Elobau EloProg Bedienungsanleitung

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016

eloProg

Configurable safety system

Manual (translation of the original manual)

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016

TABLE OF CONTENTS

1 INTRODUCTION .................................................................................................. 1-1

1.1 Contents of this handbook ................................................................................................ 1-1

1.2 Important safety instructions ............................................................................................. 1-1

1.3 Abbreviations and symbols .............................................................................................. 1-2

1.4 Applicable standards......................................................................................................... 1-2

2 OVERVIEW .......................................................................................................... 2-1

3 SCOPE OF SUPPLY............................................................................................ 3-1

4 INSTALLATION ................................................................................................... 4-1

4.1 Mechanical fastening ........................................................................................................ 4-1

4.2 Calculation of safety distance of an electro-sensitive protective system connected

to eloProg.......................................................................................................................... 4-2

4.3 Electrical connections ....................................................................................................... 4-2

4.3.1 Instructions concerning connection cables ...................................................................... 4-3

4.3.2 USB input.......................................................................................................................... 4-4

4.3.3 eloProg memory stick (350EPS)....................................................................................... 4-4

Function MULTIPLE LOAD............................................................................................... 4-5

RESTORE function ........................................................................................................... 4-5

4.3.4 Encoder connections with RJ45 connector (485EPS1, 485EPS2) ................................. 4-11

4.3.5 Example for connecting the eloProg system to the machine controller .......................... 4-13

4.4 Checklist after installation ............................................................................................... 4-13

5 FUNCTIONAL DIAGRAM .................................................................................... 5-1

6 DESCRIPTION OF SIGNALS .............................................................................. 6-1

6.1 Inputs ................................................................................................................................ 6-1

6.1.1 MASTER ENABLE............................................................................................................ 6-1

6.1.2 NODE SEL........................................................................................................................ 6-1

6.1.3 Initiator input proximity for 485EPS2N .............................................................................. 6-2

Configuration with overlapping initiator signals................................................................. 6-2

6.1.4 RESTART_FBK ................................................................................................................ 6-3

6.2 Outputs ............................................................................................................................. 6-4

6.2.1 OUT STATUS ................................................................................................................... 6-4

6.2.2 OUT TEST ........................................................................................................................ 6-4

6.2.3 OSSD (Module 485EPB, 485EPE08A02, 485EPA02, 485EPA04) .................................. 6-4

6.2.4 Relay modules (485EPR02, 485EPR04).......................................................................... 6-5

Characteristics of the output circuit................................................................................... 6-5

Module 485EPR02/485EPR04 internal contacts .............................................................. 6-6

Wiring example of the relay module 485EPR02 to the basic module 485EPB................. 6-7

Functional diagram of output circuit connected to the module 485EPR02 / 485EPR04... 6-7

7 TECHNICAL SPECIFICATIONS.......................................................................... 7-1

7.1 General system characteristics......................................................................................... 7-1

7.1.1 Safety parameters of the system ...................................................................................... 7-1

7.1.2 General data ..................................................................................................................... 7-1

7.1.3 Housing............................................................................................................................. 7-2

7.1.4 Basic module 485EPB ...................................................................................................... 7-2

7.1.5 I/O module 485EPE08A02................................................................................................ 7-2

7.1.6 Input modules 485EPE08 - 485EPE12 - 485EPE16 ........................................................ 7-3

7.1.7 Output modules 485EPA02 - 485EPA04 .......................................................................... 7-3

7.1.8 Output modules 485EPR02 - 485EPR04.......................................................................... 7-3

7.1.9 Speed monitoring modules 485EPS2N - 485EPS1 - 485EPS2........................................ 7-4

7.1.10 Modules 485EPR04S00B - 485EPR04S08B.................................................................... 7-5

7.2 Mechanical dimensions..................................................................................................... 7-5

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016

7.3 Signals .............................................................................................................................. 7-7

7.3.1 Basic module 485EPB ...................................................................................................... 7-7

7.3.2 I/O module 485EPE08A02................................................................................................ 7-9

7.3.3 Input module 485EPE08 ................................................................................................. 7-10

7.3.4 Input module 485EPE12 ................................................................................................. 7-11

7.3.5 Input module 485EPE16 ................................................................................................. 7-12

7.3.6 Output module 485EPA02 .............................................................................................. 7-13

7.3.7 Output module 485EPA04 .............................................................................................. 7-14

7.3.8 Module 485EPR04S00B ................................................................................................. 7-15

7.3.9 Module 485EPR04S08B ................................................................................................. 7-16

7.3.10 Modules 485EPS2N, 485EPS1, 485EPS2 ..................................................................... 7-17

7.3.11 Relay output modules 485EPR02/485EPR04 ................................................................ 7-18

7.4 Fault diagnosis................................................................................................................ 7-19

7.4.1 Basic module 485EPB .................................................................................................... 7-19

7.4.2 I/O module 485EPE08A02.............................................................................................. 7-20

7.4.3 Input module 485EPE08 ................................................................................................. 7-21

7.4.4 Input module 485EPE12 ................................................................................................. 7-22

7.4.5 Input module 485EPE16 ................................................................................................. 7-23

7.4.6 Output module 485EPA02/485EPA04 ............................................................................ 7-24

7.4.7 Module 485EPR04S00B ................................................................................................. 7-25

7.4.8 Module 485EPR04S08B ................................................................................................. 7-26

7.4.9 Modules 485EPS2N, 485EPS1, 485EPS2 ..................................................................... 7-27

8 CONFIGURATION SOFTWARE.......................................................................... 8-1

8.1 Installing the software ....................................................................................................... 8-1

8.1.1 PC hardware requirements ............................................................................................... 8-1

8.1.2 PC software requirements ................................................................................................ 8-1

8.1.3 How to install the configuration software .......................................................................... 8-1

8.1.4 Fundamentals ................................................................................................................... 8-2

8.1.5 Standard toolbar ............................................................................................................... 8-3

8.1.6 Textual toolbar .................................................................................................................. 8-4

8.1.7 Create a new project......................................................................................................... 8-4

8.1.8 Edit configuration (composition of the various modules) .................................................. 8-5

8.1.9 Change user parameters ................................................................................................. 8-5

8.1.10 Toolbar buttons - Operators - Configuration ..................................................................... 8-6

8.1.11 Creating the diagram (configuration) ................................................................................ 8-7

8.1.12 Example of a project ......................................................................................................... 8-8

Project validation .............................................................................................................. 8-8

Project report .................................................................................................................... 8-9

Connect to eloProg ........................................................................................................ 8-10

Send configuration to eloProg ........................................................................................ 8-10

Download a configuration file (project) from the basic module 485EPB ........................ 8-10

Configuration LOG ....................................................................................................... 8-11

System structure ............................................................................................................ 8-11

Disconnecting the system ............................................................................................. 8-12

MONITOR (status of I/O in real time - text) ................................................................... 8-12

MONITOR (status of I/O in real time - graphical) .......................................................... 8-13

8.1.13 Password protection ....................................................................................................... 8-14

Level 1 password ............................................................................................................ 8-14

Level 2 password ............................................................................................................ 8-14

Password change ......................................................................................................... 8-15

8.1.14 System Test ................................................................................................................... 8-16

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016

8.2 Function blocks ............................................................................................................... 8-17

8.2.1 OUTPUTS....................................................................................................................... 8-17

OSSD (semiconductor safety outputs)............................................................................ 8-17

Status output................................................................................................................... 8-17

FIELDBUS PROBE (fieldbus sensor) ............................................................................. 8-18

RELAY ............................................................................................................................ 8-19

8.2.2 INPUTS........................................................................................................................... 8-21

E-STOP (emergency stop, one and two-channel) .......................................................... 8-21

E-GATE (mobile separating guard, two-channel) ........................................................... 8-23

SINGLE E-GATE (mobile separating guard, one-channel)............................................. 8-25

LOCK FEEDBACK (lock monitoring) .............................................................................. 8-26

ENABLE (key switch)...................................................................................................... 8-27

ESPE (Electro sensitive protective system: safety light barrier / laser scanner)............. 8-29

FOOTSWITCH (safety pedal / foot switch) ..................................................................... 8-30

MOD-SEL (mode selection switch)................................................................................. 8-32

PHOTOCELL (Safety light barrier).................................................................................. 8-33

TWO-HAND (two hand control) ...................................................................................... 8-34

SENSOR (photocell, initiator) ......................................................................................... 8-35

S-MAT (safety mat)......................................................................................................... 8-36

SWITCH.......................................................................................................................... 8-37

ENABLING GRIP SWITCH (enabling switch)................................................................. 8-38

TESTABLE SAFETY DEVICE (mechanical safety switch) ............................................. 8-40

SOLID STATE DEVICE (safety sensor with semiconductor outputs)............................. 8-42

FIELDBUS INPUT (fieldbus inputs) ................................................................................ 8-43

LL0-LL1........................................................................................................................... 8-43

COMMENTS ................................................................................................................... 8-43

TITLE .............................................................................................................................. 8-43

8.3 Function blocks of type SPEED MONITORING.............................................................. 8-44

SPEED CONTROL ......................................................................................................... 8-44

WINDOW SPEED CONTROL (speed control in measuring window)............................. 8-47

STILL STAND (stillstand check) ..................................................................................... 8-50

STAND STILL AND SPEED CONTROL (speed and standstill control).......................... 8-53

8.3.1 GUARD LOCK block....................................................................................................... 8-57

GUARD LOCK: Safety guard lock .................................................................................. 8-57

8.4 Operators (processing blocks) ........................................................................................ 8-59

8.4.1 Logic blocks .................................................................................................................... 8-59

AND: And block............................................................................................................... 8-59

NAND (NOT-AND): AND block with an inverted output.................................................. 8-59

NOT: Inverter block......................................................................................................... 8-60

OR: OR block.................................................................................................................. 8-60

NOR (NOT OR): OR block with an inverted output......................................................... 8-60

XOR (EXCLUSIVE OR): Exclusive OR block ................................................................. 8-61

XNOR (EXCLUSIVE NOT OR): Equivalent block........................................................... 8-61

MULTIPLEXER: Selection switch ................................................................................... 8-62

8.4.2 Memory blocks................................................................................................................ 8-63

D FLIP FLOP: Data flip flop edge-controlled................................................................... 8-63

SR FLIP FLOP: Set-Reset-Flipflop ................................................................................. 8-63

USER RESTART MANUAL: Restart inhibit, reset with rising edge ................................ 8-64

USER RESTART MONITORED: Restart inhibit, Start with falling edge......................... 8-64

8.4.3 Counter blocks ................................................................................................................ 8-65

COUNTER: Counter, up and down................................................................................. 8-65

8.4.4 TIMER operators............................................................................................................. 8-67

CLOCKING: Clock generator, controllable ..................................................................... 8-67

MONOSTABLE: Monoflop .............................................................................................. 8-68

PASSING MAKE CONTACT: Maximum time (pulse time limiter)................................... 8-69

DELAY: ON / OFF delay................................................................................................. 8-70

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016

8.4.5 Muting ............................................................................................................................. 8-72

8.4.6 MUTING blocks............................................................................................................... 8-72

MUTING "Con" (Concurrent): 4-Sensor-Muting (double parallel) ................................... 8-72

MUTING "L" (L-arrangement): 2 Sensor single-side muting (parallel)............................ 8-74

MUTING "Seq" (Sequential): 4-sensor muting (serial).................................................... 8-75

MUTING "T" (T-arrangement): 2 Sensor two-sided muting (parallel) ............................. 8-77

MUTING OVERRIDE ...................................................................................................... 8-78

8.5 Various function blocks................................................................................................... 8-80

SERIAL OUTPUT: Serial transmission of status signals ................................................ 8-80

NETWORK...................................................................................................................... 8-81

INTERPAGE IN/OUT ...................................................................................................... 8-84

8.5.1 Special applications ........................................................................................................ 8-85

Output delay with manual operation ............................................................................... 8-85

8.5.2 EloProg error codes ........................................................................................................ 8-86

9 ACCESSORIES AND SPARE PARTS ................................................................ 9-1

10 EU-DECLARATION OF CONFORMITY ............................................................ 10-1

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016 1-1

1 INTRODUCTION

1.1 Contents of this handbook

This handbook describes how to use the eloProg programmable safety module and its expansion

units (termed “SLAVES”) and

includes the following:

a description of the system

installation methods

connections

signals

diagnostics

use of the configuration software

1.2 Important safety instructions

Warning

This symbol designates an important instruction relating to personal safety. Failure to

comply can lead to a very high risk for the personnel concerned.

Note

This symbol indicates an important note.

Warning

eloProg fulfills the following safety levels: SIL 3, SILCL 3, PLe and Cat. 4, according to

applicable regulations.

However, the definitive SIL and PL of the application will depend on the number of

safety components, their parameters and the connections that are made, as per the risk

analysis.

Please read Sec. 1.4 Applicable standards on page 1-2 carefully.

Perform an in-depth risk analysis to determine the appropriate safety level for your spe-

cific application, on the basis of all the applicable standards.

Programming/configuration of the eloProg is the sole responsibility of the installer or

user.

The device must be programmed/configured in accordance with the application-specific

risk analysis and all applicable standards.

Once you have programmed/configured and installed the eloProg and all the relative

devices, run a complete application safety test (see Sec. 8.1.14 System Test on

page 8-16).

elobau is not liable for these operations or any risks in connection therewith.

Refer to the operating manual and possibly the relevant product and/or equipment reg-

ulations to endure correct use of the devices connected to eloProg.

The customer must ensure full control of the system when new safety components are

added to the system itself (see Sec. 8.1.14 System Test on page 8-16).

The ambient temperature in the place where the system is installed must be compatible

with the operating temperature parameters stated on the product label and in the spec-

ifications.

For all matters concerning safety, if necessary, contact your country's competent safety

authorities or the competent trade association.

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016 1-2

1.3 Abbreviations and symbols

1.4 Applicable standards

eloProg complies with the following European Directives:

2006/42/EC “Machinery Directive”

2004/108/EC “Electromagnetic Compatibility Directive”

2006/95/EC “Low-voltage Directive”

The following standards are complied with:

Tab. 1-1 Applicable standards

350EPS = eloProg memory stick for basic module 485EPB (accessory)

350EPT = eloProg T-distributor

350EPKS = eloProg configuration software

OSSD = Output Signal Switching Device: solid state safety output (safety output)

DC = Diagnostic Coverage: level of diagnostic coverage

MTTFd=Mean Time to Dangerous Failure

PL = Performance Level

PFHd=Probability of a dangerous failure per Hour

SIL = Safety Integrity Level

SILCL = Safety Integrity Level Claim Limit

SW = Software

CEI EN 61131-2

(2007)

Programmable controllers, part 2:

Equipment characteristics and tests

ISO 13489-1

(2008)

Safety of machinery:

Safety related parts of control systems. General principles for design

EN 61496-1

(2013)

Safety of machinery: Electro-sensitive protective systems, Part 1:

General requirements and tests

IEC 61508-1

(2010)

Functional safety of electrical/electronic/programmable electronic safety-related systems:

General requirements

IEC 61508-2

(2010)

Functional safety of electrical/electronic/programmable electronic safety-related systems:

Requirements for electrical/electronic/programmable electronic safety-related systems

IEC 61508-3

(2010)

Functional safety of electrical/electronic/programmable electronic safety-related systems:

Software requirements.

IEC 61784-3

(2008)

Digital data communication for measurement and control: Functional safety field buses

IEC 62061

(2013)

Safety of machinery: Functional safety of safety-related electrical, electronic and programmable electronic

control systems

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016 2-1

2OVERVIEW

eloProg is a modular safety controller consisting of a master unit (485EPB) and a number of expan-

sion units connected via the proprietary bus.

The master unit can be configured by means of a graphical user interface and has 8 safety inputs

and 2 independent programmable two-channel safety outputs. The master module can also be op-

erated independently (stand-alone).

The following sensors can be connected to eloProg:

optoelectronic sensors (safety light curtains, laser scanners, etc.), mechanical switches, emergency

stops, safety shut-off mats, two-hand controls, enabling switches, proximity switches.

The system must consist of just one master (Master Module 485EPB) and a maximum of 14 electronic

expansion modules, but not more than 4 of the same type.

With 14 expansions, the system can have up to 128 inputs, 16 two-channel safety outputs and

16 status outputs. The MASTER and its SLAVE units communicate via the 5-way bus sensor, phys-

ically arranged on the rear panel of each unit.

Furthermore 8 inputs and 16 outputs are available in association with the field bus modules. They

enable bidirectional controlling and reporting.

The expansion modules of the eloProg system 485EPE08, 485EPE16 and 485EPE12 allow the

number of inputs in the system to be increased and allow more external devices to be connected.

The 485EPE12 also provides 8 OUT_TEST outputs.

The expansion units of the eloProg system 485EPA02, 485EPA04 provide the system, respectively,

with 2 and 4 static OSSD safety outputs for controlling devices connected downstream of the eloProg.

The 485EPE08A02 has 8 inputs and 4 OSSD safety outputs.

The eloProg system expansion units 485EPR02 and 485EPR04provide the system with 2 and 4 NO

guided contact safety relay outputs, respectively, with the related external relay feedback (NC con-

tact).

The expansion units in the 485EPF series permit connection to the most commonly used industrial

fieldbus systems for diagnostics and data transmission. The 485EPFEI, 485EPFPN and 485EPFEC

also have an Ethernet connection.

The 485EPFUB permits connection to devices with a USB port.

Note

The following is available:

Input / output expansions:

(485EPE08A02)

Input expansions:

(485EPE08, 485EPE12, 485EPE16, 485EPS2N, 485EPS1x and 485EPS2x)

Output expansions:

(485EPA02 and 485EPA04)

Output modules with safety relays and forcibly guided contacts:

(485EPR02 and 485EPR04, 485EPR04S00B and 485EPR04S08B)

Fieldbus module:

485EPFPD (PROFIBUS DP), 485EPFCO (CanOpen), 485EPFDN (DeviceNet),

485EPFEI (Ethernet IP), 485EPFEI2 (Ethernet IP 2-way), 485EPFMR (Modbus RTU),

485EPFMT (Modbus TCP), 485EPFPN (Profinet), 485EPFPN2 (Profinet 2-way),

485EPFEC (EtherCat), 485EPFUB (USB interface module)

Bus transfer modules:

485EPT1, 485EPT2

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016 2-2

The bus transfer modules 485EPT1, 485EPT2 enable the connection of 485EPB with other slave

modules, decentralized, at a distance of max. 50 m. By using a shielded cable, the bus transfer mod-

ules are connected at the desired distance.

The following functions can be monitored with the speed monitoring modules 485EPS2N,

485EPS1x, 485EPS2x:

standstill, maximum speed, speed range;

direction of rotation

There can be up to 4 switching points freely configured for speed limitation for each input (axis).

Each unit incorporates two configurable outputs and is thus capable of controlling up to 2 indepen-

dent axes.

The 485EPR04S00B and 485EPR04S08B relay modules are provided with 4 independent safety re-

lay outputs and the corresponding 4 inputs for the external feedback contacts (EDM).

2 settings are possible (configuration via elobau Safety Designer) for the outputs:

2 double connection contacts (2 NO contacts per output with 2 corresponding feedback inputs).

4 independent single connection contacts (1 NO contact per output with 1 corresponding feedback

input).

Only the 485EPR04S08B unit has 8 programmable signal outputs.

The eloProg configuration software is capable of creating complex logics, by using logical operators

and safety functions such as muting, timer, counters, etc.

All this is performed by means of an easy and intuitive graphical user interface.

The configuration performed on the PC is sent to the 485EPB module via USB connection. The file

is stored on the 485EPB and can also be stored on the proprietary Memory Stick 350EPS (accesso-

ry). Thus, a quick transfer of the configuration to other 485EPB modules is easily possible.

Note

The eloProg system is certified to the maximum safety level envisaged by the applicable

industrial safety standards (SIL 3, SILCL 3, PL e and Cat. 4).

Type no.: 350HB002 Version: 1.3 Date: 13.04.2016 3-1

3 SCOPE OF SUPPLY

The basic module 485EPB is supplied with:

– CD-ROM containing the free configuration software and PDF manual

The expansion units are supplied with:

– Rear bus (T-distributor 350EPT),

(not included with relay output modules 485EPR02 and 485EPR04 because they are connected

only via the terminals).

Note

The rear panel connector (T-distributor 350EPT) and the memory stick (350EPS) can be

ordered separately as accessories.

Note

To install an expansion unit (excluding relays) you will need the T-distributor supplied with

the unit plus another bus connector (T-distributor) for the connection to the 485EPB basic

module. This can be ordered separately as an accessory.

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