Leuze electronic ASM1/1 Bedienungsanleitung

AS-I Safety Monitor

Version V 3.08 with Muting functionality

607023-2009/09

CONNECTING AND OPERATING INSTRUCTIONS

in any form requires prior written permission from copyright owner.

Product names are used without warranty of unrestricted applicability.

Changes due to technical improvement may be made.

Operating manual for the AS-i safety monitor V 3.08 M 1

Table of Contents

Edition: 01/2010

1 General Information........................................................................................................... 5

1.1 Explanation of symbols ........................................................................................................ 5

1.2 Declaration of Conformity ....................................................................................................5

1.3 Standards............................................................................................................................. 5

1.4 Definition of terms ................................................................................................................ 6

1.5 Abbreviations ....................................................................................................................... 8

1.6 Brief description ................................................................................................................... 9

1.7 Different types of AS-i safety monitors............................................................................... 13

2 Safety ................................................................................................................................ 17

2.1 Approved purpose and foreseeable improper operation.................................................... 17

2.1.1 Proper use.............................................................................................................................. 17

2.1.2 Foreseeable misuse ............................................................................................................... 19

2.2 Competent personnel......................................................................................................... 19

2.3 Responsibility for safety ..................................................................................................... 20

2.4 Exemption of liability .......................................................................................................... 20

2.4.1 Residual risks (EN ISO 12100-1) ........................................................................................... 20

2.4.2 Areas of application................................................................................................................ 21

2.5 Additional safety notices for the "Muting" special function ................................................. 21

2.5.1 Safety Notices for Muting applications ................................................................................... 21

2.6 Organizational measures ................................................................................................... 24

3 Muting via AS-i ................................................................................................................. 25

3.1 Optoelectronic Protective Devices for Muting applications ................................................ 25

3.2 Usage examples ................................................................................................................ 26

3.2.1 4-sensor Sequential Muting.................................................................................................... 26

3.2.2 2-sensor Parallel Muting......................................................................................................... 27

3.3 System design and Muting modes ..................................................................................... 27

3.3.1 System design........................................................................................................................ 27

3.3.2 4-sensor Sequential Muting.................................................................................................... 30

3.3.3 2-sensor Parallel Muting......................................................................................................... 33

3.3.4 Muting time limit – Muting timeout.......................................................................................... 35

3.3.5 Muting restart - Override mode .............................................................................................. 35

3.3.6 Muting status .......................................................................................................................... 37

3.4 Mounting the Muting system components ......................................................................... 38

4 Specifications................................................................................................................... 41

4.1 General technical data .......................................................................................................41

4.2 Safety-relevant characteristic data..................................................................................... 43

4.3 Dimensioned drawings....................................................................................................... 46

4.4 Scope of delivery ............................................................................................................... 46

5 Mounting ........................................................................................................................... 47

5.1 Mounting in the switching cabinet ...................................................................................... 47

2 Operating manual for the AS-i safety monitor V 3.08 M

Table of Contents

Edition: 01/2010

6 Electrical connection ASM1/1, ASM1E/1 and ASM1E-m/1 ........................................... 50

6.1 Terminal assignment..........................................................................................................50

6.2 Connection overview..........................................................................................................52

7 Electrical connection ASM1/2, ASM1E/2 and ASM1E-m/2 ........................................... 53

7.1 Terminal assignment..........................................................................................................53

7.2 Connection overview..........................................................................................................55

8 Electrical connection ASM2E/1, ASM2E/2, ASM2E-m/1 and ASM2E-m/2 ................... 56

8.1 Terminal assignment..........................................................................................................56

8.2 Connection overview..........................................................................................................58

8.2.1 Connection for actuator monitoring.........................................................................................59

8.2.2 Connection for coupling to another AS-i network ...................................................................60

9 Electrical Connection of All Types................................................................................. 61

9.1 AS-i bus connection ........................................................................................................... 61

9.2 Serial interface ................................................................................................................... 62

10 Function and Commissioning ........................................................................................ 63

10.1 Function and operating modes .......................................................................................... 63

10.1.1 Start-up operation ...................................................................................................................63

10.1.2 Configuration operation ..........................................................................................................64

10.1.3 Protective operation ................................................................................................................64

10.2 Display and operating elements......................................................................................... 65

10.3 Switching on the device .....................................................................................................66

10.4 Device configuration and parameterisation........................................................................ 66

10.5 Technical safety documentation for the application ........................................................... 67

11 Maintenance ..................................................................................................................... 68

11.1 Checking for safe shutdown............................................................................................... 68

12 Status Display, Errors and Error Rectification.............................................................. 69

12.1 Status display on the device / error diagnosis on the PC .................................................. 69

12.2 Troubleshooting tips........................................................................................................... 69

12.3 Error release with the "Service" button .............................................................................. 69

12.4 Replacing defective safe AS-i slaves................................................................................. 70

12.4.1 Replacing a defective safe AS-i slave ....................................................................................70

12.4.2 Replacing several defective safe AS-i slaves .........................................................................70

12.5 Replacing a defective AS-i safety monitor ......................................................................... 72

12.6 What to do if you forget the password ............................................................................... 73

13 Diagnostics via AS-i ........................................................................................................ 74

13.1 General procedure ............................................................................................................. 74

13.2 Telegrams .......................................................................................................................... 75

13.2.1 Diagnosis of AS-i safety monitor.............................................................................................75

13.2.2 Diagnosis of devices, sorted according to OSSD ...................................................................79

13.2.3 Diagnosis of devices, unsorted...............................................................................................81

13.3 Example: Querying with diagnosis sorted according to OSSD .......................................... 83

Operating manual for the AS-i safety monitor V 3.08 M 3

Table of Contents

Edition: 01/2010

14 EC Declaration of Conformity......................................................................................... 84

4 Operating manual for the AS-i safety monitor V 3.08 M

Table of Figures

Edition: 01/2010

Figure 1.1: Safe and standard components in an AS-i network ................................................................9

Figure 1.2: Example - Monitoring of 2 decentral AS-i actuator groups ....................................................10

Figure 1.3: Example - Monitoring of 2 decentral AS-i actuator groups ....................................................11

Figure 3.1: Variants of the Optoelectronic Protective Device for Muting applications .............................25

Figure 3.2: 4-sensor Sequential-Muting application at a robot station.....................................................26

Figure 3.3: 2-sensor Parallel Muting application at a palletizer system...................................................27

Figure 3.4: Principle system design for Muting via AS-i, 2-sensor Parallel Muting..................................28

Figure 3.5: System arrangement for 4-sensor Sequential Muting ...........................................................31

Figure 3.6: Time diagram: 4-sensor Sequential Muting ...........................................................................32

Figure 3.7: System arrangement for 2-sensor Parallel Muting ................................................................33

Figure 3.8: Time diagram: 2-sensor Parallel Muting................................................................................ 34

Figure 3.9: Arrangement of the Muting sensors, 4-sensor Sequential Muting......................................... 39

Figure 3.10: Arrangement of Muting sensors MS2 and MS3.....................................................................39

Figure 3.11: Arrangement of the Muting sensors, 2-sensor Parallel Muting..............................................40

Figure 4.1: Example 1 - Calculation of the system reaction time.............................................................44

Figure 4.2: Example 2 - Calculation of the system reaction time.............................................................45

Figure 4.3: Example 3 - Calculation of the system reaction time.............................................................45

Figure 4.4: Dimensions............................................................................................................................46

Figure 5.1: Mounting................................................................................................................................47

Figure 5.2: Removable connection terminals .......................................................................................... 48

Figure 5.3: Removing and mounting encoded connection terminals.......................................................48

Figure 5.4: Mounting accessories for sealing the device......................................................................... 49

Figure 6.1: Terminal arrangement / block diagram of AS-i safety monitor ASM1/1,

ASM1E/1 and ASM1E-m/1 ....................................................................................................50

Figure 6.2: Connection overview of AS-i safety monitor ASM1/1, ASM1E/1

and ASM1E-m/1 .................................................................................................................... 52

Figure 7.1: Terminal arrangement / block diagram of AS-i safety monitor ASM1/2,

ASM1E/2 and ASM1E-m/2 ....................................................................................................53

Figure 7.2: Connection overview of AS-i safety monitor ASM1/2, ASM1E/2 and

ASM1E-m/2 ...........................................................................................................................55

Figure 8.1: Terminal arrangement / block diagram of AS-i safety monitor ASM2E/1, ASM2E/2,

ASM2E-m/1 and ASM2E-m/2................................................................................................56

Figure 8.2: Connection overview of AS-i safety monitor ASM2E/1, ASM2E/2, ASM2E-m/1

and ASM2E-m/2 .................................................................................................................... 58

Figure 8.3: Connection of the terminals of the safe AS-i output for actuator monitoring .........................59

Figure 8.4: Connection of the terminals of the safe AS-i output for network coupling .............................60

Figure 9.1: AS-i cable variants.................................................................................................................61

Figure 9.2: Location of the RS 232C configuration interface ...................................................................62

Figure 10.1: Overview of device LEDs ......................................................................................................65

Figure 13.1: Querying with diagnosis sorted according to output circuit ...................................................83

General Information

Operating manual for the AS-i safety monitor V 3.08 M 5

TNT 35/7-24V

Edition: 01/2010

1 General Information

1.1 Explanation of symbols

The symbols used in this operating manual are explained below.

1.2 Declaration of Conformity

The AS-i safety monitor has been developed and manufactured in accordance with the applicable Eu-

ropean standards and directives.

The manufacturer of the product possesses a certified quality assurance system in accordance with

ISO 9001.

1.3 Standards

• Draft: Fundamentals for the testing and certification of "Bus systems for the transmission of safety-

relevant messages"

•ISO13849-1:2008 - Safety of machines – safety-related elements of control systems - Part 1:

General principles for design

•EN50295:1999-10 - Low-voltage switching devices; control-system and device interfaces; actua-

tor sensor interface (AS-i)

•EN60204-1:2006-06 - Safety of machines – electrical equipment for machines – Part 1: general

requirements

•EN60947-5-1:2005-02 - Low-voltage switchgear and controlgear - Part 5-1: control devices and

switching elements; electromechanical control devices

•EN61496-1:2005-01 - Non-contact safety guards

•IEC61508 1-7:2000 - Functional safety of electric/electronic/programmable electronic systems

with safety function

Attention!

Pay attention to passages marked with this symbol. Failure to observe the provided instruc-

tions could lead to personal injury or damage to equipment.

Notice!

This symbol indicates text which contains important information.

Notice!

The corresponding Declaration of Conformity and prototype test certificate can be found at

the end of this operating manual.

General Information

6 Operating manual for the AS-i safety monitor V 3.08 M

Edition: 01/2010

1.4 Definition of terms

Output switching element (safety output) of the AS-i safety monitor

Element activated by the logic of the monitor which is able to safely switch off the down-

stream control elements. The output switching element may switch to or remain in the ON

state only when all components are functioning as intended.

Output circuit

Consists of the two logically connected output switching elements.

OSSD

The safe AS-i components and functional components assigned to an output circuit. They

are responsible for releasing the machine element which generates the hazardous move-

ment.

Integrated slave

Component in which sensor and/or actuator functions are grouped together with the slave to

form a unit.

Configuration operation

Operating state of the safety monitor in which the configuration is loaded and checked.

Master

Component for data transmission that controls the logical and temporal behavior on the AS-i

line.

Muting

Proper, application-intended, time-limited suppression of the protective field’s safety function.

Muting restart

Initiation of the override mode after a Muting fault (flashing Muting indicator).

Parallel Muting

Muting is initiated if 2 defined Muting sensor signals are activated within a defined time.

External device monitoring circuit (contactor monitoring)

The external device monitoring circuit allows the switching function of the contactors con-

nected to the AS-i safety monitor to be monitored.

Sequential Muting

Muting is initiated if 4 Muting sensor signals are sequentially activated in a defined order

(Muting sequence).

General Information

Operating manual for the AS-i safety monitor V 3.08 M 7

TNT 35/7-24V

Edition: 01/2010

Safety output

See output switching element.

Safe input slave

Slave which reads in the safe ON or OFF state of the connected sensor or command device

and transmits it to the master or safety monitor.

Safe slave

Slave for connecting safe sensors, actuators and other devices.

Safety monitor

Component which monitors the safe slaves and the correct function of the network.

Slave

Component for data transmission; the master cyclically addresses this component by its

address. Only then does it generate an answer.

Standard slave

Slave for connecting non-safe sensors, actuators and other devices.

Synchronization time

The maximum permissible temporal offset between the occurrence of two events which are

dependent on one another.

General Information

8 Operating manual for the AS-i safety monitor V 3.08 M

Edition: 01/2010

1.5 Abbreviations

AOPD Active Optoelectronic Protective Device

AS-i Actuator Sensor Interface

AOPD Active Optoelectronic Protective Device

CRC Cyclic Redundancy Check

EDM External Device Monitoring

EMC Electromagnetic compatibility

ESD Electrostatic Discharge

I/O Input/Output

OSSD Output Signal Switching Device

PELV Protective Extra-Low Voltage

PFD Probability of Failure on Demand

PLC Programmable Logic Control

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