPUT A INPUT B

QA* QB*

Single-channel

NC

Single-channel Testable sensors

NC/semiconducto r

Dual-channel equivalent

NC

Dual-channel non-equivalent

NC/NO

Dual-channel Semiconductor

positive switching

Dual-channel Three-wire

NC

Cross-circuit monitoring

Synchronous time monitoring

Not used

I1 & I2 & I3 & I4 ( I1 + I2 ) & ( I3 + I4 ) I5 & I6 & I7 & I8 ( I5 + I6 ) & ( I7 + I8 )







 



38

SA-IN Input Module













OR and bypass logic functions – functions 7 and 8

In functions 7 and 8 the signals from the input expansion are OR-linked with the base module function blocks. This makes it possible to create safety functions, e.g. for setup mode, for clearing parts of a system or for safe position monitoring. The configuration of input terminals I1 to I4 (function group A) and I5 to I8 (function group B) can be set separately.  OR function 7 overwrites the input circuit of the associated base module. The function

prevents switching off (e.g. setup mode with enabling button for temporary bridging of safety door functions) or is used alternative to good state of the safety sensor.

 Bypass function 8 switches the outputs on regardless of their previous control state.

The function is restricted to max. 60 s. Input pairs I3/I4 and I7/I8 are inactive; they do not have to be connected.

Logic functions

The bypass signal should be generated only by a particularly deliberate action by a person with a view into the system (e.g. by using a lockswitch). The bypass instruction is canceled by the deactivated EN enabling input of the associated base module. For the OR and bypass functions see page 46.

Output signal

Connection

* 1 : OR-linked input pairs + : Combination of flipflop + AND operation; see "Evaluating inputs", page 36.

Terminal assignment see page 41.

INPUT A

INPUT B

Dual-channel Semiconductor

positive switching

Dual-channel Three-wire

NO

Single-channel

NO

Dual-channel equivalent

NO

Cross-circuit monitoring

Input expansion

Time limit 60 s

QA*

( I1 + I2 ) 1 ( I3 + I4

QB*

( I5 + I6 ) 1 ( I7 + I8

OR

)



Bypass

( I1 + I2 ) I1 I2 I3 I4

( I5 + I6 ) I5 I6 I7 I8

Expansion

Explanation on

NOTE

39

SA-IN Input Module

p

Input Circuit Functions

Expansion function

EXAMPLE

Input expansion – function 9

Function 9 assigns the inputs of the function group to the respective other group and takes on their input circuit function. Thus with one input module you can expand function block A or B in the base module by 8 single-channel or 4 dual-channel sensors with the same input circuit function (e.g. 8x emergency stop or 4x NC/NO electromagnetic switch. Function 9 must only be selected for one of the two function groups. Otherwise a device error will be detected and the FLT LED will flash.

Settings: Input module INPUT A Function 9 (input expansion) INPUT B Function 3 (dual-channel with cross-circuit

Base module FUNCTION 6 Result: Function 6B on the base module is expanded by the 4 dual-channel inputs

With switch positions 0 to 6 there is an AND link in the base module; for switch positions 7 (OR) and 8 (BYPASS) there is an OR link. A and B on the associated base module see page 36.

___________________________________________________________________________

Example for the interaction of base and input modules

on the input module

monitoring and simultaneity monitoring)

For the effects of input module function groups

Input modules act only on the next base module to the left, with which they form a coded system group. The blue digits designate the set functions. System 1: INPUT A and INPUT B of the input module act together with base module function group AB on the four outputs (green). System 2: INPUT A of the input module acts together with base module function group A on output group A (blue); INPUT B acts together with function group B on out

ut group B (pink).

40

SA-IN Input Module

Terminal Assignment

The assignment of outputs X1 to X8 to inputs I1 to I8 depends on the selected input circuit function. The functions of groups A and B can be set independently.

Unused inputs must be bridged according to the illustrated good state.

INPUT A / INPUT B

All inputs of group A / group B unused

4x single-channel with testing

4x single-channel with testable sensors*

2x dual-channel Cross monitoring

2x dual-channel Cross monitoring Synchro-check

2x dual-channel Cross monitoring

2x dual-channel Cross monitoring Synchro-check

2x dual-channel Semiconductor

2x dual-channel Three-wire

2x single-channel

OR 2x dual-channel semiconductor

OR / MUTING 2x dual-channel Three-wire

OR 2x single-channel

BYPASS 1x dual-channel Cross monitoring

Input terminal pairs

function group A

Input terminal pairs

function group B

n.c. terminals n.c. terminals

X1-I1 X2-I2 X3-I3 X4-I4 X5-I5 X6-I6 X7-I7 X8-I8

X1-I1 X2-I2 X3-I3 X4-I4 X5-I5 X6-I6 X7-I7

X1-I1 X2-I2

Q1 Q2

Sensor

U

-I1

X

UX -I2

U

-I1

X

U

-I2

X

Sensor

UX -I1 U

-I2

X

-I1

U

X

U

-I2

X

-I1

-I2

-I1

-I2

X1-I1 X2-I2

X3-I3 X4-I4

Q1

-I3

Sensor

Q2

-I4

Sensor

UX -I3 UX -I4

U

-I3

X

U

-I4

X

-I3

Q1

Sensor

1 1

Q2

-I4

Sensor

-I3

U

X

1

U

-I4

X

UX -I3

1

U

-I4

X

I3 n.c. I4 n.c.

X5-I5 X6-I6

Q1 Q2

UX -I5 UX -I6

Q1 Q2

U U

X5-I5 X6-I6

Sensor

-I5

X

-I6

X

-I5

X

-I6

X

-I5

-I6

-I5

-I6

1

Q1 Q2

X8-I8

X7-I7 X8-I8

-I7

Sensor

-I8

Sensor

UX -I7 UX -I8

U

-I7

X

U

-I8

X

-I7

Sensor

-I8

Sensor

-I7

U

X

U

-I8

X

UX -I7 U

-I8

X

I7 n.c. I8 n.c.

NOTE

* Non-contact safety device type 2.

For the UX voltage see page 22.

Input expansion

Function as INPUT B Function as INPUT A

41

SA-OR-S1 / SA-OR-S2 Relay Output Modules

6 SA-OR-S1 / SA-OR-S2 Relay Output Modules

Relay Output Module Data

Relay output module with 2 relay groups K1, K2 Relay output module with 1 relay group K1

Relay output modules expand an existing base module with potential-free output circuits. Each potential-free output circuit comprises the seriesconnected relay contacts of two redundantly operating positively driven relays and can be used up to category 4 (EN ISO 13849-1).

The passive relay output expansions do not operate as slaves on the internal safety bus. Instead they are integrated in the functions by wiring.

Connection diagram

 SA-OR-S1  SA-OR-S2

SA-OR-S1 SA-OR-S2

Notes

Accepting configuration

42

SA-OR-S1 SA-OR-S2

 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/BS), category 4 according to EN ISO 13849-1 can be achieved if both devices are installed in the same enclosure and the samos system is separated from the power supply at least once a day.

 The voltage supply of each output circuit must be protected with a 6 A fuse (utilization

category gG) or a 6 A circuit-breaker (tripping characteristic B or C).

 Never connect or disconnect modules while the operating voltage is switched on.  The safety system must be installed in an enclosure with at least IP 54 protection.  Because the relay output modules are not directly integrated in the

communication/diagnosis of the samos system via the internal safety bus, errors are registered indirectly via the base module feedback circuits.

Accepting the system configuration

For accepting the system configuration see page 18.

SA-OR-S1 / SA-OR-S2 Relay Output Modules

Relay Output Module Data

SA-OR-S1 / SA-OR-S2

Function Function display 3 LEDs green Controls – Terminals Plug-in terminals with screws / spring force Max. number of modules / status in system 4 / passive module

___________________________________________________________________________

Input circuit (B1, B2) Min. Typical Max.

Operating voltage U Residual ripple V Rated power, DC SA-OR-S1 SA-OR-S2

, DC 18 V 30 V

B

3.0 V

SS

___________________________________________________________________________

Output circuits (relay) Min. Typical Max.

Switching voltage

Switching current Total current Off delay, t

R

Type of outputs positively-driven relay Contact type SA-OR-S1 SA-OR-S2 Contact material AgSnO Output circuit protection per current path 6 (gG) Utilization category (EN 60947-1) AC 15: 3 A, 230 V

___________________________________________________________________________

Output circuits (Y14, Y24) Min. Typical Max.

Output voltage Output current Resulting current Y14+Y24

___________________________________________________________________________

Safety parameters at ambient temperature TB +40°C (4x1.5 A)

PFH 1.65 x 10 SFF 99.6 % DC 99 %

___________________________________________________________________________

General data

Isolation



Power circuitry – input circuit



Power circuitry – output circuit



Input circuit – output circuit Rated voltage AC 230 V Connection diagram SA-OR-S1 SA-OR-S2 Weight SA-OR-S1 SA-OR-S2 General technical data See page 65 Order numbers See page 69

Relay output modules in the samos system

2.2 W

1.1 W

230 V AC 230 V DC 6 A 8 A 30 ms

2 x 2 NO 1 x 2 NO

with 1 μ Au

2

DC 13: 3 A, 24 V

18 V 24 V 30 V

75 mA 100 mA

-8 h-1

no yes yes

KS 260-1-4 KS 260-1-6

0.17 kg

0.10 kg

Technical data

43

SA-OR-S1 / SA-OR-S2 Relay Output Modules

Y

Interfaces and Operation

SA-OR-S1

Clamps

B1 Input relay K1

13/14, 23/24 Floating output circuits K1

14

B2 Feedback circuit K1

1/Y2 Input relay K2

33/34, 43/44 Floating output circuits K2

24 Single-ended output circuit K2

3/Y4 Feedback circuit K2

SBus 10-pin connector for safety bus (plug and

LEDs PWR (green)

K1 (green) K2 (green)

Single-ended output circuit K1

nut)

Voltage supply Relay K1 Relay K2

SA-OR-S2

Clamps

B1 Input relay K1

13/14, 23/24 Floating output circuits K1

Meaning of LEDs

14

1/Y2 Feedback circuit K1

SBus 10-pin connector for safety bus (plug and

LEDs PWR (green)

K1 (green)

Single-ended output circuit K1

nut)

Voltage supply Relay K1

____________________________________________________________________

 PWR on  K1 on  K2 on

Power supply to module electronics is on Relay K1 in operated condition Relay K2 in operated condition

44

7 Glossary

System Functions

Input circuit function

The input circuit function logically links input signals for further processing. In order to detect faults (e.g. in the external circuitry of safety inputs) the inputs are tested periodically in relation to function (external input dynamization).

 Input circuit function single-channel via NC contact

One input is monitored (e.g. the NC contact of an emergency stop button). A valid input signal is only generated if ON state (H-level) is present at the input and it was previously in OFF state (L-level).

 Input circuit function single-channel with testable sensors

Testable sensors (e.g. type 2 non-contact safety devices) are monitored. A valid input signal is only generated if ON state (H-level) is present at the input and it was previously in OFF state (L-level).

 Input circuit function with dual-channel equivalent activation

Two equivalent inputs (e.g. the opening contacts of an emergency stop button or actuated N/O contact / N/C contact of two safety-door position switches) are monitored. A valid input signal is only generated if ON state (H-level) is present at both inputs and both were previously in OFF state (L-level). The function can be used with/without cross-circuit monitoring and with/without synchronous time monitoring.

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

Two non-equivalent inputs are monitored. A valid input signal is only generated if ON state (H/L-level) is present at both inputs and both were previously in OFF state (L/H-level). The function can be used with/without cross-circuit monitoring and with/without synchronous time monitoring.

 Two-hand function with activation by one NO contact per hand (EN 574, IIIA)

Two equivalent inputs are monitored (e.g. the NO contacts of the two twohand buttons). A valid input signal is only generated if ON state (H-level) is present at both inputs within 0.5 s (synchronous change, both two-hand buttons actuated) and both were previously in OFF state (L-level). For jog mode the ON signal can be temporarily restricted to 5 s if required.

 Two-hand function with activation by NO/NC combination for

each hand (EN 574, IIIC)

Two pairs of non-equivalent inputs are monitored (the NO/NC contact pairs of the two two-hand buttons). A valid input signal is only generated if ON state (H/L-level) is present at both inputs within 0.5 s (synchronous change, both two-hand buttons actuated) and both were previously in OFF state (L/H-level).

 Dual-channel equivalent activation by semiconductor

Two equivalent inputs are monitored (e.g. the signals from a light barrier). A valid input signal is only generated if ON state (H-level) is present at both inputs and both were previously in OFF state (L-level).

Glossary

Safety inputs

45

Glossary

OR

For OR and muting functions see also page

22. For the reset function see page 47.

Muting

System Functions

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 OR function can be implemented by the base module (depending on the function) or by an input module. It corresponds to an input circuit function with dual-channel equivalent activation without cross-circuit monitoring.

The muting function is a special case of the OR function (conditional OR). For example, muting sensors allow a conveyor belt to transport material through a light curtain by briefly bridging the light curtain function. An ON signal (H-level) is generated only if the internal output signal of the Reset function Q function

The muting function in the samos base device corresponds to an input circuit function with dual-channel equivalent activation without cross-circuit monitoring. Muting of a safety function must not be dependent on a single signal! An output controls the corresponding muting lamp. This lamp additionally indicates by blinking that the Reset signal is expected at input S1.

has H-level at the beginning of the Muting

START

Bypass

EXAMPLE

For the input circuit functions of the input modules see page 36.

The deactivated enabling input of the associated base module shuts down the outputs (Q1..Q4) switched on by OR or MUTING. The Muting lamp output Q3 stays on during the Muting function, if function block 3 is selected. When they are subsequently activated, OR or MUTING mode continues.

___________________________________________________________________________

Bypass function

With a bypass signal an internal OFF signal (L-level) of the Reset function Q overwritten in the base module. The bypass function is generated by a high-level (see also the “Reset Function” figure on page 47). It corresponds to an input function with dualchannel equivalent activation with cross-circuit monitoring.

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 light barrier and the blockage can be cleared. In normal operation the muting function bridges automatically (see above).

The bypass signal is limited to 60 s. After the time has expired bypass mode can be reactivated. After the bypass signal has been cancelled and respectively after 60 s the enabling outputs are switched off, if the restarting inhibit function is on and the light curtain was inerrupted. However, any set release time will run in full.

Bypass can be aborted by canceling the bypass instruction on the input module or by a low signal on the EN enabling input on the associated base module. This means, for example, that a higher-priority emergency stop can shut the machine down during bypass mode.

After the bypass signal has been cancelled, the internal signal Q

Start

determines the

state of the outputs (see Reset Function on page 47).

START

can be

NOTE

46

The bypass signal should be generated only by a particularly deliberate action by a person with a view into the system (e.g. by using a lockswitch that automatically returns to off position or a combination of lockswitch and enabling button).

The starting inhibit on the associated base module is never on when bypass inputs are active. This means that when voltage is switched on with high potential on the EN ENABLE input, the outputs are enabled immediately without additional manual intervention.

Reset function

The Reset function defines which (reset) conditions must be fulfilled if, for example, an ON signal is to be passed on to output Q

. All input and muting signals from the base

START

module and the associated input modules (i.e. of a system group within the samos system), 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 (see below).

An ON signal from the Reset function can only be canceled by an OFF signal from an input circuit function (i.e. changed into an OFF signal), and is not influenced by enabling, muting or bypass functions or by feedback circuit monitoring.

& : AND blink ≥1 : OR link + : Combination of flipflop + AND link.

Muting : An ON signal is generated only if the output signal of the Reset function Q

Start

has

good state at the beginning of the muting function.

Reset condition / evaluation of feedback circuits

On the base modules there are three control inputs S1, S2, S3 for configuring the control circuit functions. They can be used, depending on the function, to set starting inhibit, restarting inhibit, retriggering and off delay (see page 24). Depending on the application, the configuration is realized using bridges or by connecting the NC contacts of connected relays/contactors. Together with the module outputs this creates feedback circuits which allow evaluation of the control states of the respective connected relays/contactors with positively driven contacts. Evaluation uses one of two different methods depending on the function (see also page 26).  The NC contact is connected directly with the respective control input. As soon as the

contact closes the Reset function is activated and it is possible to switch on the outputs. The configuration is evaluated when the system is switched on. The configuration is verified before each Reset following a safety event. If a change is detected (e.g. feedback circuit not closed) the system generates an error message and cannot be switched back on until the malfunction has been rectified.

 In operation with restarting inhibit the NC contact is connected to the respective input

via a Reset button. The required Reset condition for canceling the restarting inhibit is only fulfilled if the feedback circuit is also closed.

Glossary

Reset

Feedback circuit monitoring

The feedback circuits that belong to the safety system must be housed in the same enclosure as the samos system in order to exclude the “Short-circuit to +24 V”.

NOTE

47

Glossary

System Functions

Enable

EXAMPLE

Enable function

The enable function enables an 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

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

n

(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

semiconductor outputs are

n

locked.

The enable function makes it easy, for example, to cascade safety circuits or form dependent safety zones. Unused EN inputs are connected to supply voltage +U enabling input is open or on L-level all safety outputs on the base module shut down. Any set off delay will run in full. The enable function has priority over all other input signals (safety sensors, bypass, etc.).

. If the

B

NOTE

Diagnosis

When voltage is switched on the starting inhibit on/off Reset condition is integrated in the enable function. During operation the Reset conditions are not checked. I.e., Reset can be prepared in disabled condition. ENABLE enables the outputs.

Output function

The time behavior of the safety ON/OFF signal is defined in the output function. In order to detect faults in the safety outputs the outputs are tested periodically (output dynamization).

Depending on the function, you can use the rotary switch to set a off delay for outputs Q4 or Q3/Q4 between 0 and 5 minutes (depending on module version). This does not influence switching on procedures.

Safety shutdown of drives according to stop category 1 (controlled stopping) is possible with each base module.

Note that the delayed outputs shut down immediately if operating voltage is switched off during the off delay.

Communication

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

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. The SBus is used as the internal system communication channel.

With the display function voltage levels on terminals and particular operating states of the system are displayed via LEDs. The diagnosis and display functions are decoupled and are not safety functions. In other words, no data from external systems can enter the system via a diagnosis or bus coupler module.

48

Glossary

samos

and IEC/EN 61508/EN 62061

The international norm IEC/EN 61508/EN 62061 is the new standard for the specification, design and operation of safety systems.

The norm takes the whole system into consideration. It expands the safety requirements of single complex devices to cover the whole safety installation from sensor through control electronics and communications systems to actuators, and also includes possible errors by operators. The norm provides the framework for future developments and is decisive for manufacturers and users alike, especially as it also touches on questions of product liability.

The safety considerations concentrate on analyzing dangers and defining risks. The goal of the assessment is to reduce the risk involved in a safety system to an acceptable level of residual risk by calculating failure probabilities for components, system and design from development right through to disposal.

___________________________________________________________________________

Safety integrity level

The safety function of the samos system is shutting down or preventing a dangerous process. All the system functions described in this manual are safety functions.

A safety integrity level defines the range for failure probability of a safety function in relation to operating mode and request frequency. IEC/EN 61508/EN 62061 describes two modes for safety functions:  A safety function in demand mode is only executed on demand. It brings the

monitored system into a defined safe state and has no influence on the system in normal operation (example: emergency stop monitoring).

 A safety function in continuous mode continuously maintains the monitored system in

its normal safe state (example: speed monitoring).

This division means there are two different demand rates for safety functions:

 Mode with low demand rate when the demand rate is less than once per year;  Mode with high demand rate or continuous demand when the demand rate is more

than once per year.

The demand rates are considered in relation to failure probabilities:

 Low demand rate in relation to probability of failure on demand (PFD),  High demand rate or continuous demand in relation to probability of failure per hour

(PFH). According to IEC/EN 61508/EN 62061, the samos safety function can be used in modes with low and high demand rates.  With low demand rates the PFD for SIL 3 is

-4

10

to <10-3 (e.g. emergency stop components) for the whole safety chain.

 With high or continuous demand rates the PFD is

-8

 10

to <10-7 (e.g. two-hand application) for the whole safety chain.

___________________________________________________________________________

Other safety parameters used in this manual

 SFF - Safe Failure Fraction

The percentage of the full number of errors that do not critically affect safety. Quantitative

parameter from IEC 61508-2. It characterizes the safety structure and defines whether a

component for executing the safety function can be single-channel or must be redundant

in the safety chain of the plant/machine.  DC - Diagnostic Coverage

Quantitative parameter from IEC 61 508, prEN ISO 13849. Identifies the proportion of

dangerous faults that will be detected.

49

Glossary

Characteristic safety values

In the following, you will find the results of calculations of the MTTFd, PFD and PFH values of different system configurations. They apply under following conditions:

 Units are permanently in operation: 24 h per day, 365 days per year  Service life (PFH – applications): 20 years  Proof test interval (PFD – applications): 1 year  Average ambient temperature: 40°C

Calculation variants

Variant 1:

1. single-channel input - single-channel output

2. single-channel input - dual-channel output

3. dual-channel input - single-channel output

4. dual-channel input - dual-channel output

Variant 2:

1. single-channel input - single-channel output

2. single-channel input - dual-channel output

3. dual-channel input - single-channel output

4. dual-channel input - dual-channel output

Base moduleE A

Input

expansion

Base moduleE A

Variant 3:

1. single-channel input - single-channel output

2. single-channel input - dual-channel output

3. dual-channel input - single-channel output

4. dual-channel input - dual-channel output

Variant 4:

1. single-channel input - single-channel output

2. single-channel input - dual-channel output

3. dual-channel input - single-channel output

4. dual-channel input - dual-channel output

Base moduleE A

E

Input

expansion

Relay output

expansion

Relay output

expansion

Base module

A

50

Results of calculation

Glossary

Average time until dangerous failure

MTTFd > 300 years

(no relay output expansion) Average time until dangerous failure

MTTFd > 100 years

(with relay output expansion) Percentage of safe errors fulfilled

Shortest relay switching cycle

33 seconds

single-channel output

Single-channel input -

Variant 1

PFDavg 2,2E-05 5,2E-06 2,1E-05 3,9E-06

% of SIL 3 2,2% 0,5% 2,1% 0,4%

dual-channel output

Dual-channel input -

single-channel output

Dual-channel input -

dual-channel output

Variant 2

Variant 3

Variant 4

PFH (1/h) 6,0E-09 2,5E-09 6,0E-09 2,5E-09

% of SIL 3 6,0% 2,5% 6,0% 2,5%

PFDavg 2,4E-05 7,0E-06 2,3E-05 5,8E-06

% of SIL 3 2,4% 0,7% 2,3% 0,6%

PFH (1/h) 7,3E-09 3,8E-09 7,3E-09 3,8E-09

% of SIL 3 7,3% 3,8% 7,3% 3,8%

PFDavg 2,3E-05 5,2E-06 2,2E-05 3,9E-06

% of SIL 3 2,3% 0,5% 2,2% 0,4%

PFH (1/h) 1,2E-08 2,6E-09 1,2E-08 2,6E-09

% of SIL 3 12,2% 2,6% 12,2% 2,6%

PFDavg 2,5E-05 7,1E-06 2,3E-05 5,8E-06

% of SIL 3 2,5% 0,7% 2,3% 0,6%

PFH (1/h) 1,4E-08 3,9E-09 1,4E-08 3,9E-09

% of SIL 3 13,5% 3,9% 13,5% 3,9%

51

Glossary

Applications and Pictograms

Emergency stop monitoring

The emergency stop function is used to protect persons and machines by directly disconnecting the power supply.

Safety door monitoring Safety door monitors with sensors (e.g. position switches, coded electromagnetic switches) are used for monitoring separating safety devices.

Static valve monitoring Position monitoring with position switches.

Switching mat monitoring Short-circuiting switching mats are access monitoring sensors that alter their control state when stood upon.

Two-hand function Two-hand functions as per EN574 protect the operator of presses, cutting and bending machines, machining centers, etc. The two controls (two-hand buttons) must be actuated at the same time to initiate the dangerous operation. If one or both of the buttons is released the enable is canceled.

On press control systems the function must only be used in accordance with EN 574 Typ IIIC.

Two-hand operation in jog mode In jog mode an output signal is only generated while the controls are being pressed, e.g. for motions in setup mode. Jog mode on the base modules is restricted to 5 s.

Light barrier / light curtain monitoring Access monitoring with self-testing sensors (e.g. type 4 non-contact safety devices). A non-contact safety device is a setup of devices and/or components that work together for safety shutdown and detection of persons. The non-contact safety device has at least a sensor function (e.g. safety light barrier or other secure sensors), a monitoring function (e.g. cyclical self-tests) and an output switching element (OSSD). The function is matched for modulated self-test signals or overcurrent limitation of sensor semiconductor outputs.

Light barrier / light curtain monitoring

Access monitoring with testable sensors (e.g. type 2 non-contact safety devices). The sensors have separate activation inputs that are used to test the sensor function with a low signal; the base module analyses the response signal generated by the receiver. Several sensors can be cascaded.

Controlled stopping With the settable off delay a drive can be switched off after expiry of the time according to stop category 1 and EN 60204, and if required a brake can be applied.

Safe Position

Safe position, e.g. of a robot, is detected by a sensor. Zone protection is lifted and an operator can enter the robot zone. If the robot leaves the position it is switched off safely.

52

Logic functions

8 Logic functions

AND-linked safety inputs (sensor inputs)

E.g. emergency stop button, position switch, electromagnetic switch, light curtain, ...

All emergency stop buttons and light curtains with FUNCTION 1 from

the SA-BM-S1 and the SA-IN-S1 input expansion are AND-linked.

AND-linked safety inputs (sensor inputs)

The non-contact inductive safety sensor S1 with test input (e.g. GM 504S, GM505S from ifm) and the testable light barrier LC1 are AND-linked. Both sensors must be actuated before a new Reset can be initiated. The emergency stop button ES1 at SA-BM-S1 has priority over the enabling input on the right SA-BM-S1 by AND operation.

SA-IN-S1

SA-BM-S1

+ Combination of flipflop + AND operation

1* MUTING the conditional ORcombination is valid only if the result of the Reset function before was =1 (see pages 46/47).

53

Logic functions

+ Combination of flipflop + AND operation

AND-linking of

samos

function groups A and B

The safety door switch on the base module SA-BM-S1 and the light curtain on the input expansion SA-IN-S1 in function group B of the function block (FUNCTION 6) are AND- linked in the function block to function group A (emergency stop circuits of base module and input expansion). Function group A has priority over function group B. Via Q8 on the PLC Q3 and Q4 on the SA-BM-S1 can also be enabled or shut down.

+ Combination of flipflop + AND operation

SA-IN-S1

AND-linked

samos

function blocks

The SA-BM-S1 function block for two-hand function (FUNCTION 4) is subordinate to the SA-BM-S1 emergency stop function block (FUNCTION 1). The AND link is made by output Q2 on the SA-BM-S1 and the EN enabling input on the right SA-BM-S1.

54

SA-BM-S1

Logic functions

AND-linked

The safety door circuitry of SG1 shuts down output Q3,Q4 on the SA-BM-S1. SG2 and SG3 shut down the independent Q1 and Q2 / Q3, Q4 of the right SA-BM-S1. When ES1 (emergency stop) is actuated the internal AND link in the SA-BM-S1 function block and the connection of output Q2 on the SA-BM-S1 with the EN enabling input on the right SABM-S1 ensure complete shutdown of all outputs.

samos

function blocks

SA-BM-S1

+ Combination of flipflop + AND operation

OR-linked safety inputs (sensor inputs)

Actuation of lockswitch S1 bridges the safety door function with an OR link; i.e. all outputs Q1 to Q4 remain on. Lockswitch takes effect even with safety door opened and switches

all outputs on.

+ Combination of flipflop + AND operation

55

Logic functions

+ Combination of flipflop + AND operation

1* MUTING the conditional ORcombination is valid only if the result of the Reset function before was =1 (see pages 46/47).

OR-linked safety inputs (sensor inputs)

Actuation of muting sensors MU1 and MU2 automatically bridges the safety function of light curtain LC1 by OR operation (MUTING); i.e. outputs Q1, Q2, Q4 remain on. Light curtain LC1 must not be interrupted when the two muting sensors are actuated. Output Q3 controls the muting lamp.

+ Combination of flipflop + AND operation

1* MUTING the conditional ORcombination is valid only if the result of the Reset function before was =1 (see pages 46/47).

OR-linked safety inputs (sensor inputs)

Actuation of muting sensors MU1 and MU2 automatically bridges the safety function of light curtain LC1 by OR operation (MUTING); i.e. outputs Q1, Q2, Q4 remain on. Light curtain LC1 must not be interrupted when the two muting sensors are actuated. Output Q3 controls the muting lamp. Actuating lockswitch S4 on the SA-IN-S1 activates the BYPASS function for clearing the light curtain when power is switched on. BYPASS operates as an

OR operation on the base module SA-BM-S1 outputs via input module SA-IN-S1.

56

SA-IN-S1

Logic functions

OR-linked safety inputs (sensor inputs)

The safety door switches of SG2 in function group B of the function block (FUNCTION 6) are AND-linked in the function block with SG1 of function group A. Function group A has priority over function group B. An additional safety door circuit with an electromagnetic switch MS1 is assigned to function group A via the input expansion. The sensor input of function group B of the SA-BM-S1 is OR-linked via function INPUT 7 of the SA-IN-S1 input expansion and enabling button SET1. If enabling button SET1 is actuated, outputs Q3 and Q4 do not shut down when door SG2 is opened.

SA-IN-S1

+ Combination of flipflop + AND operation

57

A

pplications

s

Application example A 253_C

Two safety zones Safety door monitoring

with higher-priority emergency stop

Category 3 Stop category 1

Applications

Two-channel emergency stop and safety door monitoring. Emergency stop has priority over the safety door function. In case of emergency stop contactors K1, K2 and output Q3 shut down immediately. The drive shuts down immediately via the enable signal. After the preset time power to the drive is switched off via K4, K5 and a brake applied (safe stopping as per stop category 1).

Reset after emergency stop and after power on is with RESET. When the safety door is opened only the drive is stopped safely. K1 and K2 remain switched on. After the safety door has been closed and the feedback circuits checked, the safety device is reset automatically. The machine is ready to switch on.

+ Combination of flipflop + AND operation

 e

58

amos module K6

Type

SA-BM-S1

FUNCTION 7 Function group AB A B External circuitry category (EN ISO 13849-1)

up to

3 3 Cross-circuit monitoring – – Synchronous time monitoring – Stop category (EN 60204-1) 0 1 OFF delay

Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON X X AUTO-RESET X MANUAL RESET X Comment

amos modules and contactors in the same enclosure

Q4 1,5 s

A

The safety light curtain LC1 monitors the access to the machine zone. The optical muting sensors LM1 and LM2 are OR-linked with light curtain LC1 (muting function).

Both muting sensors are pulse controlled and must be active to carry out the muting

function (light curtain bypass).

The muting function requires that outputs Q1, Q2, Q4 have previously been switched

on. This means that the vision of LC1 has to be uninterrupted for power on.

Lamp L1 indicates the active muting state (static on). The expected Reset signal at S1 is

indicated by blinking of L1. L1 control complies with EN 60496-1.

Restart is possible after exiting the danger zone and pushing Reset button S3.

pplications

Application example A267

 Machine zone

protection with light curtain

 Muting function  Category 4  Stop category 0

samos

module

Type

K3

SA-BM-S1

FUNCTION 3.1 Function group AB External circuitry category (EN ISO 13849-1)

up to

4 Cross-circuit monitoring X Synchronous time monitoring -- Stop category (EN 60204-1) 0 OFF delay

Q4

0 s Retriggering ON -- AUTO-RESET after POWER ON MANUAL RESET after POWER ON X AUTO-RESET MANUAL RESET X Comment Crossmonitoring by safety sensors

+ Combination of flipflop + AND operation

1* MUTING the conditional ORcombination is valid only if the result of the Reset function before was =1 (see pages 46/47).

59

A

pplications

Application example A 258_B

 Two independent safety

zones

 Monitoring with coded

electromagnetic switches

 Higher-order emergency

stop

 Category 3/4  Stop category 0

When the safety door monitored with MS1 is opened K1 and K2 shut down. When the safety door monitored with MS2 is opened K3 and K4 shut down.

In case of emergency stop via S1, all contactors K1 to K2 shut down. With button S2 you can reset the safety system while the safety devices are closed. Reset button S2 is monitored for errors.

+ Combination of flipflop + AND operation

SA-IN-S1

samos

module

Type

K6 K6A

SA-BM-S1 SA-IN-S1

FUNCTION 8 4 4 Function group AB A B A B External circuitry category (EN ISO 13849-1)

up to

3 3 4 4 Cross-circuit monitoring – – X X Synchronous time monitoring – – – – Stop category (EN 60204-1) 0 0 OFF delay

Q4

0 s Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON X X AUTO-RESET MANUAL RESET X X Comment

samos modules and contactors in the same enclosure

60

A

Two-channel emergency stop and zone monitoring with light curtain. Emergency stop has priority over the light curtain function.

In case of emergency stop relays K1, K2 on the relay output expansion SA-OR-S1 shut

down immediately. Reset after emergency stop and after power on is with RESET.

If light curtain LC1 is interrupted only K2 is switched off. After the light curtain has been

enabled and the feedback circuits checked, the safety device is reset automatically.

pplications

Application example A 259_C

 Two safety zones  Emergency stop and

zone monitoring with light curtain.

 Output expansion with

SA-OR-S1

 Category 3  Stop category 0

samos

module

Type

K-SA1 K-SA2

SA-BM-S1 SA-OR-S1

FUNCTION 7 Function group AB A B External circuitry category (EN ISO 13849-1)

up to

3 3 Cross-circuit monitoring – – Synchronous time monitoring – Stop category (EN 60204-1) 0 0 OFF delay

Q4

0 s Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON X X AUTO-RESET X MANUAL RESET X Comment

samos modules and contactors in the same enclosure

+ Combination of flipflop + AND operation

61

A

pplications

Application example A268

 Robot zone monitoring

with light curtain

 Emergency stop  Safety door monitoring  Category 4  Stop category 1

Robot zone access is monitored by light curtain LC1. The machine zone is further protected by a safety door and an emergency stop circuit.

Sensor S3 is OR-linked with LC1 and detects the safe position of the robot.

This enables e.g. equipping through an opening in the processing area without switching off the robot power supply. If the robot is not in the safe position when the light curtain is interrupted, the entire machine and the robot are switched off.

Opening the safety door or actuating the emergency stop button also result in a safe switch off. The robot control receives the command to switch off (returning to the safe position) from Q1.

K1 and K2 immediately interrupt the power supply to other consumers. The power supply of the robot is switched off safely via K4 and K5 after 1 s.

Restart is possible after exiting the danger zone and pushing Reset button S4.

+ Combination of flipflop + AND operation

1* MUTING the conditional ORcombination is valid only if the result of the Reset function before was =1 (see pages 46/47).

SA-IN-S1

samos

module

Type

K3 K3A

SA-BM-S1 SA-IN-S1

FUNCTION 3.1 2 7 Function group AB A B External circuitry category (EN ISO 13849-1)

up to

4

AB A B

4 4

Cross-circuit monitoring X X – Synchronous time monitoring – – – Stop category (EN 60204-1) 0 OFF delay

Q4

0 s Retriggering ON – AUTO-RESET after POWER ON MANUAL RESET after POWER ON X AUTO-RESET MANUAL RESET X Comment

62

A

x

9 Annex

Anti-Manipulation Measures

Manipulation

Rotary switch moved

Change to control circuit configuration (inputs settings on

S1, S2, S3

Deliberate acceptance of an incorrect configuration

... during operation (power not switched off)

System response System response when



All outputs shut down immediately



System goes into “System error” condition



Red FLT LED on affected module flashes



Green PWR LED flashes



All other FLT LEDs continuous red



Message via field bus coupler module



Outputs of system/ system group shut down at next cycle



Red FLT LED on affected module flashes

)



Message via field bus coupler module



The configurations are saved internally in nonvolatile form and can be read out by the manufacturer if required

The leadable cover SA-COVER is available as an accessory for the safe samos modules. It prevents the rotary switches from changing their setting after system start-up.

... with power off

power connected



System outputs cannot be switched on



Red FLT LED on master module flashes



All other FLT LEDs continuous red



System/system group outputs cannot be switched on



Red FLT LED on master module flashes



All other FLT LEDs continuous red

Action required



Return switch to original position (setting aid if power remains on: flashing PWR LED switches to continuous green)



Restart system by switching power off and on again



Restore old configurations on S1, S2, S3.



Restart system by switching power off and on again



User reads out last (correct) configuration CRC via bus coupler module



Cyclical visual check of configuration

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Error Codes of

FLT

Error LED

Blink code Cause of error

Error codes FLT

 Static Secondary error on modules that have not discovered the error themselves  2x Error in module configurations on S1, S2, S3, other module configuration  3x Rotary switch altered during operation  4x Module location list comparison when power switched on has detected a

difference (including alteration of rotary switch position before or during power off)

 5x Voltage supply internal and external  6x Self-monitoring, internal error, etc. (e.g. enter button pressed longer than 5 s)

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Installing / Removing

Master module Installing Other modules

Place device on DIN rail A. Ensure that earth spring B is in the correct position. The earth spring on the module must make a secure and electrically conductive connection with the DIN rail.

Snap the module onto the DIN rail by pressing gently in the direction of the arrow.

If there are several modules, push them together one at a time in the direction of the arrow until the connectors at the sides engage and then install the end clamps at the left and right ends.

Removing

Remove the plug-in terminals, wiring and end clamps.

If there are several modules, push them apart one at a time in the direction of the arrow until the connectors at the sides disengage.

Push down at the back. While pressing down, remove the module from the DIN rail in the direction of the arrow.

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Connection of Modules

Marking -

___________________________________________________________________________

Marking -C

The modules are equipped with coded pluggable terminal blocks with 4 screw terminals each. To avoid mix-ups, all module blocks are coded differently. Individual modules are not coded differently. Up to 2 stranded wires can be contacted per terminal.

The modules are equipped with coded pluggable terminal blocks with 4 spring force terminals each. To avoid mix-ups, all module blocks are coded differently. Individual modules are not coded differently. Up to 2 stranded wires can be contacted per terminal. The spring force terminals are provided with push-in technology. This means that no tools are required for installation. Stranded wires are removed with a screwdriver by pushing the terminal from the front of the module (vertically to the inserted stranded wires). The voltage check can also be carried out vertically to the stranded wires through the inspection holes provided.

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Screw terminals

For technical data of the terminal see general technical data.

Spring force terminals

For technical data of the terminal see general technical data.

Switch Cover

The optional switch cover SA-COVER can be snapped onto the front of the safe module to prevent the switch setting from changing after start-up. The cover is leadable and can only be removed with a tool (screwdriver) after the lead has been removed.

The screwdriver is inserted at the lower edge vertically to the cover and releases the cover from its locked position using an upward lever movement.

The SA-COVER accessory can be used with safe modules as of revision C-01.

SA-COVER

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SA-BM

Dimensions

Master base module

SA-IN, SA-OR

Screw terminals pluggable Marking -A

Spring force terminals pluggable

Marking -C

___________________________________________________________________________

Input module, Output module

66

Screw terminals pluggable Marking -A

Spring force terminals pluggable

Marking -C

A

x

A

General Technical Data

Climatic conditions

Ambient operating temperature T Storage temperature –25 to +70 °C Relative humidity 10 to 95%, no condensation Climatic conditions (EN 61131-2) Air pressure in operation 860 to 1060 hPa

B

–25 to +55 °C

___________________________________________________________________________

Mechanical strength

Sinusoidal vibration (EN 60068-2-6) Frequency range 5 to 150 Hz Amplitude 3.5 mm (5 to < 9 Hz) Acceleration 1 g (9 to 150 Hz) Number of cycles 10 per axis (on 3 axes) Broad-band random vibration (EN 60068-2-64) Frequency range 5 to 500 Hz Acceleration 4.9 g Semi-sinusoidal shock (EN 60068-2-27) Acceleration / Duration 15 g / 11 ms

___________________________________________________________________________

Electrical safety

Protect. type housing / terminals (EN 60529) IP 40 / IP 20 Finger-proof to DIN EN 50274 Clearance/creepage (EN 61131 -2) Overvoltage category III Contamination level 2 inside, 3 outside Test voltage DC 24 V AC 300 V

350 V 2000 V

___________________________________________________________________________

Electromagnetic compatibility

Burst EN 61000-4-4 Supply 2 kV I/O 1 kV Functional earth (shield) 1 kV Surge EN 61000-4-5, diff. mode / com. mode Supply 1.0 kV / 2.0 kV I/O 1.0 kV / 2.0 kV Functional earth (shield) – / 1.0 kV Communication (field bus) – / 1.0 kV High-frequency electromagnetic fields acc. to EN 61000-4-3 Conducted induced disturbances acc. to EN 61000-4-6 Electrostatic discharge acc. to EN 61000-4-2

Interference emissions acc. to DIN EN 55011:2003 class A

10 V/m

10 V

 4 kV (contact discharge)  8 kV (air discharge)

40 dB (V/m) (20 - 230 MHz) 47 dB (V/m) (230 -1000 MHz)

___________________________________________________________________________

System safety (not for bus coupling modules)

Safety integrity level SIL 3 (IEC/EN 61508/EN 62061)

Unless otherwise stated, the general technical data applies to all base, expansion and bus coupler modules.

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The system must be switched off and restarted at least once a year and the safety functions must be tested!

pprovals

SIL 3 (EN 61508/EN 62061) and PLe/category 4 (EN ISO 13849-1) (not for bus coupling modules) TÜV cULus

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Mechanical and installation

Housing material Polycarbonate Housing type Enclosure installation Color Bus coupler modules Other modules

light gray / light gray yellow / light gray

Terminals

Number of terminals 16 (base modules, I/O modules)

4 (bus coupler modules)

Plug-in terminals with screws

Conductor sizes



single-core / finely stranded



finely stranded with wire-end ferrules

1x 0.2 to 2.5 mm² / 2x 0.2 to 0.75 mm²

1 x 0.25 to 2.5 mm² / 2 x 0.25 to 0.5 mm² Stripping length max. 8 mm Max. tightening torque 0.5 to 0.6 Nm For UL and CSA applications



Conductor sizes



Max. tightening torque

AWG 24-12 (use only Cu conductors)

5.25 lbs-in

Plug-in spring force terminals

Conductor sizes



single-core / finely stranded



with wire-end ferrules

2x 0.2 to 1.5 mm²

2x 0.25 to 1.5 mm² (AWG 24-16) Stripping length max. 8 mm

SBus connector

Poles 10 Number: Master base module Slave base module, I/O modules Bus coupler modules

1 female (right), coded

1 female (right), 1 male (left), coded

1 male (left) Rail DIN rail EN 50022-35

___________________________________________________________________________

Module connections

Max. number of parallel-connected module inputs

or Sn that can be controlled from one module

I

n

output X

or Qn

n

8

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Overview of Devices and Order Numbers

Type Description Coding* Plug-in

terminals

Base modules

SA-BM-S1-4EKL-A Master module, off delay 0-5 s Cod. 1 Screws R1.180.0010.0 SA-BM-S1-4EKL-A Master module, off delay 0-50 s Cod. 1 Screws R1.180.0020.0 SA-BM-S1-4EKL-A Master module, off delay 0-5 min Cod. 1 Screws R1.180.0030.0 SA-BM-S1-4EKL-C Master module, off delay 0-5 s Cod. 1 Spring force R1.180.0360.0 SA-BM-S1-4EKL-C Master module, off delay 0-50 s Cod. 1 Spring force R1.180.0370.0 SA-BM-S1-4EKL-C Master module, off delay 0-5 min Cod. 1 Spring force R1.180.0380.0

Input module

SA-IN-S1-K-A 2 x 4 inputs, 2 x 10 input functions Cod. 1 Screws R1.180.0070.0 SA-IN-S1-K-C 2 x 4 inputs, 2 x 10 input functions Cod. 1 Spring force R1.180.0420.0

*) Please consider the needed coding and the note More safety via coding on page 7 by ordering.

Relay output modules

SA-OR-S1-4RK-A 2 x 2 relay outputs Screws R1.180.0080.0 SA-OR-S2-2RK-A 1 x 2 relay outputs Screws R1.180.0320.0 SA-OR-S1-4RK-C 2 x 2 relay outputs Spring force R1.180.0430.0 SA-OR-S2-2RK-C 1 x 2 relay outputs Spring force R1.180.0440.0

Gateways

SA-PROFIBUS-DP-A Profibus-DP field bus Screws R1.180.0090.0 SA-CANopen-A CANopen field bus Screws R1.180.0100.0 SA-DeviceNet-A DeviceNet field bus Screws R1.180.0350.0 SA-EN-MOD-A Modbus/TCP Screws R1.180.0750.0 SA-EN-PN-A Profinet Screws R1.180.0760.0 SA-EN-IP-A EtherNet/IP Screws R1.180.0770.0

Accessories

SA-COVER Cover for samos modules, leadable,PU 10 p. R9.211.0430.0

Order number

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Manuals (downloadable PDF documents)

SA-MANUAL-D BA000255 SA-MANUAL-GB BA000256 SA-MANUAL-BUS-D BA000268

SA-MANUAL-BUS-GB BA000269

samos manual, German samos manual, English samos bus coupler manual,

German samos bus coupler manual,

English

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Index

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A Access monitoring 52 Activation inputs 23, 52 Adding modules 18 Addressing 13 AND link 21, 38, 40, 47, 53 AND operation 39 Application examples 58 Applications

Access monitoring 19 Bypass 19 Coded electromagnetic switch 19 Emergency stop 19 Enabling input 19 jog mode 19 Muting 19 OR 19 Safety door 19 Switching mats 19 Two-hand control 19

Valve 19 Automatic reset 24 B Blink code 63 Brake 52 Bridge 21, 24 Bus coupler module 8, 12, 48 Bus master 8 Bypass function 12, 21, 37, 46 C Canceling of enabling 18 Cascading safety circuits 48 Category 19 Clearance 12, 46 clock output 24 Clock output 21, 27 Coded electromagnetic switch 52 Combination functions 20 Communication 12, 48 Conditional OR function 12, 39, 46 Configuration 63 Configuration phase 24, 27 Connection diagram

Relay output module 42 Continuous mode 49 Control category 19, 36 Control circuit functions 24, 47 Control circuit terminal

S1 24, 26

S2 23, 26

S3 25, 26 Control input 47 Controlled stopping 21, 48, 52

Controller category 10, 13 Controls 23, 52 Cross monitoring 11, 21, 27, 36, 39, 45 D DC 49 Delay time 25 Demand mode 49 Demand rate 49 Detection of persons 52 Diagnosis function 10, 12, 48 Diagnosis module 12, 48 Diagnostic coverage 49 DIN rail 64 Disassembly 3 Drives 48 Dual function 20 E Electrical equipment 10 Emergency stop monitoring). 52 Enable function 12, 48 Enable input 21 Enabling button 12, 46 Enabling input 24, 46, 48 Enclosure 13, 18, 74 End clamps 64 ENTER button 18 Equivalent activation 36, 45 Evaluating input circuits 20 Exclusion of liability 4 External circuitry 13, 18 External contactors/relays 24 F Failure probability 49 Feedback circuit 12, 21 Feedback circuit monitoring 27, 47 Flipflop 37, 38, 39, 47 FLT error codes 63 Function blocks 27, 28, 30 Function group 20, 21, 36 Funktionseinstellung 65 G Good state 25 H Handling errors 18 I IEC/EN 61508/EN 62061 6, 49 Inductive loads 13 Input circuit function 11, 36, 38, 40, 45 Input circuit functions 19 Input dynamization 45 Input expansion 39, 40 Input module 8, 32 INPUT rotary switch 36

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Installation 3 Installation, conditions of 4 Installing 64 Interfaces

Base module 17, 18 Input module 35

Relay output module 44 J Jog mode 23, 45, 52 K Kategorie 36, 37 L Light barrier monitoring 52 Light curtain function 12 Light grille function 46 Logic functions 39 Logic operation 12, 47 M Machine safety 4 Machinery directive 4 Manipulation 18, 63 Manual reset 24, 25 Master base module 6, 8, 13 Minimum configuration 6 Mode 18 Modulated self-test signals 52 Module address 13 Muting function 12, 22, 46 Muting inputs 23 Muting lamp 22, 46 Muting lamp output 23 Mutinglampenausgang 23 N Non-contact safety device type 2 19 Non-contact safety device type 4 19 Non-equivalent activation 11, 45 Notes

Base modules 13

Input module 32

Relay output module 42 O Occupational health and safety directive

4 Operating errors 18 Operating voltage 18, 48 Operation

Base module 17, 18

Input module 35

Relay output module 44 OR function 22, 37 OR link 40, 47, 55 OR operation 21, 39 Order numbers 69 OSSD 22, 52 Output dynamization 48 Output function 12, 48

Output switching element 52 Overcurrent limitation 52 Overview of devices 69 P Parallel-connected module inputs 14, 68 PFD 49 PFH 49 PLC 12, 48 Position monitoring 52 Position switch 52 Press control 23, 52 Probability of failure 49 Product liability 4, 49 Proper use 4 R RC combination 13 Relay output module 8, 11, 18, 42 Release delay 12, 21, 23, 25, 47, 48, 52 Release time 25 Removing 64 Removing modules 18 Reset 24 Reset after safety event. 47 Reset behavior 21, 24 Reset button 21, 24, 47 Reset condition 18, 47 Reset function 12, 47, 48 Residual risk 9, 49 Response signal 23, 52 Restart 18 Restarting lockout 24, 47 Retriggering 23, 25, 47 Risk assessment 9 Risk minimization 9 S SA-BM-S1 13 Safe state of inputs 24, 25 Safety bus 11, 12, 21, 32, 48 Safety chain 49 Safety circuits 10 Safety communication 11 Safety devices 10 Safety door monitoring 52 Safety event 24 Safety function 11, 49 Safety integrity level 49 Safety level 23 Safety measures 3 Safety requirements 49 Safety rules 3 Safety sensors 10 Safety shutdown 52 Safety standards 4 Safety structure 49 Safety zones 10, 48 Safety-related information 3

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SA-OR-S1 42 SA-OR-S2 42 SBus 11 Self-testing sensors 19, 52 Semiconductor 11, 37, 45 Sensor connections 19 Sensoranschlüsse 36 Separating safety devices 52 Setup mode 12, 46, 52 SFF 49 Signal 22 Signal flow 21 Signal source 22 Single functions 20 Special functions 23 Standard functions 38 Starting lockout 24, 46, 47 Startup 3 Statutory regulations 4 Stop category 48, 52 Structure 6 Subsystem 6 Summary analysis 9 Supply terminals 21 Switch off and on again 18 Switching mats 52 Switching on procedures 48 Synchronous time monitoring 11, 36, 45

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System configuration 18 System data 12, 48 System functions 11, 45 Systemkonfiguration 65 T Technical data

General 67 Terminal assignment 41 Terminal configuration 12, 47 Test cycles 3 Test function 23 Testable sensors 19, 23 Three-wire 38, 39 Three-wire circuit 36 Time behavior 12, 48 Tripping characteristic 13 Two-hand button 52 Two-hand function 11, 45, 52 Two-hand operation 23 Type 2 non-contact safety devices 52 Type 4 non-contact safety devices 52 Type IIIA 19 Type IIIC 19, 52 U Use of work equipment directive 4 V Valve monitoring 52

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03C

samos

Configuration List

This is a blank samos configuration list (module location list) for copying. We recommend keeping a record of the configuration with the documentation or in a clearly visible place in the enclosure.

___________________________________________________________________________

Notes on the

EN S1 S2 S3 I1 I2 I3 I4

HHHL HHHL

Type: SW-Ver:

FUNCTION: DELAY:

I1 I2 I3 I4 I5 I6 I7 I8

LLHH LLHH

Q1 Q2 Q3 Q4

LLHH

samos

SA-BM-S1 0524

K936 FLT K936A

8 5min

configuration list

Aktuelle CRC der Steckplatzliste

Current module configuration CRC

Anzahl der vorhandenen aktiven

sicheren Module.

Number of available active safe

Zeitpunkt der Datenübertragung

Position des Moduls von Links

Position of the module from the

Anwender-Modulbezeichnung

Code in the event of failure/error

SA-IN: Eingangskreisfunktion A

SA-IN: Input circuit function A

SA-IN: Eingangskreisfunktion B

SA-IN: Input circuit function B

Anzahl der entdeckten Fehler

Useable fields to enter project

Button for start of data transfer

modules

Date of the data transfer

Klemmenbezeichnung

Terminal designation

High- oder Low-Pegel

High or low level

Modultyp

Module type

Software-Version

left side

User module-reference

Evtl. Fehlercode des Moduls

SA-Bx: Funktionbaustein Nr.

SA-Bx: Function block No.

SA-Bx: Verzögerungszeit

SA-Bx: Time delay setting

Number of detected faults

Frei verwendbare Felder für

Projektinformationen

information

Schaltfläche zum Start der

Datenübertragung

System-CRC: No. of modules:

Timestamp: 23.12.2005

EN S1 S2 S3

HHHL

Type: SW-Ver:

K935

FUNCTION: DELAY:

I1 I2 I3 I4

LLHH

Q1 Q2 Q3 Q4

LLHH

Type: SW-Ver:

INPUT A: INPUT B:

A 5

SA-BM-S1 0524

8 5min

SA-IN-S1 0524

8 3

74

Reading samos-config

Ref. to drawing No.:

Company: Project:

Rev.:

Comment:

Date:

Name:

Faults: 1

A

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x

S

CRC

N

Type:

=

SW-Ver:

=

Release 2.0

ystemo. of active modules:

Date:

Left side module

Type: SW-Ver:

Type:

=

SW-Ver:

=

:

samos-configuration graphics

Diese Übersicht zeigt die Anzahl, Reihenfolge und Konfiguration der aktiven sicheren samos-Module eines Systems in einem bestimmten, vom Anwender gewählten Zustand der Maschine. Sie dient der Dokumentationsergänz ung einer Anlage/Maschine.

Die dargestellt en Informationen sind vo m Anwender mit dem tatsächlichen Zust and des samo s-Systems zu vergleic hen! Für die Rich tigkeit u nd

D

Vollständigkeit der Daten übernimmt die Firma Wieland keine Haftung!

Ausgangsmodule Relais SA-OR sind nicht dargestellt.

This overview shows the number, the order, and the configuration of the active samos modules of a system designed and constructed by the user's selected structure of the machine. This overview can be used to supplement the documentation for the machine configuration.

The indicated information must be compared with the actual conditions of the samos syst em! Company Wielan d does no t take responsibilit y for the

GB

correctness a nd comp letion of th e dates!

Output modules relays SA-OR are not shown in this overview.

Type:

=

SW-Ver:

=

== = =

== = = == = =

Type:

=

SW-Ver:

=

Type:

=

SW-Ver:

=

== = =

== = = == = =

Type:

=

SW-Ver:

=

== = =

== = = == = =

Reading samos-config

Type:

=

SW-Ver:

=

Type:

=

SW-Ver:

=

Type:

=

SW-Ver:

=

Type:

=

SW-Ver:

=

Type:

=

SW-Ver:

=

max. m odule num ber

Type:

=

SW-Ver:

=

Faults:

Company: Project:

Ref. to drawing No.:

Date:

Comment:

Rev.:

Name:

Sign:

Data transfer betw een samos-module SA-PROFIBUS-DP-A and P C via Mastersimulator BW1131 (company Bihl+Wiedemann) Download of samosConf igListSetupX.X.zip under www.wieland-electric.com --> Infoservice --> Download Center

Wieland-Service: www.wieland-electric.com info@wieland-electric.comHotline: + 49 951 9324- 995

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