Programmable Safety Systems PSS-Range

Transcription

1 Programmable Safety Systems PSS-Range PSS Standard Function Blocks MBS Hydraulic Presses Version 3.2 Operating Manual Item No The spirit of safety.

2 All rights to this manual are reserved by the publishers. Copies may be made for internal purposes. While every effort has been made to ensure that the information in this manual is accurate, no responsibility can be accepted for errors or omissions contained within it. We reserve the right to amend specifications without notice. We are grateful for any feedback on the contents of this manual. The names of products, goods and technologies used in this manual are trademarks of the respective companies.

3 Contents Introduction 1-1 MBS Modular Block System 1-2 Categories/requirement classes 1-3 Overview of manual 1-4 Definition of symbols 1-5 Terminology 1-6 Overview 2-1 Software package 2-1 Range 2-2 Safety 3-1 Safety guidelines 3-1 Use of qualified personnel 3-1 Warranty and liability 3-1 Application guidelines 3-2 Standards 3-3 Fault detection 3-4 Fault detection techniques 3-5 Feasibility test 3-5 Pulsed input signals 3-6 Self test on the outputs 3-6 Fault prevention 3-6 Intended Use 4-1 System software 4-1 Intended use of the standard function blocks 4-2 SB051: Operating mode selector switch 1 from SB052: Operating mode selector switch 2 from SB059: Two-hand monitoring 4-4 Modular Block System: Hydraulic Presses 1

4 Contents SB061: Emergency stop monitoring 4-4 SB063: Emergency stop monitoring 4-5 SB064: Safety gate monitoring 4-6 SB065: Feedback loop monitoring 4-7 SB066: Safety gate monitoring 4-8 SB067: Feedback loop monitoring 4-8 SB068: Monitoring ESPE/AOPDs with guarding and control function 4-9 SB069: Monitoring ESPE/AOPDs with guarding function 4-10 SB070: Initialisation of administration data block (DB015) 4-11 SB071: Initialisation of administration data blocks (DB015/DB016/DB017) 4-11 SB072: Temporary suspension of safety functions 4-12 SB075: Controlling and monitoring safety gates with guard locking 4-12 SB086: Overrun control on linear-driven presses 4-13 SB087: Driving/monitoring the position of a single hydraulic valve 4-14 SB088: Driving/monitoring the position of a dual hydraulic valve 4-14 SB089: Driving/monitoring the position of two hydraulic valves 4-16 SB092: Enable switch 4-17 SB097: Monitoring muting lamps 4-18 MBS Basics 5-1 Block design 5-1 Structure 5-1 Formal parameters and actual parameters 5-2 Administration data blocks DB015, DB016 and DB Structure of the administration data blocks 5-3 Blocks contained in the administration data blocks 5-5 Input parameter SSNR 5-7 Fault diagnostics 5-9 Error types 5-9 Fault diagnostics using the administration data blocks 5-10 Temporary flag range in MBS blocks 5-11 Output parameter FG/ENBL 5-11 Assignment of input and output parameters 5-12 Minimum scan time 5-12 Global parameters Modular Block System: Hydraulic Presses

5 Standard Function Blocks 6-1 Guidelines for selecting standard function blocks 6-1 Emergency stop monitoring 6-1 SB061 NA_1 6-1 SB063 E-STOP 6-1 Safety gate monitoring 6-2 SB066 ST-K4 6-2 SB064 S-GATE 6-3 Feedback loop monitoring 6-3 SB067 RFK_K4 6-3 SB065 FBL 6-4 Initialisation of administration data blocks 6-4 SB070 INIT_MBS 6-4 SB071 INIT_MBS 6-5 SB051: Operating mode selector switch 1 from Block header 6-6 Input parameters 6-6 Output parameters 6-7 Error messages 6-8 Global parameters used in administration data block DB Blocks required 6-10 SB052: Operating mode selector switch 2 from Block header 6-10 Input parameters 6-10 Output parameters 6-12 Error messages 6-13 Global parameters used in administration data block DB Blocks required 6-14 Modular Block System: Hydraulic Presses 3

6 Contents SB059: Two-hand monitoring 6-16 Block header 6-16 Input parameters 6-16 Output parameters 6-20 Error messages 6-20 Global parameters used in administration data block DB Blocks required 6-22 SB061: Emergency stop monitoring Category Block header 6-24 Input parameters 6-24 Output parameters 6-25 Error messages 6-25 Global parameters used in administration data block DB Blocks required 6-27 SB063: Emergency stop monitoring Category Block header 6-28 Input parameters 6-28 Output parameters 6-29 Function test 6-29 Error messages 6-30 Global parameters used in the administration data blocks 6-31 Blocks required 6-31 SB064: Safety gate monitoring 6-32 Block header 6-32 Input parameters 6-32 Output parameters 6-34 Functions 6-35 Error messages 6-38 Global parameters used in the administration data blocks 6-39 Blocks required 6-39 SB065: Feedback loop monitoring 6-40 Block header 6-40 Input parameters 6-40 Output parameters 6-41 Functions 6-42 Error messages 6-43 Global parameters used in the administration data blocks 6-45 Blocks required Modular Block System: Hydraulic Presses

7 SB066: Safety gate monitoring 6-46 Block header 6-46 Input parameters 6-46 Input circuitry 6-47 Output parameters 6-48 Functions 6-48 Error messages 6-52 Global parameters used in administration data block DB Blocks required 6-53 SB067: Feedback loop monitoring on contactors 6-54 Block header 6-54 Input parameters 6-54 Output parameters 6-54 Error messages 6-55 Global parameters used in administration data block DB Blocks required 6-56 SB068: Monitoring ESPE/AOPDs with guarding and control function 6-58 Block header 6-58 Input parameters 6-58 Wiring the input parameters 6-62 Output parameters 6-62 Function 6-63 Cycle modes 6-65 Error messages 6-65 Global parameters used in administration data block DB Blocks required 6-67 Diagrams for ESPE/AOPD 6-68 Timing diagram for guard only mode of ESPE/AOPD 6-68 Timing diagram for double break mode of ESPE/AOPD 6-70 SB069: Monitoring ESPE/AOPDs with guarding and control function 6-72 Block header 6-72 Input parameters 6-72 Wiring the input parameters 6-74 Output parameters 6-74 Function 6-75 Error messages 6-76 Modular Block System: Hydraulic Presses 5

8 Contents Global parameters used in administration data block DB Blocks required 6-77 Timing diagram 6-78 SB070: Initialisation of administration data block DB Block header 6-80 Input parameters 6-80 Function 6-80 Error messages 6-82 Blocks required 6-82 SB071: Initialisation of administration data blocks 6-84 Block header 6-84 Input parameters 6-84 Function 6-84 Error messages 6-86 Blocks required 6-86 SB072: Temporary suspension of safety functions (ESPE/AOPD muting) 6-88 Block header 6-88 Input parameters 6-88 Wiring the input parameters 6-91 Output parameters 6-91 Wiring the output parameters 6-92 Operating modes 6-92 Terminology 6-92 Sequential muting mode (muting when entering the danger area) 6-93 Parallel muting mode (muting when leaving the danger area) 6-95 Parallel muting mode (muting when entering and leaving the danger area) 6-97 Safety guidelines 6-99 Error messages Global parameters used in administration data block DB Blocks required Cycle diagrams Parallel muting cycle Sequential muting cycle SB075: Controlling and monitoring safety gates with guard locking Block header Input parameters Input circuitry Modular Block System: Hydraulic Presses

9 Output parameters Operating modes Procedures Additional safety guidelines Error messages Global parameters used in administration data block DB Blocks required SB086: Overrun control on linear-driven presses Block header Input parameters Output parameters Procedures Timing diagram Error messages Global parameters used in administration data block DB Blocks required SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve) Block header Input parameters Output parameters Function Safety guidelines for input parameters TOn and TOff Settings for the parameters TOn and TOff Error messages Global parameters used in administration data block DB Blocks required SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve) Block header Input parameters Output parameters Function Safety guidelines for input parameters TOn and TOff Settings for the parameters TOn and TOff Error messages Global parameters used in administration data block DB Blocks required Modular Block System: Hydraulic Presses 7

10 Contents SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet and directional control valves) Block header Input parameters Output parameters Function Safety guidelines for input parameters TOn and TOff Settings for the parameters TOn and TOff Error messages Global parameters used in administration data block DB Blocks required SB092: Enable switch Block header Input parameters Output parameters Function Switching diagrams Error messages Global parameters used in administration data block DB Blocks required SB097: Monitoring muting lamps Block header Input parameters Output parameters Wiring the output parameters Wiring diagram Function Guidelines for the design and layout of muting lamps Error messages Global parameters used in administration data block DB Blocks required Timing diagrams Link Blocks 7-1 Check list Modular Block System: Hydraulic Presses

11 Examples 8-1 Application and parameters of individual blocks 8-2 Emergency stop monitoring with manual start (start-up and operation), category Emergency stop monitoring with automatic start-up, manual start (operation) and function test, category Feedback loop monitoring Shutdown with two contactors connected in series, category Feedback loop monitoring Shutdown with two main contactors connected in series and pulsed outputs, category Feedback loop monitoring (selective shutdown), category Emergency stop monitoring with monitoring of feedback loop, category Safety gate monitoring with manual start and manual restart, category Safety gate monitoring with automatic start and manual restart, category Safety gate monitoring with manual start and manual restart, category Safety gate monitoring with automatic start and manual restart, category Safety gate monitoring with manual start and manual restart, category Safety sensors PSEN 2.1p-10 and PSEN 2.1p-11 with block SB066 (ST_K4) 8-36 ESPE/AOPD in guard mode with automatic function test (SB068) 8-40 ESPE/AOPD in single break mode with cycle reset via a pulse at top dead centre (TDC) 8-42 ESPE/AOPD in guard mode with automatic function test (SB069) 8-44 Monitoring muting lamps 8-46 Safety gate monitoring with guard locking, automatic start and manual restart, category Modular Block System: Hydraulic Presses 9

12 Contents Appendix 9-1 Assignment table Category and requirement class 9-1 Standard function blocks: current versions 9-2 Changes to the standard function blocks 9-3 Changes to the operating manual 9-15 Allocation of safety subroutine numbers - enable flags Modular Block System: Hydraulic Presses

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15 Introduction This manual describes how to manage the standard function blocks in the MBS Hydraulic Presses software package in accordance with their intended use. Standard function blocks in the MBS Hydraulic Presses package are part of the Pilz MBS Modular Block System. They can be used in the failsafe section of a PSS-range programmable safety system. To fully understand this manual you will need to be conversant with the information found in the general documentation for the PSS-range (System Manual, Installation Manual for the modular/compact PSS, PSS SW PG Programming Manual/PSS WIN-PRO Programming Manual). In particular you should refer to the following documents from the System Manual: Safety Manual FS System Description Error List To fully understand the bus-specific requirements and correlations for SafetyBUS p applications you will need some knowledge of the design and management of SafetyBUS p. Knowledge of the safety regulations for the particular area of application is assumed. This installation manual is intended for instruction and should be retained for future reference. Modular Block System: Hydraulic Presses 1-1

16 Introduction MBS Modular Block System Safety-related areas can be equipped with a multitude of safety devices such as E-STOPs, safety gates, light barriers etc. Safety devices are required in various quantities and combinations, depending on the object requiring protection. The Pilz MBS Modular Block System was developed to drive the various safety devices and to carry out process engineering functions, helping users to save time and money. The MBS consists of individual standard function blocks (SBs), which are geared specifically towards the relevant safety device or process engineering function. It allows standard function blocks to be used in any combination. The standard function blocks can be combined in any sequence (max. 600). Standard function blocks are encoded by an authorised body so that they cannot be modified. If an encoded standard function block is used within an application program, program testing may be restricted to the new parts of the program, considerably reducing the test time. 1-2 Modular Block System: Hydraulic Presses

17 Categories / requirement classes EN divides safety devices into categories. All standard function blocks are designed for the highest category permitted for the safety device to be monitored. If safety devices with lower categories are to be monitored, input parameters may be assigned identical inputs (further information can be found in the description for the relevant standard function block). In process engineering, safety requirements must conform to DIN V (Basic Safety Requirements for Measurement and Control Protection Devices). Requirement classes in accordance with DIN V may be referred to the categories as per EN The Appendix contains a table showing the assignment of category requirement class. Modular Block System: Hydraulic Presses 1-3

18 Introduction Overview of manual 1 Introduction The chapter you are reading provides an introduction to the Modular Block System (MBS). It is designed to familiarise you with the contents, structure and specific order of this manual and also contains terminology definitions. 2 Overview This chapter provides information on the most important features of the software package and provides a brief overview of the application range. 3 Safety This chapter must be read as it contains important information on safety regulations. 4 Intended Use This chapter must be read as it contains information on intended use. 5 MBS Basics This chapter explains the basic functions and safety requirements of the MBS. 6 Standard Function Blocks This chapter explains the function of the standard function blocks in the software package. 7 Link Blocks This chapter is designed to help you link the standard function blocks into your project and to commission the safety functions. 8 Examples This chapter is designed to give an overview of how the standard function blocks may be applied and contains typical application examples. 9 Appendix The Appendix contains a table that explains the relationship between categories and requirement classes, plus a list that documents the current version status of the standard function blocks. 1-4 Modular Block System: Hydraulic Presses

19 Definition of symbols Information in this manual that is of particular importance can be identified as follows: DANGER! This warning must be heeded! It warns of a hazardous situation that poses an immediate threat of serious injury and death and indicates preventive measures that can be taken. WARNING! This warning must be heeded! It warns of a hazardous situation that could lead to serious injury and death and indicates preventive measures that can be taken. CAUTION! This refers to a hazard that can lead to a less serious or minor injury plus material damage, and also provides information on preventive measures that can be taken. NOTICE This describes a situation in which the product or devices in its immediate environment could be damaged. It also provides information on preventive measures that can be taken. INFORMATION This gives advice on applications and provides information on special features, as well as highlighting areas within the text that are of particular importance. Modular Block System: Hydraulic Presses 1-5

20 Introduction Terminology The term input is frequently abbreviated to I (e.g. I-Parameter). The term output is frequently abbreviated to O (e.g. O-Parameter). The term PSS is always used when the description is valid for all applicable PSS programmable safety systems. If the description only relates to a specific PSS series, the specific name for that series will be used (e.g. PSS 3000 or PSS SB 3056). In this manual, the system software PSS SW PG and PSS WIN-PRO is referred to as programming device or PG. 1-6 Modular Block System: Hydraulic Presses

21 Overview Software package The MBS Hydraulic Presses software package is part of the Pilz MBS Modular Block System. The software package contains all the standard function blocks necessary for electronically-monitored safety devices on distributed automation plants. This includes: Monitoring the position of operating mode selector switches for safe mode selection (automatic, manual, cycle mode etc.) Monitoring two-hand circuits for simultaneity Evaluation of E-STOP buttons, grab wires etc. Monitoring safety, maintenance and supply gates Monitoring of power contactors through control of the feedback loop Controlling and monitoring electrosensitive protective equipment Safe, temporary suspension of safety functions (muting mode) Driving and monitoring a press safety valve Monitoring enable switches Standard function blocks in the MBS Hydraulic Presses software package are used in the failsafe section of a PSS-range programmable safety system. Modular Block System: Hydraulic Presses 2-1

22 Overview Range The software package consists of: The files for the software package on CD and An operating manual: PSS Standard Function Blocks MBS Hydraulic Presses, Version 3.2 The software package on the CD contains the following standard function blocks: SB051 SB052 SB059 SB061 SB063 SB064 SB065 SB066 BA_1AUS8 Operating mode selector switch 1 from 8 (approved safety block) BA_2AUS6 Operating mode selector switch 2 from 6 (approved safety block) 2_HAND Two-hand monitoring (approved safety block) NA_1 Monitoring E-STOP button up to category 4 in accordance with EN 954-1, 03/97 and AK 6 in accordance with DIN V , 05/94 (approved safety block) E-STOP Monitoring E-STOP button up to category 4 in accordance with EN 954-1, 03/97 and AK 6 in accordance with DIN V , 05/94 (approved safety block) S-GATE Safety gate monitoring (approved safety block) FBL Feedback loop monitoring (approved safety block) ST-K4 Safety gate monitoring (approved safety block) 2-2 Modular Block System: Hydraulic Presses

23 SB067 SB068 SB069 SB070 SB071 SB072 SB075 SB086 SB087 SB088 SB089 RFK_K4 Feedback loop monitoring (approved safety block) BWS_AOS Monitoring ESPE/AOPD with guarding and control function (approved safety block) AOPD_GDO Monitoring ESPE/AOPD with guarding function (approved safety block) INIT_MBS Initialisation of the administration data block (DB015) (approved safety block) INIT_MBS Initialisation of the administration data blocks (DB015/DB016/ DB017) (approved safety block) MUTING Temporary suspension of safety functions (approved safety block) GRD_LCK Control and monitoring of safety gates with guard locking (approved safety block) OVERRUN Overrun control on linear-driven presses (approved safety block) H_VALV_S Control and position monitoring of single hydraulic valves (poppet valve and directional control valve) (approved safety block) H_VALV_D Control and position monitoring of dual hydraulic valves (poppet valve and directional control valve) (approved safety block) H_VALV_P Sequential control and position monitoring of two hydraulic valves (poppet valve and directional control valve) (approved safety block) Modular Block System: Hydraulic Presses 2-3

24 Overview SB092 SB097 SB255 ENBL_DEV Enable switch (approved safety block) MUT_LAMP Monitoring muting lamps (approved safety block) System block SB255 is described in the PSS System Description 2-4 Modular Block System: Hydraulic Presses

25 Safety Safety guidelines These safety guidelines are an important part of this manual. Failure to keep to these guidelines will render all warranty, guarantee and liability claims invalid. All health and safety / accident prevention regulations for the particular area of application must be observed. Before using one or more of the standard function blocks in this software package, you must perform a safety assessment in accordance with the Machinery Directive. Use of qualified personnel The package may only be assembled, installed, commissioned, operated, maintained and decommissioned by qualified personnel who, because they are Qualified electrical engineers and/or Have received training from qualified electrical engineers are suitably experienced to operate devices, systems, plant and machinery in accordance with the general standards and guidelines for safety technology. Warranty and liability All claims to warranty and liability will be rendered invalid if: Standard function blocks are used contrary to the purpose for which they were intended Damage can be attributed to not having followed the guidelines in the manual Operating personnel are not suitably qualified. Modular Block System: Hydraulic Presses 3-1

26 Safety Application guidelines The instructions given in the Safety Manual and in the Installation Manual must be followed. Please read the information in Chapter 4 regarding the intended use of these blocks. The use of Pilz SBs does not detract from the fact that it is the responsibility of the user to design appropriate safety systems for plant, machinery and software. It is the users' responsibility to determine their application requirements by carrying out a detailed risk analysis, which should take into account relevant regulations and standards, etc. WARNING! Please note: To achieve the corresponding category or requirement class, the whole system including all safety-related components (parts, devices, user program etc.) must be included in the assessment. For this reason, Pilz cannot accept liability for the correct classification into a category or requirement class. 3-2 Modular Block System: Hydraulic Presses

27 Standards To use the SBs correctly you will need to have a good knowledge of the relevant standards and directives. The following gives an overview of the most important standards: E-STOP circuits EN 418 Safety of machinery - Two-hand controls EN 574 Mechanical presses EN 692 Hydraulic presses EN 693 Hydraulic stamping and bending presses EN Machinery directive- basic terminology EN and EN Printing and paper machinery pren 1010 Safety gates EN 1088 Electrosensitive protective equipment EN Electrical equipment EN Machinery safety EN Basic Safety Requirements for Measurement and Control Protection Devices DIN V Electrical equipment on firing plants pren Please note this is not an exhaustive list of safety standards and directives. Modular Block System: Hydraulic Presses 3-3

28 Safety Fault detection The detection of errors and defects is an important function of the PSS, in addition to pure control tasks. Potential faults are subdivided into: Errors in the system hardware and wiring errors in the periphery units: - Errors in the system hardware are automatically detected and managed by the PSS - If test signals are used, wiring errors in the periphery units will automatically be detected and managed by the PSS. Users do not need to take this type of error into account within the application program (additional information can be found in the PSS System Description ). Feasibility errors and functional errors in the process periphery units (input devices, actuators, wiring etc.). These errors must be detected and managed through the PSS control program. WARNING! It is particularly important to detect open circuits and shorts within the safety circuits (e.g. two-hand, E-STOP etc.) It is the responsibility of the user to select and apply an appropriate fault detection system. 3-4 Modular Block System: Hydraulic Presses

29 Fault detection techniques Various options are available to the user to help detect and rectify errors in the process periphery units: Errors can be detected via the feasibility checks in the application program, e.g. by using redundant input devices. Errors can be detected by pulsing the signal lines using the test pulses from the PSS DI2O T module. Errors can be detected by using the automatic tests in the output modules. Avoid potential errors by using appropriate wiring. Additional information on how to exclude potential errors can be found in the directive VDI 2854 (safety requirements on automated manufacturing systems). Feasibility test Redundant input devices for safety functions must undergo a feasibility test within the application program. Example: A two-hand button has a N/C and a N/O contact. Once the application program has detected the open N/C contact, it must check that the N/O contact closes within an appropriate period of time. The function test must be carried out for all possible combinations of the two contacts. The plant must be stopped immediately if a feasibility error occurs. Similar tests will also be required for other input devices. If safety valves have feedback contacts, these must be evaluated accordingly. Modular Block System: Hydraulic Presses 3-5

30 Safety Pulsed input signals Input devices for inputs with infrequent operation (e.g. E-STOP, off buttons, etc.) must be pulsed using test signals. The connection of test pulses to input devices is described in the Installation Manual. Test pulses should also be used for input devices which have an important safety function and frequent operation (e.g. two-hand, camshaft etc.). Self test on the outputs PSS output modules regularly carry out function tests. Using these tests, dual-pole switching output modules on the PSS are automatically able to detect and deal with open circuits, short circuits and external power sources in the periphery wiring. Single-pole switching output modules can detect short circuits but not open circuits. Fault prevention Not all potential faults can be detected and managed. Such faults must be excluded by suitable wiring. Example: If the feed to the input device and the feedback from the input device to the input use the same multicore cable, a short circuit between the two wires could short out the input device. Such a fault would go undetected. 3-6 Modular Block System: Hydraulic Presses

31 Intended Use The software package MBS Hydraulic Presses is designed for use within the failsafe section of the PSS-range of programmable safety systems. INFORMATION Use of standard function blocks outside the specifications described here will be deemed improper use. INFORMATION Always use the current version of the relevant standard function block. Please ensure you refer to the Appendix, sections entitled Standard function blocks: current versions and Changes to the standard function blocks. System software The software package MBS Hydraulic Presses can be used with the following system software: PSS SW PG PSS WIN-PRO INFORMATION Depending on the programming language selected on PSS WIN-PRO, designations for formal parameters and operands may differ from those found on PSS SW PG. Any designations that are different will automatically be replaced by PSS WIN-PRO. Further information is available in the programming manual for PSS SW- PG or PSS WIN-PRO. Modular Block System: Hydraulic Presses 4-1

32 Intended Use Intended use of the standard function blocks SB051: Operating mode selector switch 1 from 8 SB051 is a standard function block designed to monitor the position of lockable standard operating mode selector switches. Safe coding is achieved by means of the selection process 1 from 8. Features: Maximum of 8 operating modes are possible Break-free switchover within the adjustable contact switchover time Input circuitry: 1 input is required per operating mode INFORMATION If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses. 4-2 Modular Block System: Hydraulic Presses

33 SB052: Operating mode selector switch 2 from 6 SB052 is a standard function block designed to monitor the position of lockable standard operating mode selector switches. Safe coding is achieved by means of the selection process 2 from 6. Coding reduces the number of inputs required. Operating modes: Maximum 15 switch positions possible when 6 inputs are used Break-free switchover within the adjustable contact switchover time Input circuitry: Output signals (contacts) from the mechanical operating mode selector switch INFORMATION If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses. Modular Block System: Hydraulic Presses 4-3

34 Intended Use SB059: Two-hand monitoring The function of standard function block SB059 is determined in accordance with EN 574, 02/97. It fulfils all the requirements of category 4, in accordance with EN 954-1, 03/97. Operating modes: Monitoring two buttons (N/C and N/O) in accordance with EN 954-1, 03/97 Monitoring the synchronisation time of two buttons (<0.5 s) Can also be used to monitor foot switches INFORMATION Input circuitry: Two-hand buttons must use test pulses. SB061: Emergency stop monitoring SB061 is a standard function block for monitoring E-STOP buttons up to category 4, in accordance with EN 954-1, 03/97 and AK 6, in accordance with DIN V , 05/94. It is also possible to use SB061 to monitor safety gates up to category 4, in accordance with EN 954-1, 03/97. Operating modes: With or without start-up reset on cold-start With or without automatic reset when E-STOP is released INFORMATION Input circuitry: Use E-STOP button with test pulses When using SB061 for category 4 applications: - use dual-channel elements When using SB061 for category 2 applications: - use single-channel elements 4-4 Modular Block System: Hydraulic Presses

35 SB063: Emergency stop monitoring SB063 is a standard function block for monitoring E-STOP buttons up to category 4, in accordance with EN 954-1, 03/97 and AK 6, in accordance with DIN V , 05/94. It is also possible to use SB063 to monitor safety gates up to category 4, in accordance with EN 954-1, 03/97. INFORMATION On SB063, the SSNR may lie in the range of 1 to 600. Operating modes: With or without start-up reset on cold start or on a SafetyBUS p group start With or without automatic reset when E-STOP is released With or without prompt for function test after a synchronisation error when the E-STOP is released INFORMATION Input circuitry: Use E-STOP button with test pulses When using SB063 for category 4 applications: - use dual-channel elements When using SB063 for category 2 applications: - use single-channel elements SB064: Safety gate monitoring SB064 is designed for monitoring a safety gate. It can monitor a safety gate with one or two switches. SB064 meets all the requirements up to category 4, in accordance with EN 954-1, 03/97. The block is designed in such a way that it can be used generally to monitor the synchronisation of two signals and contact welding. INFORMATION On SB064, the SSNR may lie in the range of 1 to 600. Modular Block System: Hydraulic Presses 4-5

36 Intended Use Operating modes: Automatic start when PSS starts up or when starting I/O-Groups (SafetyBUS p)/start-up reset when PSS is cold-started or when starting I/O-Groups (SafetyBUS p) (start-up disabler) No function test/function test on the gate during start-up (function test = opening and closing the gate) Automatic restart/reset to start (reset lock) Restart without function test/start only after function test on the gate (reset lock) (function test = opening and closing the gate) Synchronisation time is selectable INFORMATION Input circuitry: Inputs should have pulsed outputs SB065: Feedback loop monitoring SB065 is a standard function block for the direct control and monitoring of 1 or 2 contactors up to category 4, in accordance with EN 954-1, 03/97. INFORMATION On SB065, the SSNR may lie in the range of 1 to 600. Features and application areas: Feedback loop is monitored during the change in the switch signal and while the contactors are in a static condition. Feedback loop can be monitored on two separate feedback loops of contactors connected in series Feedback loop can be monitored on two separate feedback loops of contactors connected in parallel Feedback loop can be monitored on group contactors Selectable time for feedback loop monitoring Parameter to suppress error messages when an I/O-Group stops (SafetyBUS p) 4-6 Modular Block System: Hydraulic Presses

37 INFORMATION Input circuitry: To achieve category 4, two independent shutdown routes must be provided within the current path of the potentially dangerous drive If wiring is to be laid outside the control cabinet, feedback loops must use test pulses. Feedback loops must use test pulses if the possibility of a short-circuit cannot be excluded. If only one contactor is used to switch a potentially dangerous drive, it must be possible to switch this off via a group contactor within the current path (selective shutdown). The group contactor must also be monitored through a feedback loop. SB066: Safety gate monitoring SB066 is designed for monitoring a safety gate. It can monitor a safety gate with one or two switches. SB066 meets all the requirements of category 4, in accordance with EN 954-1, 03/97. Operating modes: Automatic restart Automatic start when PSS starts up Start-up reset when PSS is cold-started No function test on the gate (function test = opening and closing the gate) INFORMATION Input circuitry: Inputs should have pulsed outputs Modular Block System: Hydraulic Presses 4-7

38 Intended Use SB067: Feedback loop monitoring SB067 is a standard function block for the direct control and monitoring of contactors up to category 4, in accordance with EN 954-1, 03/97. Features and application areas: Feedback loop is monitored during the change in the enable flag and while the contactor is in a static condition Feedback loop can be monitored on two separate feedback loops of main contactors connected in series Feedback loop can be monitored on group contactors INFORMATION Input circuitry: To achieve category 4, two independent shutdown routes must be provided within the current path of the potentially dangerous drive If wiring is to be laid outside the control cabinet, feedback loops must use test pulses. Feedback loops must use test pulses if the possibility of a short-circuit cannot be excluded. If only one contactor is used to switch a potentially dangerous drive, it must be possible to switch this off via a group contactor within the current path (selective shutdown). The group contactor must also be monitored through a feedback loop. 4-8 Modular Block System: Hydraulic Presses

39 SB068: Monitoring ESPE/AOPDs with guarding and control function SB068 is a standard function block which is designed to monitor ESPE/ AOPDs up to category 4, in accordance with EN 954-1, 03/97, with guarding and control function. Features: Monitors the ESPE/AOPD outputs: feasibility check on the contact switchover time of the two N/O contacts Start-up disabler Reset lock Test mode Cycle mode (control): enabled via single or double break of the ESPE/ AOPD. Cycle time monitoring Operating modes AUS (OFF): Safety (GdO): 1-Break (SBrK): 2-Break (DBrK): Guard function of ESPE/AOPD is deactivated ESPE/AOPD as guarding device with reset lock Enabled via single break of ESPE/AOPD Enabled via double break of ESPE/AOPD INFORMATION This block performs safety functions. When using this block you must comply with the relevant standards and regulations, in particular: EN , 06/98 Regulations laid down by the manufacturer of your ESPE/AOPD INFORMATION Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4. Modular Block System: Hydraulic Presses 4-9

40 Intended Use SB069: Monitoring ESPE/AOPDs with guarding function SB069 is a standard function block which is designed to monitor ESPE/ AOPDs up to category 4, in accordance with EN 954-1, 03/97, with guarding function. INFORMATION On SB069, the SSNR may lie in the range of 1 to 600. Features: Monitors the ESPE/AOPD outputs: feasibility check on the contact switchover time of the two N/O contacts Start-up disabler Reset lock Test mode Parameter to suppress error messages when an I/O-Group stops (SafetyBUS p) Operating modes Guard function of ESPE/AOPD is deactivated (ESPE/AOPD switched off) ESPE/AOPD as guarding device with reset lock INFORMATION This block performs safety functions. When using this block you must comply with the relevant standards and regulations, in particular: EN , 06/98 Regulations laid down by the manufacturer of your ESPE/AOPD INFORMATION Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category Modular Block System: Hydraulic Presses

41 SB070: Initialisation of administration data block (DB015) SB070 is used to calculate the global parameters, depending on the set minimum scan time (see also under Minimum Scan Time in Chapter 5). The global parameters in administration data block DB015/DW DW 1023 are initialised using SB070. Function: Reads in the set minimum scan time from DB002 (configurator) Calculates the cycles based on the times transferred in the parameters Enters the calculated values into the administration DB. SB071: Initialisation of administration data blocks (DB015/DB016/DB017) SB071 is used to calculate the global parameters, depending on the set minimum scan time (see also under Minimum Scan Time in Chapter 5). Global parameters DW DW1023 in administration data blocks DB015, DB016 and DB017 are initialised using SB071. Function: Reads in the set minimum scan time from DB002 (configurator) Calculates the cycles based on the times transferred in the parameters Enters the calculated values into the administration data blocks NOTICE It is absolutely essential that SB071 is called in OB120 when using the following standard function blocks: SB063 E-STOP SB064 S-GATE SB065 FBL Modular Block System: Hydraulic Presses 4-11

42 Intended Use SB072: Temporary suspension of safety functions SB072 is a standard function block designed to temporarily suspend the safety functions (ESPE/AOPD) without interrupting the process (muting). SB072 was approved in accordance with the requirements of EN Appendix A7.1, 06/98 (requirement of the function) and A7.2, 06/98 (requirement in case of failure). For a limited period of time, and for a specific operational phase (e.g. for feeding materials), it will suspend the effect of safety devices during the working process. Once completed, it will reset the safety function. Function: Muting via light barriers or limit switches Sequential and parallel muting mode Muting time is adjustable Muting timer can be interrupted Time monitoring of the muting limit switch Monitoring of ESPE/AOPD with two N/O contacts INFORMATION Input circuitry: Category 4 ESPE/AOPDs with semiconductor outputs must be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4. SB075: Controlling and monitoring safety gates with guard locking SB075 is designed for controlling and monitoring a safety gate with guard locking. SB075 meets the requirements of category 4, in accordance with EN 954-1, 03/97. It can monitor a safety gate with one or two switches and control and monitor a guard locking device. The safety gate is monitored in almost exactly the same way as on blocks SB064 and SB066. INFORMATION On SB075, the SSNR may lie in the range of 1 to Modular Block System: Hydraulic Presses

43 Features: Synchronisation time of the gate switches is monitored The guard locking device is controlled Feasibility of the guard locking device is monitored Status display for safety gate and guard locking Operating modes: Automatic start when PSS starts up or when starting I/O-Groups (SafetyBUS p)/start-up reset when PSS is cold-started or when starting I/ O-Groups (SafetyBUS p) (start-up disabler) No function test/function test on the gate during start-up and each time the gate is unlocked (function test = opening and closing the gate) Automatic restart/reset to start (reset lock) SB086: Overrun control on linear-driven presses SB086 is designed to perform overrun control on linear-driven hydraulic presses in accordance with VBG 7n Function Check performed via the overrun cam TLS (Test Limit Switch) Overrun measurement can only be started from the extreme top position (ETP) of the press. Ability to set the overrun measuring period Overrun errors and hardware errors can only be reset when the press is in the extreme top position Reset via 0/1 pulse edge at RSET input Can be used for overrun measurement on AKAS systems (Fiessler) Modular Block System: Hydraulic Presses 4-13

44 Intended Use SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve) SB087 is a standard function block which is designed to control and monitor the position of a single hydraulic valve. The position of the valve is acknowledged via an input. Features: Input for selecting the valve type (poppet valve/directional control valve) Valves switched on in start position only Operation with or without reaction time monitoring An error message is issued if the valve is in the wrong position Valve is immediately switched off if an error occurs Reset latch when an error is detected WARNING! The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB087 description (see Chapter 6) must be adhered to at all times. SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve) SB088 is a standard function block which is designed to control and monitor the position of a dual hydraulic valve. The position of each valve is acknowledged via a separate input. Valves can be switched off individually for external overrun measurement. Features: Input for selecting the valve type (poppet valve/directional control valve) Two valves controlled and monitored simultaneously 4-14 Modular Block System: Hydraulic Presses

45 Valves switched on in start position only Operation with or without reaction time monitoring An error message is issued if the valve is in the wrong position Valve is immediately switched off if an error occurs Reset latch when an error is detected INFORMATION If both valve signals are acknowledged via switches, the supply to these switches must be from test pulses. If both valve signals are acknowledged via proximity switches which cannot be pulsed, the signal lines of the proximity switches must be laid in different multicore cables within the duct. This will ensure that a short cannot occur between the two signal lines. This safety precaution will not be necessary if you use proximity switches with diverse signals. This block is designed for dual valves. You can assume that these will have a similar switching characteristic. This means that the switch- on and switch-off times for both valves can be monitored through a single time parameter for each function. Please note that when driving structurally separated valves, these will also show a similar switching characteristic. WARNING! The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB088 description (see Chapter 6) must be adhered to at all times. Modular Block System: Hydraulic Presses 4-15

46 Intended Use SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet valve and directional control valves) SB089 is a standard function block which is designed for the sequential drive and position monitoring of two hydraulic valves. The two valves may be driven individually. However, only one valve may be switched on at a time. Each valve is interlocked with respect to the other. The position of each valve is acknowledged via a separate input. Features: Input for selecting the valve type (poppet valve/directional control valve) Controls and monitors two valves (structurally separated valves also) Valves switched on in start position only Operation with or without reaction time monitoring An error message is issued if the valve is in the wrong position Valve is immediately switched off if an error occurs Reset latch when an error is detected INFORMATION If both valve signals are acknowledged via switches, the supply to these switches must be from test pulses. If both valve signals are acknowledged via proximity switches which cannot be pulsed, the signal lines of the proximity switches must be laid in different multicore cables within the duct. This will ensure that a short cannot occur between the two signal lines. This safety precaution will not be necessary if you use proximity switches with diverse signals. Both valves are monitored via a single time parameter for switch-on and switch-off. If you are using structurally separated valves, make sure that these have a similar switching characteristic Modular Block System: Hydraulic Presses

47 WARNING! The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. A dangerous situation can arise if parameters for the reaction times are set values which are greater than the actual reaction time of the valves. The detailed safety guidelines provided in the SB089 description (see Chapter 6) must be adhered to at all times. SB092: Enable switch SB092 monitors three-position enable switches designed to protect personnel where operating modes have safety devices suspended. Application and use: SB092 can be used for the following applications: For enable switches conforming to pren 1921, 10/95 and VDE 2853, 07/87 For three-position switches conforming to EN 692 section , 08/ 96, and EN 693 section , 1995, with automatic reset and slow closing speed (10 mm/s) For the documented switching diagrams INFORMATION Please bear in mind the following points (EN 1921, 10/95): An enable switch approves a dangerous movement but does not actually trigger it. A potentially hazardous situation may not be initiated by the enable switch alone. If an enable device is required, it must be connected to either a category 0 or category 1 stop If the switching device is fed back from stage 3 through stage 2 to stage 1, the enable function in stage 2 will not occur. It is possible to set a start-up and reset lock after feedback from stage 3. Modular Block System: Hydraulic Presses 4-17

48 Intended Use SB097: Monitoring muting lamps SB097 is a standard function block for controlling and monitoring two redundant muting lamps, up to and including category 4 in accordance with EN 954-1, 03/97. Application and use: SB097 can be used for the following applications: Displaying muting status in accordance with EN , 06/98. Connecting muting lamps to single-pole outputs. Controlling two redundant muting lamps (24 V incandescent lamps). Monitoring muting lamps for a break in the filament. Defective muting lamps can be exchanged while the plant is running. Removing the enable when the second filament blows. Can be used with just one output. Positive-switching: 1 output. Negative-switching: 2 outputs. INFORMATION This block undertakes muting safety functions in conjunction with the block SB072. When using this block you must comply with the relevant standards and regulations, in particular EN , 06/ Modular Block System: Hydraulic Presses

49 MBS Basics Block design Structure Safety-related areas can be equipped with a multitude of safety devices such as (e.g. E-STOPs, safety gates, light barriers). These safety devices are used in various quantities and combinations, depending on the object requiring protection. The Modular Block System (MBS) is made up of individual standard function blocks. A standard function block is geared towards the requirements of specific safety devices (e.g. monitoring an E-STOP button, safety gate monitoring). A standard function block must be assigned to each safety device in order for it to be evaluated and monitored using the MBS. This procedure enables any combination of individual safety devices to be evaluated and monitored. The standard function blocks can be combined in any sequence within the user program (max. 600). One exception to this are standard function blocks used to drive and monitor contactors or valves. For control engineering reasons, these should be called up at the end of the user program. Modular Block System: Hydraulic Presses 5-1

50 MBS Basics Formal parameters and actual parameters Parameters can be set on the MBS standard function blocks. Formal parameters are established in the block header. The user must assign a corresponding actual parameter to each formal parameter. When the standard function block is called up in the user program, the formal parameters will be replaced by the user-specific actual parameters. Formal parameter PSS SW PG PSS WIN-PRO: Pilz IL X B W D Z Actual parameter PSS SW PG PSS WIN-PRO: Pilz IL Input bit E Output bit A Flag bit M Input byte EB Output byte AB Flag byte MB Constant KB Input word EW Output word AW Flag byte MW Constant KW Data block DB Timer or counter INFORMATION Depending on the programming language selected on PSS WIN-PRO, designations for formal parameters and operands may differ from those found on PSS SW PG. Any designations that are different will automatically be replaced by PSS WIN-PRO. Further information is available in the programming manual for PSS SW- PG or PSS WIN-PRO. 5-2 Modular Block System: Hydraulic Presses

51 Administration data blocks DB015, DB016 and DB017 Data blocks DB015, DB016 and DB017 are permanently specified within the Modular Block System (MBS). These data blocks are common administration blocks for fault and diagnostic data from the MBS standard function blocks and for block and parameter data that is required internally. The administration data block DB015 must always be installed when using MBS standard function blocks. Administration data blocks DB016 and DB017 are installed when necessary. The administration data blocks must always be installed with their full length of 1024 data words and they must always have read/write status. NOTICE Data blocks DB015, DB016 and DB017 should only be used as MBS administration data blocks and not for other data. Structure of the administration data blocks The administration data blocks DB015, DB016 and DB017 have the same structure. Each standard function block in the user program has 5 data words available in one of the administration data blocks. These data words are used to back up the temporary flags from the standard function block (see section entitled Temporary flag range in MBS blocks ). In each of the administration data blocks, the range DW0001 to DW1000 is divided into 5 blocks, each with 200 data words (see Fig. 5-1). Modular Block System: Hydraulic Presses 5-3

52 MBS Basics DB017 DB016 DB015 DW0000 Block data words Block data words Block data words Block data words Block data words DW 0001 to DW 0200 DW 0201 to DW 0400 DW 0401 to DW 0600 DW 0601 to DW 0800 DW 0801 to DW 1000 Block 6 Global parameters DW 1001 to DW 1023 Fig. 5-1: Structure of the administration data blocks 5-4 Modular Block System: Hydraulic Presses

53 Blocks contained in the administration data blocks Each standard function block occupies 1 data word per block (see Fig. 5-2). This means a max. of 200 safety devices (e.g. E-STOP 1, E- STOP 2, safety gate 1) can be managed per administration data block. The PSS uses a standard function block s SSNR to automatically generate the corresponding data words (see section entitled Input parameter SSNR ). DB017 DB016 DB015 DW0000 Block 1 Data word 1 Block 2 Data word 2 Block 3 Block 4 Data word 3 Data word 4 Data words 1 to 5 of an MBS standard function block Block 5 Data word 5 Block 6 Global parameters Fig. 5-2: Contents of the administration data blocks Modular Block System: Hydraulic Presses 5-5

54 MBS Basics DW0000 (DB015) If parameters for a standard function block s input parameter SSNR are not within the permitted range, DW0000 of DB015 will contain the incorrect SSNR parameter. The standard function block will not be enabled (output parameter FG/ ENBL= 0). If the SSNR=0, DW0000 of DB015 will contain the decimal value -1 or KH FFFF. 1st data block (DB015/DB016/DB017): DW DW0200 Bits for hardware and operator errors The significance of the individual bits can be found in the description for the relevant standard function block (see section entitled Fault diagnostics ). If a data word contains the value 0, no error has been found 2nd data block... 5th data block (DB015/DB016/DB017): DW DW1000 Data blocks are used for internal block data. 6th data block (DB015/DB016/DB017) DW DW1023 Data block 6 contains the global parameters (see section entitled Global parameters ). 5-6 Modular Block System: Hydraulic Presses

55 Input parameter SSNR MBS standard function blocks have input and output parameters which can be adapted to suit the respective control configuration. The input parameter SSNR (safety subroutine number) is available on all MBS standard function blocks. It is required to manage the administration data blocks DB015, DB016 and DB017. INFORMATION MBS standard function blocks may differ in terms of the permitted value range for the SSNR. The following value ranges are possible for the SSNR: Value range of input parameter SSNR: (byte constant type: KB KB200) Value range of input parameter SSNR: (word constant type: KF KF000600) The valid value range for the SSNR of a standard function block is documented in the standard function block description. The input parameter SSNR determines the administration data block plus the 5 data words assigned in the administration data block of the corresponding safety device (1 DW per block). The administration data blocks are assigned the following SSNR ranges: SSNR : DB015 SSNR : DB016 SSNR : DB017 The one data word per block is generated automatically internally (SSNR + offset). Modular Block System: Hydraulic Presses 5-7

56 MBS Basics NOTICE One MBS standard function block must be used for each safety device. Each standard function block should be assigned its own SSNR. Make sure that each SSNR is assigned once only. If two SB calls have the same value for the SSNR, they will access the same data word in the administration data block. This can lead to malfunctions. Document the assignment of the safety device to the respective SSNR of the standard function block. Example Safety device 2 (E-STOP button) is monitored using SB061. The value KB002 is assigned to input parameter SSNR of SB061. The following DWs in DB015 are therefore assigned to safety device 2: Block 1: DW0002 Block 2: DW0202 Block 3: DW0402 Block 4: DW0602 Block 5: DW0802 The user program has read-only access to these data words. INFORMATION On some blocks (e.g. SB061), the input parameter SSNR is monitored. These blocks must be run through as part of each PSS cycle. The following commands should therefore be entered once only at the end of OB 101: A DB015 I DW1015 Effect: The counter for monitoring the SSNR in DB015/DW1015 (global parameters) will be incremented. 5-8 Modular Block System: Hydraulic Presses

57 Fault diagnostics Error types On programmable safety systems from the PSS-range, a distinction is made between two types of errors. On the one hand there are errors which are detected and evaluated through the PSS operating system, and on the other there are errors which are detected and evaluated through the user program. The reaction to these two types of errors is different. Where errors are detected through the operating system, the FS section of the PSS will switch to a STOP condition and all outputs will be switched off safely. Where errors are detected through the user program, only the configured error reaction will occur. Errors that are detected via an MBS standard function block belong to this second type of error. Modular Block System: Hydraulic Presses 5-9

58 MBS Basics Fault diagnostics using the administration data blocks Data words DW DW0200 of an administration data block contain the error messages from the individual MBS standard function blocks (see Fig 5-3). 1 data word is reserved for each standard function block used. The assignment is made using the SSNR. SB061 KB001 KB005 KF KF SSNR FG SB061 SSNR FG SB065 SSNR ENBL SB065 SSNR ENBL DB015 DW0000 DW DW DW DW DW1023 DB016 DW0000 DW DW DW DW DW1023 DB017 DW0000 DW DW DW DW DW1023 Fig. 5-3: Managing the MBS error messages using the administration data blocks (example) 5-10 Modular Block System: Hydraulic Presses

59 Temporary flag range in MBS blocks Internally, MBS blocks use the flags in the range M M69.31 as temporary flags. NOTICE We recommend the following: Do not use flags from the temporary flag range for your own applications. Malfunctions may occur if you use the temporary flag range M M69.31 for your own applications. If it is absolutely necessary to use this flag range, under no circumstances should you use the flags: - in alarm OBs - as input parameters for standard function blocks - as output parameters for standard function blocks - as global parameters Output parameter FG/ENBL Many standard function blocks have an enable output FG/ENBL. This output parameter indicates the enable status of a standard function block. The enable status results from the standard function block s check of the inputs. FG / ENBL = 1: FG / ENBL = 0: No error found, function is enabled An error has been found, function is not enabled. INFORMATION If you are using a Pilz evaluation package we recommend that you use flags M M88.23 for the output parameter FG/ENBL. You will need to note the allocation of the flags to the safety subroutine numbers (input parameter SSNR): SSNR = 1 should use flag M70.00; SSNR = 600 should use flag M The Appendix contains a table showing the allocation of safety subroutine numbers to enable flags. Modular Block System: Hydraulic Presses 5-11

60 MBS Basics Assignment of input and output parameters Input and output parameters should be assigned in accordance with the details given in the operating manual. WARNING! If several unused output parameters are connected to the same flag, malfunctions may occur in the standard function blocks. If an unused output has to be assigned a flag, make sure the output is assigned to a flag that is not used anywhere else in the program. Minimum scan time Most of the timer functions required within the blocks are performed using cycle counters. This means that almost all the timers are available for use in applications. WARNING! If MBS blocks are used, a minimum scan time must always be entered in the configurator. Empirical values should be used. The empirical value can be determined by reading the maximum program processing time values from DB000: DB000 DW10 -> max. scan time of FS section DB000 DW12 -> max. scan time of ST section The sum of these values plus 10 ms for the operating system test times plus a tolerance time of ms, for example, will provide an initial value for the Minimum scan time. Once the program is loaded, special monitoring of the Minimum scan time is automatically activated in the CPU. This will put the FS section into STOP (with the error display F-20/ 06) if the Minimum scan time is exceeded several times. With this particular STOP, the error message will read: F-0C/04 Minimum scan time exceeded too often. The value for the Minimum scan time will therefore need to be increased. This automatic monitoring is implemented from the CPU3 generation, with operating system version V39. On earlier versions the FS section does not stop, but the error message F20/06 does appear Modular Block System: Hydraulic Presses

61 If the error message F-20/06 (error category/error number) appears on the CPU display, you must amend the minimum scan time appropriately. This error message indicates that the minimum scan time has been exceeded. The PSS must not be operated while this error message is present. If you continue to operate the PSS despite this error message, the monitoring times may be increased and the planned safety functions may be adversely affected. Further guidelines for setting the minimum scan time are given in the PSS operating manual (e.g. FS System Description, item no , page 6-11). SB070 and SB071 automatically enter the minimum scan time in DW1022 of the administration data blocks. In this way it is automatically available to the MBS. INFORMATION Please note that the times are imprecise. The lack of precision on times is due to the cyclical processing of the user program. It is determined by the scan time of the respective user program. The following is generally valid: The greater the ratio of time value to scan time, the greater accuracy you will have with the required times. Global parameters Block 6 (DW DW1023) of the administration data blocks contains global parameters. These are parameters that are valid for several blocks. For details of which global parameters a standard function block uses, please refer to the description of the individual standard function blocks. The data words in block 6 must be initialised when the program is started (OB120) using SB070/SB071 (INIT_MBS). The abbreviations in brackets {... :...} at the end of each data word correspond to the parameters in SB071. The times that are also specified within the brackets are empirical values, unless stated otherwise. Modular Block System: Hydraulic Presses 5-13

62 MBS Basics DW1001 DW1002 DW1003 DW1004 DW1005 DW1006 DW1007 DW1009 DW1010 DW1011 DW1012 DW1013 DW1014 DW1015 DW1016 DW1017 DW1018 DW1019 DW1020 DW1021 DW1022 DW1023 Number of cycles in the contact synchronisation time between 2 N/O contacts or 2 N/C contacts (e.g. E-STOP button, reset key, etc.) {CoSy : 50 ms} Number of cycles in the feedback loop s reaction time to a change in the PSS output connected to the main contactor {RFbL : 100 ms} Number of cycles in the contact switchover time between a N/O and N/C contact (pushbutton) {CS_B : 100 ms} Number of cycles in the contact switchover time between a N/O and N/C contact (relay) {CS_R: 50 ms} Number of cycles in the machine clock time {MaCy : max. 30 s in accordance with EN section A.8.4, 06/98} Number of cycles in the permitted ESPE reaction time {ESPE : max. 150 ms in accordance with EN section 5.2.4, 06/98} Reserved Reserved Reserved Reserved Reserved Reserved Reserved Counter for monitoring the SSNR Reserved Reserved Reserved Reserved for administration Reserved Reserved for burner management Min. scan time from DB002/DW0002 Reserved 5-14 Modular Block System: Hydraulic Presses

63 Standard Function Blocks Guidelines for selecting standard function blocks Several standard function blocks are available for the following safety devices: E-STOP button Safety gate Feedback loop and Initialisation of the administration data blocks The following information is designed to help you select the standard function block that is most appropriate for your application. Emergency stop monitoring SB061 NA_1 SB061 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p). INFORMATION Do not use SB061 in applications with SafetyBUS p. SB061 cannot be used to monitor whether contacts switch synchronously when releasing an E-STOP button that has been operated. The additional commands for monitoring the SSNR are required (A DB015, I DW1015). Further information is available in Chapter 5, in the section entitled Input parameter SSNR. SB063 E-STOP SB063 is used in applications up to category 4. This standard function block is suitable for applications with SafetyBUS p. It has an input parameter to evaluate the status of the I/O-Group (SafetyBUS p), for which parameters are set on the E-STOP button contacts. Modular Block System: Hydraulic Presses 6-1

64 Standard Function Blocks It is possible to monitor whether contacts switch synchronously when releasing an E-STOP button that has been operated. SB063 provides an additional input parameter for this task. The value range for the safety subroutine number SSNR has been expanded to (see Chapter 5, section entitled Input parameter SSNR ). The use of SB063 is preferred in very extensive applications (> 200 standard function blocks). In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable. The additional commands for monitoring the SSNR are not required. Safety gate monitoring SB066 ST_K4 SB066 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p). INFORMATION Do not use SB066 in applications with SafetyBUS p. 6-2 Modular Block System: Hydraulic Presses

65 SB064 S-GATE SB064 is used in applications up to category 4. The function range of SB064 corresponds largely to that of SB066. However, the value range for the safety subroutine number SSNR has been expanded to (see Chapter 5, section entitled Input parameter SSNR ). This standard function block is suitable for applications with SafetyBUS p. It has an input parameter to evaluate the status of the I/O-Group (SafetyBUS p), for which parameters are set on the safety gate contacts. The use of SB064 is preferred in the following applications: Applications with SafetyBUS p Very extensive applications (> 200 standard function blocks) with/without SafetyBUS p In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable. Feedback loop monitoring SB067 RFK_K4 SB067 is used in applications up to category 4. This standard function block has no parameter to evaluate the status of I/O-Groups (SafetyBUS p). INFORMATION Do not use SB067 in applications with SafetyBUS p. Modular Block System: Hydraulic Presses 6-3

66 Standard Function Blocks SB065 FBL SB065 is used in applications up to category 4. The function range of SB065 corresponds largely to that of SB067. However, the value range for the safety subroutine number SSNR has been expanded to (see Chapter 5, section entitled Input parameter SSNR ). Other changes compared with SB067: Additional input parameter to set the time for monitoring the feedback loop individually Additional output parameter to drive 2 contactors Improved error message output This standard function block is suitable for applications with SafetyBUS p. It has an input parameter to evaluate the status of the I/O-Group (SafetyBUS p), for which parameters are set on the feedback loop contacts. The use of SB065 is preferred in the following applications: Applications with SafetyBUS p Very extensive applications (> 200 standard function blocks) with/without SafetyBUS p In this case, a fast PSS-CPU (e.g. CPU 3) is also preferable. Initialising the administration data blocks SB070 INIT_MBS SB070 exclusively initialises administration data block DB015 with global parameters. For this reason it can only be used in applications which: Comprise a maximum of 200 standard function blocks Do not use standard function blocks SB063, SB064, SB065, SB069 and SB Modular Block System: Hydraulic Presses

67 SB071 INIT_MBS SB071 initialises all three administration data blocks (DB015, DB016 and DB017) with global parameters. It can be used for all applications. NOTICE SB071 is essential if you are using any one of the following standard function blocks: SB063 SB064 SB065 SB069 SB075 In this case, the use of SB071 is firmly specified. Modular Block System: Hydraulic Presses 6-5

68 Standard Function Blocks SB051 SB051: Operating mode selector switch, 1 from 8 Block header Input parameters SSNR: SB 051 BA_1AUS8 B - SSNR FG - X X - S1 BA - B X - S2 RSET - X X - S3 X - S4 X - S5 X - S6 X - S7 X - S8 X - RSet X - LOCK W - TIME Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). S1... S8: Switch levels from operating mode selector switch On each position of the selector switch, a 1-signal must be present at one switch contact only. Unused inputs should be assigned RLO-0 (M ) Input coding of selector switch (mode 1 from 8): Position S8 S7 S6 S5 S4 S3 S2 S1 Dec.Value S Modular Block System: Hydraulic Presses

69 Output parameters RSet: Reset input for error acknowledgement RSet = 0/1 signal edge: Reset occurs LOCK: Lock switch position LOCK = 0: Switch position unlocked LOCK = 1: Switch position locked If the switch position changes, an error will be triggered immediately The parameter LOCK can be allocated the flag Machine running or press safety valve: on, for example. TIME: Maximum permitted contact switchover time between two correct switch positions Permitted time range: ms INFORMATION If possible you should use the PSS(1) DI2 as input module. If this is not possbible, the inputs must use test pulses. FG: BA: Enable flag bit FG = 1: Enabled (no errors) i.e. existing errors were reset via RSet and only one input (S1... S8) = 1. Operating mode, Output parameter: Byte format (8 Bit) If the input signal is faulty, no bit will be set in output byte BA. Output coding of selector switch (mode 1 from 8): Position Output Parameter BA (Byte Format) Dec. Value Bit: Modular Block System: Hydraulic Presses 6-7

70 Standard Function Blocks SB051 RSET: Reset output RSET = 1: The operating mode has been changed. If the operating mode has been changed (e.g. reset ESPE/AOPD ), the RSET output will be high for one cycle. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Incorrect input signal More than one input (S1... S8) is high. Remedy: Check switch, cable and input card, then reset (input parameter RSet) - Bit 01: No input signal (S1... S8) is high, all inputs are low (cable break) Remedy: Check switch, cable and input card, then reset (input parameter RSet) - Bit 08: Switch changed when LOCK = 1 Remedy: If switch has not changed: Check switch, cable and input card, then reset (input parameter RSet) If switch has changed: Check switch position and then reset (input parameter RSet) - Bit 14: RSet input constantly high or set too early Remedy: If RSet input was not set too early and is constantly high: Check switch, cable and input card, then reset (input parameter RSet) If RSet input was set too early: reset again (input parameter RSet) INFORMATION Error bits 00, 01 and 08 can only be reset in Setup mode. 6-8 Modular Block System: Hydraulic Presses

71 Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: Minimum scan time from DB002/DW002 Blocks required DB015: SB070 Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB015 Modular Block System: Hydraulic Presses 6-9

72 Standard Function Blocks SB052 SB052: Operating mode selector switch, 2 from 6 Block header SB052 BA_2AUS6 B - SSNR X - S1 X - S2 X - S3 X - S4 X - S5 X - S6 X - RSet X - LOCK W- TIME FG - X BA - W RSET - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB 200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). S1... S6: Switch levels from coded operating mode selector switch On each position of the selector switch, a 1-signal must be present at two switch contacts only. If a maximum of 6 switch settings (operating modes) are used, switch contacts S5 and S6 may be omitted (see table overleaf: Input coding of selector switch ). If a maximum of 10 switch settings are used, switch contact S6 may be omitted (see table overleaf: Input coding of selector switch ). Unused inputs should be assigned RLO-0 (M ) Modular Block System: Hydraulic Presses

73 Input coding of selector switch (mode 2 from 6): Position S6 S5 S4 S3 S2 S1 Dec. Value RSet: LOCK: TIME: Reset input for error acknowledgement RSet = 0/1 signal edge: Reset occurs Lock switch position LOCK = 0: Switch position unlocked LOCK = 1: Switch position locked If the switch position changes, an error will be triggered immediately. The parameter LOCK can be allocated the flag Machine running or Press safety valve: on (input parameter EIN from SB 080), for example. Maximum permitted contact switchover time between two correct switch settings. Permitted time range: ms INFORMATION If possible you should use the PSS(1) DI2 as input module. If this is not possible, the inputs must use test pulses. Modular Block System: Hydraulic Presses 6-11

74 Standard Function Blocks SB052 Output parameters FG: BA: Enable flag bit FG = 1: Enabled (no errors) i.e. existing errors were reset via input parameter RSet and two inputs (S1... S6) = 1. Operating mode Output parameter: Word format (16 Bit) Bit 00 represents no switch position. If the input code is faulty, no bit will be set. Output coding of selector switch (mode 2 from 6): Position Output Parameter BA (Word Format) Dec. Value HIGH-Byte LOW-Byte Modular Block System: Hydraulic Presses

75 RSET: Reset output RSET = 1: The operating mode has been changed. If the operating mode has been changed (e.g. reset ESPE/AOPD ), the RSET output will be high for one cycle. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Incorrect code from switch Remedy: Check switch position Otherwise: Check switch, cable and input card, then reset (input parameter RSet) - Bit 01: No signal from operating mode selector switch, both signals interrupted Remedy: Check switch Otherwise: Check cable and input card, then reset (input parameter RSet) - Bit 08: Switch changed when LOCK = 1 Remedy: If switch has not changed: Check switch, cable and input card, then reset (input parameter RSet) If switch has changed: Check switch position and then reset (input parameter RSet) - Bit 14: RSet input constantly high or set too early Remedy: If RSet input was not set too early and is constantly high: Check switch, cable and input card, then reset (input parameter RSet) If RSet input was set too early: reset again (input parameter RSet) INFORMATION Error bits 00, 01 and 08 can only be reset in Setup mode. Error messages on the CPU-display - None Modular Block System: Hydraulic Presses 6-13

76 Standard Function Blocks SB052 Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: Minimum scan time from DB002/DW002 Blocks required DB015: SB070 Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB Modular Block System: Hydraulic Presses

77 Notes Modular Block System: Hydraulic Presses 6-15

78 Standard Function Blocks SB059 SB059: Two-hand monitoring Block header SB 059 2_HAND B - SSNR X - STFG X - MEin X - T1.2 X - T1.4 X - T2.2 X - T2.4 W- KU_S X - RSET X - Tipp X - Auf X - Off FG - X GST - X AUF - X OFF - X Input parameters SSNR: STFG: MEin: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Static enable STFG = 0: Function disabled STFG = 1: Function enabled The two-hand control can only be enabled (FG = 1) if STFG is high. The STFG signal is the result when all the signals that must be present to operate the press are linked (e.g. FG from the E-STOP, FG from the operating mode selector switch etc.) Machine On A 1/0-pulse edge on the MEin signal activates a lock (singlestroke protection), which will only be lifted when the start position is achieved (both buttons T1 and T2 released). MEin = e.g. Safety valve on flag: Activation of lock required MEin = RLO-0 (M ): Activation of lock not required Modular Block System: Hydraulic Presses

79 T1.2: N/C button 1 T1.4: N/O button 1 T2.2: N/C button 2 T2.4: N/O button 2 KU_S: Contact switchover time between N/O and N/C contact on pushbuttons Permitted time range: ms Format: Constant fixed point number KF00001 KF01000 Suggested value: KF00100 INFORMATION If your plant does not run stably using the suggested value, you can work out the value that suits your plant as follows: - Select the suggested value as a starting point. - Increase this value by appropriate time intervals until your plant runs stably. Please note: Entering an excessively high time value for monitoring will reduce the level of safety on your plant. RSET: Reset input RSET = 0/1-signal edge: Trigger reset WARNING! The input parameter Tipp is not intended for use on presses and therefore must not be activated on presses. On presses, this input should be assigned RLO-0 (M110.00). Tipp: Mode: Jog mode using one button and setup speed Tipp = 0: Mode: Jog mode using one button is blocked. To disable jog mode using one button, the input should be assigned RLO-0 (M110.00). Modular Block System: Hydraulic Presses 6-17

80 Standard Function Blocks SB059 Tipp = 1: Mode: Jog mode using one button is permitted. The input should be assigned the flag Setup mode. The input parameter Tipp = 1 has no effect on normal two-hand operation. However, jog mode using one button, where the other button is constantly operated, is additionally permitted. Procedure: To start jog mode, press both two-hand buttons simultaneously, then release one button while the keeping the other pressed down. Operate jog mode using the two-hand button that was released. WARNING! The input parameter Auf is intended exclusively for use on hydraulic presses. It must not be activated on eccentric presses. On eccentric presses, this input should be assigned RLO-0 (M110.00). Auf: Off: Activate upward movement with one button (output parameter AUF) Auf = 0: Output parameter AUF is inactive (AUF = 0) Assign the input RLO-0 (M110.00) if you want to use both buttons to activate the upward movement. Auf = 1: Output parameter AUF is set (AUF = 1), if one button is operated for longer than 0.5 s Assign the input RLO-1 (M110.01) if you want to use one button to activate the upward movement. Deselect two-hand control circuit Where plug-in two-hand devices/consoles are being monitored, there is the option to deselect a two-hand device/ console (e.g. re-tooling to two-man operation from 4-man). Off = 0: Two-hand control circuit/console is selected Off = 1: Two-hand control circuit/console is deselected 6-18 Modular Block System: Hydraulic Presses

81 INFORMATION The two-hand device/console is correctly disconnected and deselected when: Input parameter T1.2 and T1.4 = 0 T2.2 and T2.4 = 0 Output parameter FG, GST, AUF = 0 OFF = 1 In all cases, an error message will be issued when a two-hand device/ console is disconnected. You will need to take one of the following actions: The two-hand device/console is disconnected, but still selected via the key switch: Deselect the console via the key switch and then reset. The two-hand device/console is now correctly deselected and disconnected (please refer to Error messages under Bit 04 ). The two-hand device/console is deselected via the key switch, but is still connected: Disconnect the console and then reset. The two-hand device/console is now correctly deselected and disconnected (please refer to Error messages under Bit 05 ). A dummy connector is not required to act as a buffer when unplugging a two-hand device/console. DANGER! If a two-hand circuit is deselected using the input parameter Off, a different safety device must be employed in its place. Remember that the two-hand circuit has a safety function in addition to its operator function. Modular Block System: Hydraulic Presses 6-19

82 Standard Function Blocks SB059 INFORMATION All two-hand buttons must use test pulses. These pulses should be entered in the configurator (DB 002) accordingly. Ensure the selector switch contact for input parameter Off has a test pulse output and enter this output in the configurator (DB 002) accordingly If the block is to be used to monitor a foot switch, the inputs of the N/O and N/C contacts on the foot switch must be connected to T1.2 and T2.2 or T1.4 and T2.4 respectively. In accordance with EN 574 section 3.5, 02/97, monitoring of the synchronisation time between the two buttons is set at < 0.5 s. Output parameters FG: GST: AUF: OFF: Enable flag bit FG = 0: Not enabled FG = 1: Two-hand operation is enabled Two-hand operation is enabled provided the output parameter STFG = 1, both buttons (T1 and T2) are operated within 0.5 s and any errors have been rectified and reset. Start position GST = 0: T1 and T2 not in start position GST = 1: Both buttons (T1 and T2) are released. (for use only with hydraulic presses) AUF = 0: Upward movement with one button is inactive AUF = 1: Only one button needs to be operated for longer than 0.5 s to trigger an upward movement. This output may only move the press slide upwards. Ejectors and die cushions may only be moved to TDC using a separate button. Two-hand control circuit/console is selected/deselected (input parameter Off) OFF = 0: Two-hand control circuit/console selected (Off = 0) OFF = 1: Two-hand control circuit is correctly deselected (Off = 1) and disconnected Modular Block System: Hydraulic Presses

83 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB 015 (1st data block), until the fault has been fully dealt with. Error messages in DB Bit 00: T1 N/O and N/C contact open Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 01: T1 N/O and N/C contact closed Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 02: T2 N/O and N/C contact open Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 03: T2 N/O and N/C contact closed Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 04: Two-hand control circuit/console selected, but the console is disconnected Remedy: Check switch, cable, input card and all conditions, then reset (input parameter RSET) - Bit 05: Two-hand control circuit/console is deselected, but the console is connected Remedy: Check switch, cable, input card and all conditions, then reset (input parameter RSET) - Bit 08: Reset (input parameter RSET) pressed too soon or constantly pressed Remedy: If RSET input has not been set too early and is contantly high: Check switch, cable and input card, then reset (input parameter RSET) If RSET input has been set too early: reset again (input parameter RSET) Modular Block System: Hydraulic Presses 6-21

84 Standard Function Blocks SB059 - Bit 09: Button pressed without start enable Remedy: Check enable input, cable, input card and all conditions, then reset (input parameter RSET) - Bit 10: Synchronisation time error, T1 missing (no Auf mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 11: Synchronisation time error, T2 missing (no Auf mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 12: Two-hand control RESET via MEin (button released) Remedy: Check switch, cable, input card and all conditions, then reset (input parameter RSET) - Bit 14: T1 not released (no Jog mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) - Bit 15: T2 not released (no Jog mode) Remedy: Check input button, cable, input card and all conditions, then reset (input parameter RSET) Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: Minimum scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access Modular Block System: Hydraulic Presses

85 Notes Modular Block System: Hydraulic Presses 6-23

86 Standard Function Blocks SB061 SB061: Emergency stop monitoring, category 4 Block header SB 061 NA_1 B - SSNR X - EIN X - S1_Ö X - S2_Ö X - QAnf X - QAut FG - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). EIN: Reset button (N/O contact) EIN = 0/1-pulse edge: Reset occurs S1_Ö : E-STOP N/C contact 1 S2_Ö : E-STOP N/C contact 2 QAnf: Automatic reset (PSS cold start) QAnf = RLO-0 (M ): No reset required. Cycle: When the PSS is started up or cold started, the enable is triggered without an additional reset. QAut: QAnf = RLO-1 (M ): Reset required. Cycle: When the PSS is started up or cold started, a reset is required through the input parameter EIN in order to trigger the enable. Automatic reset when E-STOP button is released QAut = 0: Reset through input parameter EIN is required Modular Block System: Hydraulic Presses

87 QAut = 1: Automatic reset when EIN = 1: E-STOP-button is released QAnf = 0: INFORMATION Automatic reset is only possible in conjunction with: EIN = RLO-1 (M ) and QAnf = RLO-0 (M ). This means that an automatic reset (QAut = 1) and a reset on PSS start-up (QAnf = 1) are mutually exclusive. Output parameters FG: Enable flag bit FG = 0: Not enabled FG = 1: Function enabled when no errors are present Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB 015 (1st data block), until the fault has been fully dealt with. Error messages in DB Bit 00: E-STOP button operated Remedy: Check button, cable and input card, release E-STOP button and reset (input parameter EIN) - Bit 01: Contact synchronisation time exceeded for N/C contact S1_Ö Remedy: Check button, cable and input card, release E-STOP button and reset (input parameter EIN) - Bit 02: Contact synchronisation time exceeded for N/C contact S2_Ö Remedy: Check button, cable and input card, release E-STOP button and reset (input parameter EIN) Modular Block System: Hydraulic Presses 6-25

88 Standard Function Blocks SB061 - Bit 03: With: Automatic reset (PSS cold start) : E-STOP button operated and reset button pressed Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter EIN). With: Automatic reset when E-STOP button is released : E-STOP button operated Remedy: Release E-STOP button - Bit 08: E-STOP released, ready for reset Remedy: Press reset button (input parameter EIN) - Bit 09: Reset button pressed constantly (i.e. stuck in) Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter EIN) - Bit 10: Reset successful, but N/C contact S1_Ö failed to open when the E-STOP button was operated. Remedy: Press E-STOP button again to ensure that contacts open correctly and then reset; otherwise: check cable and input card, release the E-STOP button and reset (input parameter EIN) - Bit 11: Reset successful, but N/C contact S2_Ö failed to open when the E-STOP button was operated. Remedy: Press E-STOP button again to ensure that contacts open correctly and then reset; otherwise: check cable and input card, release the E-STOP button and reset (input parameter EIN) Error messages on the CPU-display - E 001: Parameter error SSNR does not lie within the limits of E 002: Parameter error SSNR assigned more than once OR DW1015 in DB015 was not incremented 6-26 Modular Block System: Hydraulic Presses

89 Global parameters used in administration data block DB015 Global parameters may be set with SB070 in OB120. DW1001: Number of cycles in the contact synchronisation time between the 2 N/C contacts on the E-STOP button DW1015: Counter for monitoring the SSNR INFORMATION On some blocks (e.g. E-STOP) the input parameter SSNR is monitored. These blocks must be run through as part of each PSS-cycle. The following commands should therefore be entered once only at the end of OB101: A I DB015 DW1015 Effect: The counter for monitoring the SSNR in DB015/DW1015 (global parameters) will be incremented. Blocks required DB015: SB070 SB255: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB015 To call up the operating system Modular Block System: Hydraulic Presses 6-27

90 Standard Function Blocks SB063 SB063: Emergency stop monitoring, category 4 Block header SB063 E-STOP W - SSNR X - GRP X - NC_1 X - NC_2 X - AuSt X - ARSt X - FTST X - RSET ENBL - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Word constants KF KF (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). GRP: I/O-Group status flag (SafetyBUS p) containing the inputs NC_1 and NC_2 (M for I/O-Group 0 to M for I/O-Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1. NC_1: E-STOP N/C contact 1 NC_2: E-STOP N/C contact 2 AuSt: Reset on start-up (PSS cold start) or when I/O-Group is started (SafetyBUS p) AuSt = 0: Initial reset required. Sequence: When the PSS is cold/warm started or the I/O- Group is started (GRP = 0/1-pulse edge), an initial reset is required through input parameter RSET, in order to trigger the enable Modular Block System: Hydraulic Presses

91 ARSt: FTST RSET: AuSt = 1: No initial reset required Sequence: When the PSS is cold/warm started or the I/O- Group is started (GRP = 0/1-pulse edge), the enable is triggered without a further initial reset. NC_1 = 1 und NC_2 = 1 is also required in order to set the enable. Automatic reset when E-STOP button is released ARSt = 0: Reset through input parameter RSET is required ARSt = 1: Automatic reset required when E-STOP button is released Function test FTST = 0: No function test required FTST = 1: A function test must be performed if a synchronisation error occurs when the E-STOP button is released. Reset button (N/O contact) RSET = 0/1-pulse edge: Reset occurs RSET should be assigned RLO-0 if you do not need a reset button (e.g. with automatic reset). Output parameters ENBL: Enable bit ENBL = 0: Enable is blocked ENBL = 1: This function is error-free, the E-STOP button has not been operated Function test The function test will check whether both contacts on the E-STOP button are switching synchronously. A function test must always be performed if a synchronisation error occurs when the E-STOP button is operated. Input parameter FTST can be used to establish whether or not a function test is required if a synchronisation error occurs when the E-STOP button is released. Modular Block System: Hydraulic Presses 6-29

92 Standard Function Blocks SB063 Sequence of function test: Press E-STOP button Release E-STOP button Press reset button (input parameter RSET) Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of the administration data block (1st data block), until the fault has been fully dealt with. Error messages in the administration data block - Bit 00: E-STOP button operated Remedy: Release E-STOP button and reset (input parameter RSET) - Bit 01: Reset required Remedy: Reset (input parameter RSET) - Bit 03: Function test required due to a synchronisation error Remedy: Perform function test (press E-STOP button, release it and reset (input parameter RSET)) - Bit 04: E-STOP button operated and reset button pressed Remedy: Check button, cable and input card, release E-STOP button and reset again (input parameter RSET) - Bit 05: Reset button pressed too soon or constantly pressed Remedy: Check reset button, cable and input card and reset again (input parameter RSET) - Bit 06: Initial reset required Remedy: Reset (input parameter RSET) - Bit 07: Synchronisation error N/C contact 1 Remedy: Check button, cable and input card, release the E- STOP button and perform a function test (press E-STOP button, release it and reset (input parameter RSET)) 6-30 Modular Block System: Hydraulic Presses

93 - Bit 08: Synchronisation error N/C contact 2 Remedy: Check button, cable and input card, release the E- STOP button and perform a function test (press E-STOP button, release it and reset (input parameter RSET)) - Bit 09: I/O-Group stop triggered while PSS is in RUN mode Remedy: Start I/O-Group Error messages on the CPU-display - E003 Administration data block has not been initialised Remedy: Call SB071 in OB120 Global parameters used in the administration data blocks The global parameter may be set in OB120 using SB071. DW1001: Number of cycles in the contact synchronisation time between the 2 N/C contacts on the E-STOP button Blocks required DB015, DB016, DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words and have READ/WRITE access (see Chapter 5, section entitled Administration data blocks... ). SB071: Initialisation of global parameters in DB015, DB016 and DB017 Modular Block System: Hydraulic Presses 6-31

94 Standard Function Blocks SB064 SB064: Safety gate monitoring Block header SB064 ST_K4 W - SSNR X - GRP X - S1 X - S2 W - SyTi X - MRun X - AuSt X - ARSt X - NoFT X - RSET ENBL - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Word constants KF KF (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). GRP: I/O-Group status flag (SafetyBUS p) containing the inputs S1 and S2 (M for I/O-Group 0 to M for I/O-Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1 S1: Gate switch: Signal 1 If the gate is closed, both gate S2: Gate switch: Signal 2 switches must supply a 1-signal SyTi: Synchronisation time between S1 and S2 Value in ms [ ]; 0 = infinite; format: word constants 6-32 Modular Block System: Hydraulic Presses

95 MRun: AuSt: ARSt: NoFT: RSET: Machine is running MEin = 0: Machine standing MEin = 1: Machine is running MEin = 1/0-pulse edge: Activate reset lock. This parameter can force the operator to carry out a function test of the gate (gate open/closed). The reset lock is lifted by carrying out a function test on the gate followed by the RSET signal. Automatic start/start-up disabler AuSt = 0: Start-up disabler (initial reset is required) AuSt = 1: Automatic start/no start-up disabler on PSS cold/ warm start or when starting the I/O-Group; only effective in conjunction with NoFT = 1 (see also under Operating modes ) Automatic restart/reset lock ARSt = 0: Reset lock (reset is required) ARSt = 1: Automatic restart/no reset lock (see also under Operating modes ) Function test on the gate NoFT = 0: Function test required on the gate NoFT = 1: Cold/warm start without function test on the gate (see also under Operating modes ) Reset input RSET = 0/1 pulse edge: - Reset errors or - Reset start-up disabler or - Reset reset lock Modular Block System: Hydraulic Presses 6-33

96 Standard Function Blocks SB064 Input circuitry Inputs S1 and S2 must use test pulses. These pulses should be entered in the configurator (DB002) accordingly. Using SB064 for safety gate monitoring: - Category 2 CAUTION! This can only be used on safety gates which are regularly opened and closed as part of the machine cycle. If you are only using one switch/contact, S1 and S2 will have the same input address. The switch must close when the safety gate is closed. If you only use one switch/contact, malfunctions such as a button plunger sticking or the gate failing to actuate cannot be detected. A function test must therefore be carried out on the gate as part of each cycle, i.e. the gate must be opened and closed regularly. This requirement is met if the reset lock is activated each cycle by a 1/0 pulse edge at the MRun input (e.g. each time the machine stops), so that it is only possible to restart the machine after the gate has been opened and closed. - Category 4: Use two separate switches/contacts, which must be operated independently. Both switches must close when the safety gate is closed. A cyclical function test on the gate is not required. Output parameters ENBL: Enable bit ENBL = 0: ENBL = 1: Enable is blocked Enable occurs if the safety gate is closed (S1 = 1 and S2 = 1), any errors have been rectified and confirmation has been given via the RSET signal Modular Block System: Hydraulic Presses

97 Functions The operation of SB064 is established via the following input parameters: ARSt: No reset lock (Automatic Restart) AuSt: No start-up disabler (Automatic Start) on PSS cold/warm start or when starting the I/O-Group NoFT: No function test on the gate Please note that a combination of various settings is possible with these input parameters (e.g. start-up disabler activated/reset lock activated or start-up disabler activated/reset lock disabled etc.). These input parameters are also used to establish what the operator needs to do should an error occur (function test and error acknowledgement/reset). The individual options can be found in the following tables. Tables for setting the functions: Procedure for achieving the enable (output parameter ENBL) on PSS cold/ warm start Op. mode Start disabler AuSt *1 0 1 *1 Parameter ARSt NoFT Func- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x *2 - x *2 - x - x - x - x - test Open and close x *2 gate x x *2 x x *3 or - - RSET Table 1: Function: Start-up disabler Modular Block System: Hydraulic Presses 6-35

98 Standard Function Blocks SB064 Procedure for achieving the enable (output parameter ENBL) when PSS is in RUN mode (subsequent statuses only after enable is issued) Op. mode Reset ARSt lock Parameter AuSt *1 0 1 *1 NoFT Func- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x - x - x - x - x - x - test Open and close gate RSET Table 2: Function: Reset lock Required reaction from operator in the case of a fault Parameter ARSt AuSt *1 0 1 *1 NoFT Funk- Status of gate open shut open shut open shut open shut open shut open shut tion Close gate x - x - x - x - x - x - test Open and close gate x* 4 x x* 4 x x 4 x x* 4 x x* 4 x x* 4 x RSET Table 3: Reaction in the case of a fault x Function activated or operator reaction required - Function not activated or no operator reaction required or reset not required Reset required via the reset input *1 The function No start-up disabler on PSS cold/warm start is only possible when no function test is set (NoFT = 1). *2 First close the gate, then open it and close it again. *3 The enable can be set by opening/closing the gate or by a pulse at the reset input. *4 When synchronisation time S1-S2 is exceeded (error bit 09) 6-36 Modular Block System: Hydraulic Presses

99 Example 1: Parameters ARSt, AuSt and NoFT = 0 These settings mean that the start-up disabler and reset lock functions are activated; a function test of the gate is required. With PSS cold or warm start (start-up disabler), proceed as follows: - If the gate is open, close, open and then close the gate again, then reset via the reset button (RSET). - If the gate is closed, open and close the gate and reset via the reset button (RSET). Subsequent statuses only after enable is issued (reset lock): - If the gate is open, close the gate and reset via the reset button (RSET). - If the gate is closed, reset via the reset button (RSET). If there has been a fault, this must first be rectified before proceeding as follows: - If the gate is open, close the gate and reset via the reset button (RSET). If error bit 09 occurs (synchronisation time exceeded), close, open and then close the gate again, then reset via the reset button (RSET). - If the gate is closed, open and close the gate and reset via the reset button (RSET). Example 2: Parameters ARST and AuST = 0, NoFT = 1 These settings mean that the start-up disabler and reset lock functions are activated and a function test of the gate is not required. With PSS cold or warm start (start-up disabler), proceed as follows: - If the gate is open, close the gate and reset via the reset button (RSET). - If the gate is closed, reset via the reset button (RSET). Subsequent statuses only after enable is issued (reset lock): - If the gate is open, close the gate and reset via the reset button (RSET). - If the gate is closed, reset via the reset button (RSET). Modular Block System: Hydraulic Presses 6-37

100 Standard Function Blocks SB064 If there has been a fault, this must first be rectified before proceeding as follows: - If the gate is open, close the gate and reset via the reset button (RSET). If error bit 09 occurs (synchronisation time exceeded), close, open and then close the gate again, then reset via the reset button (RSET). - If the gate is closed, open and close the gate and reset via the reset button (RSET). Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of administration data block (1st data block), until the fault has been fully dealt with. Error messages in the administration data block - Bit 06: I/O-Group stop triggered while the PSS is in RUN mode Remedy: Start I/O-Group - Bit 07: Gate open (S1 and S2 open) Remedy: Close gate and then reset (input parameter RSET) - Bit 08: Function test not carried out (gate open/closed) Remedy: Carry out function test and/or check switch, cable and input card and then reset (input parameter RSET) - Bit 09: S1 and S2 synchronisation time exceeded Remedy: Check switch, cable and input card, carry out a function test and then reset (input parameter RSET) - Bit 10: Gate open (S1 open) Remedy: Close gate, check switch, cable and input card and then reset (input parameter RSET) - Bit 11: Gate open (S2 open) Remedy: Close gate, check switch, cable and input card and then reset (input parameter RSET) 6-38 Modular Block System: Hydraulic Presses

101 - Bit 12: Gate closed, S1 was not open Remedy: Open gate, check switch, cable and input card and then carry out function test and reset (input parameter RSET) - Bit 13: Gate closed, S2 was not open Remedy: Open gate, check switch, cable and input card, carry out a function test and then reset (input parameter RSET) - Bit 14: RSET input constantly high or set too early Remedy: If RSET input was not set too early and is constantly high: Check switch, cable and input card, then reset (input parameter RSET). If RSET input was set too early: reset again (input parameter RSET) - Bit 15: Gate closed, RSET signal is missing Remedy: Check all conditions and then reset (input parameter RSET) Error messages on the CPU-display - E003 Administration data block has not been initialised Remedy: Call SB071 in OB120 Global parameters used in the administration data blocks The global parameter may be set in OB120 using SB071. DW1022: Minimum scan time Blocks required DB015, DB016, DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words and have READ/WRITE access (see Chapter 5, section entitled Administration data blocks... ). SB071: Initialisation of global parameters in DB015, DB016 and DB017 Modular Block System: Hydraulic Presses 6-39

102 Standard Function Blocks SB065 SB065: Feedback loop monitoring Block header SB065 FBL W- SSNR X - GRP X - ON X - FbL1 X - FbL2 W- TFbL X - RSET ENBL - X K1 - X K2 - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Word constants KF KF (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). GRP: I/O-Group status flag (SafetyBUS p) containing the inputs FBL1 and FBL2 (M for I/O-Group 0 to M for I/O- Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1 ON: Switch on contactors via output parameters K1 and K2 ON = 0/1 pulse edge: Switch on output parameters K1 and K2 (K1 = 1 and K2 = 1) ON = 1/0 pulse edge: Switch off output parameters K1 and K2 (K1 = 0 and K2 = 0) FbL1: Feedback loop N/C contact on contactor 1 FbL2: Feedback loop N/C contact on contactor Modular Block System: Hydraulic Presses

103 TFbL: Time for feedback loop monitoring when switching on/off Permitted value range in ms: When TFbL = 0, the default value for feedback loop monitoring will be used from DW1002 of the administration data block (global parameter RFbL). Format: Word constants KF KF Recommended value: 100 ms (KF000100) INFORMATION The value for feedback loop monitoring should be less than the interval between consecutive operations. Irrespective of parameter TFbL, the initial acknowledgements from feedback loops FbL1 =1 and FbL2 = 1 must always be present when switching on (ON = 0/1 pulse edge). RSET: Reset input RSET = 0/1 pulse edge: trigger reset Input circuitry If you are only using one feedback loop, connect the feedback loop input to FbL1 and FbL2. Output parameters ENBL: Enable bit ENBL = 0: Enable is blocked ENBL = 1: Contactors are free from error K1: Output for driving contactor 1 K2: Output for driving contactor 2 Output circuitry If you are only using one contactor, connect the contactor output to K1 and K2. Modular Block System: Hydraulic Presses 6-41

104 Standard Function Blocks SB065 Wiring for category 4 If you use two contactors in applications for category 4, please note the following guidelines when using the various output modules: DOS: The contactors must be connected to adjacent blocks of 8 outputs (see Installation Manual for the PSS 3000/PSS 3100 series ) DI2OZ: The contactors may be connected to a dual-pole output. Connect the contactor output to K1 and K2. DI8O8: The contactors must be connected to two different single-pole outputs in the range O 0 to O 5. Alternatively, where the outputs are so configured, the contactors may be connected to a dualpole output O 4 or O 5 (see Installation Manual PSS SB DI8O8 ). In this case, connect the contactor output to K1 and K2. Functions The contactors can only be switched on when they are in their start position (FbL1 =1 and FbL2 = 1). The operation is monitored via acknowledgements from FbL1 and FbL2. When switching on and off, acknowledgements must change state within a maximum reaction time. This reaction time can be set within the range of ms via input parameter TFbL. If the maximum reaction time is exceeded, an error message will be issued (ENBL = 0) and the contactors will be switched off immediately (K1 = 0 and K2 = 0). The error will need to be reset. The time for feedback loop monitoring should be set as short as possible. When TFbL = 0, the default value for feedback loop monitoring will be used from DW1002 of the administration data block (global parameter RFbL, recommended value: 100 ms). The value for feedback loop monitoring should in any case be less than the interval between consecutive operations Modular Block System: Hydraulic Presses

105 Error messages The acknowledgements FbL1 and FbL2 are also monitored in the static condition. If there are discrepancies between the set and true condition, an error message will be issued (ENBL = 0) and the contactors will be switched off immediately (K1 = 0 and K2 = 0). The error will need to be reset. It is possible to reset errors via the input parameter RSET both when ON = 0 and when ON = 1. However, a prerequisite for setting the enable and, when ON = 1, switching on the contactors, is that the signals from the feedback loops are correct. Any fault that is detected will be stored in the corresponding error data word (SSNR) of the administration data block (1st data block), until the fault has been fully dealt with. Error messages in the administration data block - Bit 00: Fault as the signal changes at input parameter ON, feedback loop 1 (FbL1) remains open Remedy: Check contactor, contacts, cable, input card, output card, value of input parameter TFbL and all conditions and then reset (input parameter RSET) - Bit 01: Fault as the signal changes at input parameter ON, feedback loop 1 (FbL1) remains closed Remedy: Check contactor, contacts, cable, input card, output card, value of input parameter TFbL and all conditions and then reset (input parameter RSET) - Bit 02: Fault as the signal changes at input parameter ON, feedback loop 2 (FbL2) remains open Remedy: Check contactor, contacts, cable, input card, output card, value of input parameter TFbL and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses 6-43

106 Standard Function Blocks SB065 - Bit 03: Fault as the signal changes at input parameter ON, feedback loop 2 (FbL2) remains closed Remedy: Check contactor, contacts, cable, input card, output card, value of input parameter TFbL and all conditions and then reset (input parameter RSET) - Bit 04: Fault during the static condition at input parameter ON, feedback loop 1 (FbL1) interrupted Remedy: Check contactor, contacts, cable, input card, output card and all conditions and then reset (input parameter RSET) - Bit 05: Fault during the static condition at input parameter ON, feedback loop 1 (FbL1) closed Remedy: Check contactor, contacts, cable, input card, output card and all conditions and then reset (input parameter RSET) - Bit 06: Fault during the static condition at input parameter ON, feedback loop 2 (FbL2) interrupted Remedy: Check contactor, contacts, cable, input card, output card and all conditions and then reset (input parameter RSET) - Bit 07: Fault during the static condition at input parameter ON, feedback loop 2 (FbL2) closed Remedy: Check contactor, contacts, cable, input card, output card and all conditions and then reset (input parameter RSET) - Bit 08: Reset input constantly 1 or set too early Remedy: Release reset button and press again, otherwise: check switch, cable and input card and reset again (input parameter RSET) - Bit 09: I/O-Group stop triggered while PSS is in normal RUN mode Remedy: Start I/O-Group Error messages on the CPU-display - E003: Administration data block has not been initialised Remedy: Call SB071 in OB Modular Block System: Hydraulic Presses

107 Global parameters used in the administration data blocks Global parameters may be set in OB120 using SB071. DW1002: Number of cycles for the reaction time of the feedback loop with contactors DW1022: Minimum scan time Blocks required DB015, DB016, DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words and have READ/WRITE access (see Chapter 5, section entitled Administration data blocks... ). SB071: Initialisation of global parameters in DB015, DB016 and DB017 Modular Block System: Hydraulic Presses 6-45

108 Standard Function Blocks SB066 SB066: Safety gate monitoring Block header SB 066 ST_K4 B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). S1: Gate switch: Signal 1 S2: Gate switch: Signal 2 SyTi: MEin: Strt: If the gate is closed, both gate switches must supply a 1-signal Synchronisation time between S1 and S2 Value in ms [ ]; 0 = infinite time; format: word constants (KF) Machine is running MEin = 0: Machine standing MEin = 1: Machine running MEin = 1/0-pulse edge: Activate reset lock This parameter can force the operator to carry out a function test of the gate (gate open/closed). The reset lock is lifted by carrying out a function test on the gate followed by the Strt Signal. Reset input Strt = 0/1-pulse edge: - Reset errors OR - Reset start-up disabler OR - Reset reset lock 6-46 Modular Block System: Hydraulic Presses

109 ARSt: AuSt: NFkT: Automatic restart/reset lock ARSt = 0: Reset lock ARSt = 1: Automatic restart / no reset lock (see also under Operating modes ) Automatic start / start-up disabler AuST = 0: Start-up disabler AuST = 1: Automatic start / no start-up disabler on PSS startup; only effective in conjunction with NFkT = 1 (see also under Operating modes ) No function test on the gate NFkT = 0: Function test required on the gate NFkT = 1: Start up without a function test on the gate (see also under Operating modes ) Input circuitry Inputs S1 and S2 must use test pulses. These pulses should be entered in the configurator (DB 002) accordingly. Using SB066 for safety gate monitoring: - Category 2 CAUTION! This can only be used on safety gates which are regularly opened and closed as part of the machine cycle. If you are only using one switch/contact, S1 and S2 will have the same input address. The switch must close when the safety gate is closed. If you only use one switch/contact, malfunctions such as a button plunger sticking or the gate failing to actuate cannot be detected. A function test must therefore be carried out on the gate as part of each cycle, i.e. the gate must be opened and closed regularly. This requirement is met if the reset lock is activated each cycle by a 1/0 pulse edge at the MRun input (e.g. each time the machine stops), so that it is only possible to restart the machine after the gate has been opened and closed. Modular Block System: Hydraulic Presses 6-47

110 Standard Function Blocks SB066 - Category 4: Use two separate switches/contacts, which must be operated independently. Both switches must close when the safety gate is closed. A cyclical function test on the gate is not required. Output parameters FG: Enable bit FG = 0: FG = 1: Not enabled Enable occurs if: the safety gate is closed (S1 = 1 and S2 = 1), any errors have been rectified and confirmation has been given via the Strt-Signal. Functions The operation of SB066 is established via the following input parameters: ARSt: Automatic restart AuSt: Automatic start when PSS starts up (warm/cold start) NFkT: No function test on the gate The settings at these input parameters are loaded into auxiliary flags when the PSS is started up and cannot be amended during operation. Please note that a combination of various settings is possible with these input parameters (e.g. start-up disabler activated/reset lock activated or start-up disabler activated/automatic reset etc.). These input parameters are also used to establish what the operator needs to do should an error occur (function test and error acknowledgement / reset). The individual options can be found in the following tables Modular Block System: Hydraulic Presses

111 Tables for setting the functions: Procedure for achieving the enable (output parameter FG) on PSS cold start/warm start Op. mode Start disabler AuSt *1 0 1 *1 Parameter ARSt NFkT Function Status of gate open shut open shut open shut open shut open shut open shut test Close gate x *2 - x *2 - x - x - x - x - Open and close x *2 gate x x *2 x x *3 or - - Strt Table 1: Function: Start-up disabler Procedure for achieving the enable (output parameter FG) when PSS is in RUN mode (subsequent statuses only after enable is issued) Op. mode Reset lock ARSt Parameter AuSt *1 0 1 *1 NFkT Function Status of gate open shut open shut open shut open shut open shut open shut test Close gate x - x - x - x - x - x - Open and close gate Strt Table 2: Function: Reset lock Modular Block System: Hydraulic Presses 6-49

112 Standard Function Blocks SB066 Required reaction from operator in the case of a fault Parameter ARST AuST *1 0 1 *1 NFkT Function Status of gate open shut open shut open shut open shut open shut open shut test Close gate x - x - x - x - x - x - Open and close gate x *4 x x *4 x x *4 x x *4 x x *4 x x *4 x Strt Table 3: Reaction in the case of a fault x Function activated or operator reaction required - Function not activated or no operator reaction required or reset not required Reset required via the reset input *1 The function No start-up disabler on PSS cold/warm start is only possible when no function test is set (NFkT = 1). *2 First close the gate, then open it and close it again. *3 The enable can be set by opening/closing the gate or by a pulse at the reset input. *4 When synchronisation time S1-S2 is exceeded (error bit 09) 6-50 Modular Block System: Hydraulic Presses

113 Example 1: Parameters ARST, AuST and NFkT = 0 These settings mean that the start-up disabler and reset lock functions are activated and a function test of the gate is required. With PSS start-up or PSS cold start (start-up disabler), proceed as follows: - If the gate is open, close, open and then close the gate again, then reset via the reset button (Strt). - If the gate is closed, open and close the gate and reset via the reset button (Strt). Subsequent statuses only after enable is issued (reset lock): - If the gate is open, close the gate and reset via the reset button (Strt). - If the gate is closed, reset via the reset button (Strt). If there has been a fault, this must first be rectified before proceeding as follows: - If the gate is open, close the gate and reset via the reset button (Strt). If error bit 09 occurs (synchronisation time exceeded), close, open and then close the gate again, then reset via the reset button (Strt). - If the gate is closed, open and close the gate and reset via the reset button (Strt). Example 2: Parameters ARST and AuST = 0, NFkT = 1 These settings mean that the start-up disabler and reset lock functions are activated and a function test of the gate is not required. With PSS start-up or PSS cold start (start-up disabler), proceed as follows: - If the gate is open, close the gate and reset via the reset button (Strt). - If the gate is closed, reset via the reset button (Strt). Subsequent statuses only after enable is issued (reset lock): - If the gate is open, close the gate and reset via the reset button (Strt). - If the gate is closed, reset via the reset button (Strt). Modular Block System: Hydraulic Presses 6-51

114 Standard Function Blocks SB066 If there has been a fault, this must first be rectified before proceeding as follows: - If the gate is open, close the gate and reset via the reset button (Strt). If error bit 09 occurs (synchronisation time exceeded), close, open and then close the gate again, then reset via the reset button (Strt). - If the gate is closed, open and close the gate and reset via the reset button (Strt). Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 08: Function test not carried out (gate open/closed) Remedy: Carry out function test and/or check switch, cable and input card and then reset (input parameter Strt) - Bit 09: S1 and S2 synchronisation time exceeded Remedy: Check switch, cable and input card, carry out a function test and then reset (input parameter Strt) - Bit 10: Gate open (S1 open) Remedy: Close gate, check switch, cable and input card and then reset (input parameter Strt) - Bit 11: Gate open (S2 open) Remedy: Close gate, check switch, cable and input card and then reset (input parameter Strt) - Bit 12: Gate closed, S1 was not open Remedy: Open gate, check switch, cable and input card and then carry out function test and reset (input parameter Strt) - Bit 13: Gate closed, S2 was not open Remedy: Open gate, check switch, cable and input card, carry out a function test and then reset (input parameter Strt) 6-52 Modular Block System: Hydraulic Presses

115 - Bit 14: Strt input constantly high or set too early Remedy: If Strt input was not set too early and is constantly high: Check switch, cable and input card, then reset (input parameter Strt). If Strt input was set too early: reset again (input parameter Strt) - Bit 15: Gate closed, Strt signal is missing Remedy: Check all conditions and then reset (input parameter Strt) Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: Minimum scan time Blocks required DB015: SB070 Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB015 Modular Block System: Hydraulic Presses 6-53

116 Standard Function Blocks SB067 SB067: Feedback loop monitoring Block header SB 067 RFK_K4 B - SSNR X - RFK1 X - RFK2 X - RSET X - Ein FG - X K - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). RFK1: Feedback loop N/C contact on contactor 1 RFK2: Feedback loop N/C contact on contactor 2 RSET: Reset input RSET = 0/1 signal edge: Trigger reset Ein: Switches on main contactor via output parameter K Ein = 0/1-signal edge: Switch on output parameter K (K = 1) Ein = 1/0-signal edge: Switch off output parameter K (K = 0) Input circuitry If you are only using one feedback loop, connect the RFK input to RFK1 and RFK2. Output parameters FG: K: Enable bit FG = 0: Not enabled FG = 1: No error found on this relay block function Output to main contactor 6-54 Modular Block System: Hydraulic Presses

117 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Faults which occur as the pulse edge changes at the input parameter EIN RFK 1 remains open Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 01: Faults which occur as the pulse edge changes at the input parameter EIN RFK 1 remains closed Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 02: Faults which occur as the pulse edge changes at the input parameter EIN RFK 2 remains open Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 03: Faults which occur as the pulse edge changes at the input parameter EIN RFK 2 remains closed Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 04: Faults which occur as the pulse edge changes at the input parameter EIN RFK 1 interrupted Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 05: Faults which occur as the pulse edge changes at the input parameter EIN RFK 1 closed Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses 6-55

118 Standard Function Blocks SB067 - Bit 06: Faults which occur as the pulse edge changes at the input parameter EIN Faults which occur as the pulse edge changes at the inputrfk 2 interrupted Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 07: Faults which occur as the pulse edge changes at the input parameter EIN RFK 2 closed Remedy: Check contacts, cable, input card and all conditions and then reset (input parameter RSET) - Bit 08: Faults which occur as the pulse edge changes at the input parameter EIN Reset input constantly high or set too early Remedy: Release reset button and press it again. If this does not work, check contacts, cable, input card and all conditions and then reset (input parameter RSET) Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1002: Number of cycles for reaction time of RFK Blocks required DB015: SB070 Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB Modular Block System: Hydraulic Presses

119 Notes Modular Block System: Hydraulic Presses 6-57

120 Standard Function Blocks SB068 SB068: Monitoring ESPE / AOPDs with guarding and control function Block header SB068 BWS_AOS B - SSNR X - NO_1 X - NO_2 X - OFF X - GdO X - SBrk X - DBrk X - RUN X - CyRs X - SSeq X - ARSt X - STyp X - Test X - RSET ENBL - X TEST - X RdCy - X PWR - X Input parameters SSNR: NO_1: NO_2: OFF: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: No error found N/O contact 1 of ESPE/AOPD NO_1 = 0: Protected field broken NO_1 = 1: Protected field clear N/O contact 2 of ESPE/AOPD NO_2 = 0: Protected field broken NO_2 = 1: Protected field clear ESPE/AOPD in OFF mode OFF = 1 GdO = 0 Guard function of ESPE/AOPD is deactivated. SBrk = 0 The signal must come from a connected DBrk = 0 operating mode selector switch block (SB51/52) Modular Block System: Hydraulic Presses

121 GdO: SBrk: DBrk: RUN: CyRs: Guard only mode of ESPE/AOPD OFF = 0 GdO = 1 ESPE/AOPD has guarding function and reset lock. SBrk = 0 The signal must come from a connected DBrk = 0 operating mode selector switch block (SB 51/52) Single break mode of ESPE/AOPD OFF = 0 Enable via single break of ESPE/AOPD GdO = 0 (output parameter ENBL). SBrk = 1 The signal must come from a connected DBrk = 0 operating mode selector switch block (SB 51/52) Double break mode of ESPE/AOPD OFF = 0 Enable via double break of ESPE/AOPD GdO = 0 (output parameter ENBL). SBrk = 0 The signal must come from a connected DBrk = 1 operating mode selector switch block (SB 51/52) Static enable (StFG) for operating the ESPE/AOPD RUN = 0: Not enabled RUN = 0/1-pulse edge: Runs in accordance with the preselected run mode (see input parameter SSeq) SSeq = 0: Function test required SSeq = 1: Reset required RUN = 1: Enable INFORMATION The output parameter PWR which switches the supply voltage to the ESPE/AOPD will remain high even when RUN = 0. Cycle reset This parameter is only effective in single break (SBrk) or double break (DBrk) mode. CyRs = 0/1-pulse edge: Resets the cycle time counter and sets the cycle lock for the first cycle On presses for example, assign input parameter CyRs the signal from top dead centre (TDC), i.e.: CyRs = 0: CyRs = 1: On the dangerous downward movement CyRs = 1: At top dead centre (TDC) In addition, the combination of all the safety enables from emergency stop buttons, start-up disablers etc. should have the following effect on input parameter CyRs: when the device is operated in a downward movement (ENBL = 1), a 0/1-pulse edge at input parameter CyRs will reset and therefore restart the cycle time counter. Modular Block System: Hydraulic Presses 6-59

122 Standard Function Blocks SB068 SSeq: The input parameter SSeq establishes the start-up sequence: - for the PSS start-up in Guard only mode (GdO = 1) - for changing the operating mode from Aus (OFF = 1) to Guard only (GdO = 1) - for 0/1-pulse edge at input parameter RUN in Guard only mode (GdO = 1) SSeq = 0: No automatic start-up (start-up disabler) Function test required: break the protected field, clear it and then press the reset button (input parameter RSET). See section entitled Function. SSeq = 1: No automatic start-up (start-up disabler) No function test required Reset required (input parameter RSET) In cycle mode (single or double break), the start-up procedure is established via the input parameter STyp (see input parameter STyp). INFORMATION SSeq = RLO-0 (M110.00) must be set on presses. ARSt: Automatic restart after fault: Protected field broken ARSt = 0: After fault: Protected field broken, no automatic restart once the protected field is clear i.e. after the protected field is broken, a reset lock will become active ARSt = 1: Automatic restart after fault Protected field broken i.e. once the protected field is broken and then cleared, the reset lock is automatically reset. DANGER! The reset lock must always be activated on presses. For this reason you should always set ARSt = RLO-0 (M ) if your application does not require access to the protected field outside the potentially dangerous movement. ARSt may be assigned a signal that is always set at a static 0 during the potentially dangerous movement, and is only set to 1 outside this movement Modular Block System: Hydraulic Presses

123 Example of a suitable signal formation: set ARSt to 1 using the enable signal and back to 0 using the OU signal (TDC) or the signal for downward movement. Above all, make sure that input parameter ARSt remains set at a static 0 during the potentially dangerous movement. This means that the input parameter will also remain set at 0 if the protected field is broken. STyp: Test: This input parameter establishes the start-up procedure in cycle mode. This setting effects: - PSS start-up in single break and double break mode - The change of mode from Aus (Off = 1) to single break (SBrK = 1) or double break (DBrK = 1) mode. - 0/1-pulse edge at RUN in single break (SBrK = 1) or double break (DBrK = 1) mode (see also under Cycle modes ). STyp = 0: STyp = 1: The sequence is fixed as follows: First break the protected field and then press the reset button (input parameter RSET). The sequence is fixed as follows: First press the reset button (input parameter RSET) and then break the protected field. Test input (simulating a break in the protected field) This input parameter is only effective in Guard only mode (see also under Function ). Test = 0/1 pulse edge: A test cycle is started. The output parameter TEST is set at 0, i.e. the ESPE/AOPD emitter is switched off. For example, the enable or TDC signal should be connected to this parameter. DANGER! In Guard only mode (GdO = 1), a test on the ESPE/AOPD must only be carried out at a time when the guarding function of the ESPE/AOPD will not be called upon. RSET: Reset button (N/O contact) RSET = 0/1-pulse edge: Reset occurs Modular Block System: Hydraulic Presses 6-61

124 Standard Function Blocks SB068 Wiring the input parameters Output parameters Wiring for category 2 (ESPE/AOPD type 2) It is sufficient to use one N/O contact from the ESPE/AOPD. In this case, parameters for input parameters NO_1 and NO_2 should be set for the same input. WARNING If only one N/O contact is used, certain faults will not be detected. For this reason you should carry out a function test of the ESPE/AOPD at regular intervals. This requirement can be met by requesting an automatic function test at appropriate intervals via the input parameter Test. Wiring for category 4 (ESPE/AOPD Type 4) To achieve category 4 you will need to use two N/O contacts from the ESPE/AOPD. Type 4 ESPE/AOPD devices with semiconductor outputs can be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4. Test pulses If the relay outputs of the ESPE/AOPD do not have their own test pulse signals, these will need to be set via the PSS. CAUTION If you are using SB068 in single break or double break mode, do not use Type 4 ESPE/AOPDs that attempt to automatically switch back to normal mode after a short circuit between the ESPE/AOPD outputs. This would cause the ESPE/AOPD outputs to switch from 0/1, which the block would detect as a test pulse control signal - if test pulse monitoring time has not yet elapsed - and this could trigger an unexpected start-up. The guard function during the hazardous downward movement is retained, however. ENBL : Enable flag bit ENBL = 0: Protected field broken ENBL = 1: Protected field clear The enable is issued if the protected field is clear, (NO_1 = 1, NO_2 = 1), any faults have been rectified and the ESPE/AOPD has been interrupted for cycling (see also under Cycle modes ) Modular Block System: Hydraulic Presses

125 Function TEST: RdCy: PWR: Test output TEST = 0: Simulated break in protected field Automatic function test of ESPE/AOPD by switching off the ESPE/AOPD emitter (see also under Function ). ESPE/AOPD emitter in operation TEST = 1: ESPE/AOPD ready for new cycle RdCy = 0: Cycle mode not selected or cycle mode selected but ESPE/AOPD not ready for break RdCy = 1: Cycle mode selected and ESPE/AOPD ready for break Output for switching the operating voltage to the ESPE/AOPD (POWER) PWR = 0: ESPE/AOPD switched off (input parameter: OFF = 1; RUN irrelevant) PWR = 1: ESPE/AOPD switched on (input parameter: GdO or SBrk or DBrk = 1; RUN irrelevant) Monitoring the ESPE/AOPD inputs: Feasibility check on N/O 1 and N/O 2 (input parameters NO_1 and NO_2), monitoring contact synchronisation time (DB 015/DW 1001). Reset pulse edge Existing errors can be reset via a 0/1-pulse edge at the reset button (input parameter RSET). Function test: A function test is carried out by breaking the protected field, clearing it again and then pressing the reset button (input parameter RSET). In the case of hardware errors, a function test must always be carried out after the error has been rectified. Start-up disabler: A start-up disabler will be set if the PSS is switched on or monitoring of the ESPE/AOPD is activated via the input parameter RUN. The lifting of the disable will depend on the set start-up procedure. The start-up sequence is established via the input parameter SSeq (function test or just reset in Guard only mode). Modular Block System: Hydraulic Presses 6-63

126 Standard Function Blocks SB068 Reset lock: A reset lock will be set if the protected field is broken during operation. The lifting of the reset lock will depend on the set reset procedure. The reset sequence is established via the input parameter ARSt (automatic reset/press reset button). In the case of hardware errors you will need to reset first and then carry out a function test. Automatic test of ESPE/AOPD: This block can be used to carry out an automatic function test (input parameter Test). A break in the protected field is simulated by switching off the ESPE/AOPD emitter (output parameter TEST). The maximum permitted duration of the whole test on type 2 ESPE/AOPDs is 150 ms (EN , see also SB070/DW 1006). DANGER! In Guard only mode, the automatic function test of the ESPE/AOPD must only be carried out via the input parameter Test at a time when the guard function of the ESPE/AOPD will not be called upon. INFORMATION If an external switch is used to trigger the automatic function test of the ESPE/AOPD, the feasibility and function of this external switch must be tested by the user. Cycle mode: The ESPE/AOPD can be enabled (output parameter ENBL) by means of a single or double break of the ESPE/AOPD (single or double break mode). The enable is reset using CyRs = 0/1-pulse edge (e.g. at top dead centre TDC). Monitoring cycle time: After max. 30 s (see also SB 070/DW 1005), automatic start of the machine in cycle mode will no longer be possible. A restart can only be achieved via the established sequence set at the input parameter STyp (see Cycle modes ). The enable criteria will depend on the set operating mode. Switching the ESPE/AOPD supply voltage: The block has an output for switching the supply voltage to the ESPE/ AOPD (output parameter PWR) Modular Block System: Hydraulic Presses

127 Cycle modes Cycle modes are used to determine the start-up procedure for single break and double break mode. The settings that are made will only be valid in cycle mode. Cycle modes are set using the input parameter STyp. They differ only in the start-up and reset phase of the preset cycle mode, i.e. the setting affects: - PSS start-up - Changing modes from Aus to single break or double break mode - 0/1-pulse edge at RUN in single break or double break mode - Time exceeded in cycle time monitoring. INFORMATION When the operating mode is switched from Aus (Off) via Guard only to Single break or Double break, a function test must be performed (when SSeq = 0) or a reset must occur (when SSeq = 1). Input parameter STyp = 0 - Single break mode The ESPE/AOPD is broken once. The initial stroke is triggered via the reset button (input parameter RSET). - Double break mode The ESPE/AOPD is broken twice. The initial stroke is triggered via the reset button (input parameter RSET). Input parameter STyp = 1 - Single break mode The reset button (input parameter RSET) must be operated before the ESPE/AOPD is interrupted in order to activate cycle counting. The initial stroke will occur immediately after the first time the ESPE/AOPD's protected field is cleared. - Double break mode The reset button (input parameter RSET) must be operated before the ESPE/AOPD is interrupted in order to activate cycle counting. The initial stroke will occur immediately after the second time the ESPE/AOPD's protected field is cleared. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Modular Block System: Hydraulic Presses 6-65

128 Standard Function Blocks SB068 Error messages in DB015 - Bit 00: N/O contacts 1 and 2 on ESPE/AOPD (input parameter NO_1 and NO_2) are not synchronised Remedy: Check inputs, cable, input card and all conditions, reset and then carry out a function test. - Bit 02: Time exceeded on test of ESPE/AOPD Remedy: Check inputs, cable, input card and all conditions, reset and then carry out a function test. - Bit 05: Start-up disabler; not yet reset Remedy: Reset (input parameter RSET) - Bit 07: Change of operating mode Remedy: Reset reset lock - Bit 08: Protected field broken Remedy: Clear protected field, reset if necessary. Otherwise: Check inputs, cable, input card and all conditions and then reset (input parameter RSET) - Bit 09: Start-up disabler Remedy: Carry out a function test on the ESPE/AOPD and reset (input parameter RSET) - Bit 10: Cycle start-up disabled, manual start (initial start with cycle mode) Remedy: Depends on which cycle mode is selected (input parameter STyp): STyp = 0: Break the protected field, clear it and then press the reset button (input parameter RSET). STyp = 1: Press the reset button (input parameter RSET), break the protected field and then clear it. - Bit 11: Cycle lock active, waiting for pulse 1 Remedy: Break protected field and re-enable - Bit 12: Cycle lock active, waiting for pulse 2 Remedy: Break protected field and re-enable - Bit 13: Cycle disable time exceeded, manual start (initial start with cycle mode) Remedy: Depends on which cycle mode is selected: 6-66 Modular Block System: Hydraulic Presses

129 STyp = 0: Break the protected field, clear it and then press the reset button (input parameter RSET). STyp = 1: Press the reset button (input parameter RSET), break the protected field and then clear it. - Bit 14: More than one operating mode selected Remedy: Check selector switch, cable, input card and all conditions, then carry out a function test. - Bit 15: No operating mode selected Remedy: Check selector switch, cable, input card and all conditions, then carry out a function test INFORMATION Bits contain user information and cannot be released via the reset button. Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1001: Cycles for contact synchronisation time N/O / N/O DW1005: Cycles for time for cycling ESPE/AOPD DW1006: Cycles for ESPE/AOPD reaction time Blocks required DB015: SB070 Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Initialisation of global parameters in DB015 Modular Block System: Hydraulic Presses 6-67

130 Standard Function Blocks SB068 Diagrams for ESPE/AOPD Legend for diagrams: Signal level: 1-Signal 0-Signal Timing diagram for guard only mode of ESPE/AOPD The ESPE/AOPD is set to have a guarding function with start-up and reset lock. Input parameters: SSeq = 0: Start-up disabler (function test required) ARSt = 0: No automatic reset of error ESPE/AOPD interrupted after the protected field is cleared (reset lock) OFF = 0 GdO = 1 SBrk = 0 DBrk = 0 Mode: ESPE/AOPD as guard (guard only) The input parameters CyRs, STyp have no effect in Guard mode. They are assigned RLO-0 (M110.00). Abbreviations: F-Test Function test KoSy Contact synchronisation time between two N/O contacts This is a global parameter (see also under Global parameters and SB070). RBWS ESPE/AOPD reaction time (150 ms in accordance with EN , 06/98). This is a global parameter (see also under Global parameters and SB070) Modular Block System: Hydraulic Presses

131 RUN NO_1 Break Break Testing NO_2 RSET max. KoSy max. RBWS Test F-Test occurs ENBL TEST RdCy PWR Modular Block System: Hydraulic Presses 6-69

132 Standard Function Blocks SB068 Timing diagram for double break mode of ESPE/AOPD The ESPE/AOPD is set with cycle reset (input parameter CyRs) via a pulse at the press TDC. Input parameters: RUN = 1: Static enable for operation of the ESPE/AOPD STyp = 0: Start-up procedure (cycle mode): first break the protected field and then reset. ARSt = 0: OFF = 0 GdO = 0 SBrk = 0 DBrk = 1 No automatic reset of the error ESPE/AOPD interrupted after the protected field is cleared (reset lock). Mode: Double break of ESPE/AOPD (DBrk) A function test of the ESPE/AOPD is carried out. The input parameter TEST has no effect in Guard mode. It is assigned RLO-0 (M110.00). Abbreviations: MaZy Machine cycle time for cycling the ESPE/AOPD ( ms in accordance with EN section A.8.4, 06/98). This is a global parameter (see also under Global parameters and SB070) Modular Block System: Hydraulic Presses

133 NO_1 Break Break Break Break NO_2 CyRs max. MaZy RSET 1st pulse occurs 2nd pulse occurs ENBL TEST RdCy PWR Modular Block System: Hydraulic Presses 6-71

134 Standard Function Blocks SB069 SB069: Monitoring ESPE/AOPDs with guarding function Block header SB 069 AOPD_GDO W- SSNR X - GRP X - NO_1 X - NO_2 X - GdOn B - MTD X - SSeq X - ARSt X - Test X - RSET ENBL - X TEST - X PWR - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KF KF (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: No error found GRP Status flag of the I/O-Group (SafetyBUS p) whose I/O signals are used for this function (M for I/O-Group 0 to M for I/O-Group 31). If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1. NO_1: Output signal 1 from the ESPE/AOPD (normally open 1) NO_1 = 0: Protected field broken NO_1 = 1: Protected field clear NO_2: Output signal 2 from the ESPE/AOPD (normally open 2) NO_2 = 0: Protected field broken NO_2 = 1: Protected field clear GdOn: Guard Only mode of ESPE/AOPD GdOn = 0 Guard function of ESPE/AOPD is deactivated, i.e. the ESPE/AOPD is switched off. GdOn = 1 ESPE/AOPD is operating as a guarding device. The signal can come from a connected operating mode selector switch Modular Block System: Hydraulic Presses

135 MTD: SSeq: Maximum permitted duration of the whole automatic function test of the ESPE/AOPD Permitted value range: ms With type 2 ESPE/AOPDs, EN specifies that the maximum permitted duration of the complete test is 150 ms. The input parameter SSeq establishes the start-up procedure at a PSS cold or warm start, when the SafetyBUS I/O-Group starts up or at a 0/1-pulse edge at the input parameter GdOn. SSeq = 0: No automatic start-up (start-up disabler) Function test required (please refer to Function ) SSeq = 1: No automatic start-up (start-up disabler) No function test required Reset required (input parameter RSET) INFORMATION SSeq = RLO-0 (M110.00) must be set on presses. ARSt: Test: RSET: Automatic restart after fault Protected field interrupted once the protected field is clear. ARSt = 0: No automatic reset after fault Protected field interrupted once the protected field is cleared, i.e. a reset signal is required once the protected field is broken (reset lock). ARSt = 1: Automatic reset after fault Protected field interrupted Test input (simulating a break in the protected field) Test = 0/1-pulse edge: A test cycle is started. The output parameter TEST is set at 0, i.e. the ESPE/AOPD emitter is switched off. For example, the enable or OT signal should be connected to this parameter. Reset button (N/O contact) RSET = 0/1-pulse edge: Reset occurs Modular Block System: Hydraulic Presses 6-73

136 Standard Function Blocks SB069 Wiring the input parameters Wiring for category 2 (ESPE/AOPD Type 2) It is sufficient to use one output signal from the ESPE/AOPD. In this case, parameters for input parameters NO_1 and NO_2 should be set for the same input. WARNING! If only one signal is used, certain faults will not be detected. For this reason you should carry out a function test of the ESPE/AOPD at regular intervals. This requirement can be met by requesting an automatic function test at appropriate intervals via the input parameter Test. Wiring for category 4 (ESPE/AOPD type 4) To achieve category 4 you will need to use two output signals from the ESPE/AOPD. Type 4 ESPE/AOPD devices with semiconductor outputs can be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4. Test pulses If the relay outputs of the ESPE/AOPD do not have their own test pulse signals, these will need to be set via the PSS. Output parameters ENBL : TEST: PWR: Enable bit ENBL = 0: ENBL = 1: Test output TEST = 0: Protected field broken Protected field clear The enable is issued if the protected field is clear (NO_1 = 1, NO_2 = 1) and no faults are present. Simulated break in protected field Function test of ESPE/AOPD by switching off the ESPE/AOPD emitter ESPE/AOPD emitter in operation TEST = 1: Output for switching the operating voltage to the ESPE/AOPD (POWER) PWR = 0: ESPE/AOPD switched off PWR = 1: ESPE/AOPD switched on 6-74 Modular Block System: Hydraulic Presses

137 Function Monitoring the ESPE/AOPD outputs: Feasibility check on signal 1 and signal 2 (input parameters NO_1 and NO_2), monitoring contact synchronisation time (DB 015/DW 1001). Reset pulse edge Existing errors can be reset via a 0/1-pulse edge at the reset button (input parameter RSET). Function test: A function test is carried out by breaking the protected field, clearing it again and then pressing the reset button (input parameter RSET). In the case of hardware errors, a function test must always be carried out after the error has been rectified. Start-up disabler: A start-up disabler will be set if the PSS is switched on (PSS cold/warm start), the SafetyBUS p I/O-Group is started (0/1 pulse edge at input parameter GRP) or if the guard function of the ESPE/AOPD is activated (0/1 pulse-edge at the input parameter GdOn). The lifting of the disable will depend on the set start-up procedure. The start-up sequence is established via the input parameter SSeq (function test or just reset in guard only mode). Reset lock: A reset lock will be set if the protected field is interrupted during operation. The lifting of the reset lock will depend on the set reset procedure. The reset sequence is established via the input parameter ARSt (automatic reset/press reset button). In the case of hardware errors you will need to reset first and then carry out a function test. Switching the ESPE/AOPD supply voltage: The block has an output for switching the supply voltage to the ESPE/ AOPD (output parameter PWR). Automatic Test of ESPE/AOPD This block can be used to carry out an automatic function test (input parameter Test). A break in the protected field is simulated by switching off the ESPE/AOPD emitter (output parameter TEST). The maximum Modular Block System: Hydraulic Presses 6-75

138 Standard Function Blocks SB069 permitted duration of the whole test on type 2 ESPE/AOPDs is 150 ms (EN , see also SB071/DW1006). DANGER! The automatic function test of the ESPE/AOPD must only be carried out via the input parameter Test at a time when the guarding function of the ESPE/AOPD will not be called upon. INFORMATION If an external switch is used to trigger the automatic function test of the ESPE/AOPD, the feasibility and function of this external switch must be tested by the user. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of the administration data block (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: ESPE/AOPD output signal 1 and 2 (input parameter NO_1 and NO_2) are not synchronised. Remedy: Check ESPE/AOPD outputs, cable, input card and all conditions, and then carry out a function test. - Bit 02: Time exceeded on automatic function test of ESPE/AOPD Remedy: Check ESPE/AOPD outputs, cable, input card and all conditions, and then carry out a function test. - Bit 05: Start-up disabler; not yet reset Remedy: Reset (input parameter RSET) Otherwise: Check switch, cable, input card and all conditions, and then reset. - Bit 06: Reset constantly pressed or pressed too early Remedy: Reset input parameter RSET Otherwise: Check switch, cable, input card and all conditions, and then reset Modular Block System: Hydraulic Presses

139 - Bit 08: Protected field broken Remedy: Clear protected field, reset if necessary Otherwise: Check ESPE/AOPD outputs, cable, input card and all conditions and then reset (input parameter RSET) - Bit 09: Start-up disabler Remedy: Carry out a function test on the ESPE/AOPD (break protected field and then clear) and then reset (input parameter RSET) - Bit 10: I/O-Group stop triggered while PSS is in normal RUN mode Remedy: Start I/O-Group Error messages on the CPU-display - E003: Administration data block has not been initialised Remedy: Call SB071 in OB120 Global parameters used in the administration data blocks Global parameters may be set in OB120 using SB071. DW1001: Number of cycles in the contact synchronisation time between two N/O or N/C contacts DW1022: Minimum scan time Blocks required DB015, DB016, DB017: Administration data blocks DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. SB071 Initialisation of global parameters in DB015, DB016 and DB017 Modular Block System: Hydraulic Presses 6-77

140 Standard Function Blocks SB069 Timing diagram Legend for diagram: Signal level: 1-Signal 0-Signal The ESPE/AOPD is set to have a guarding function, with start-up and reset lock. Input parameters: SSeq = 0: Start-up disabler (function test required) ARSt = 0: Reset lock GdOn = 1: Operating mode: ESPE/AOPD has guarding function (guard only) Abbreviations: F-Test Function test KoSy Contact synchronisation time between two N/O contacts This is a global parameter (see also under Global parameters and SB071). MTD Maximum permitted duration of test (150 ms for type 2 ESPE/AOPDs, in accordance with EN ) 6-78 Modular Block System: Hydraulic Presses

141 GRP NO_1 Break Break Testing NO_2 max. KoSy max. MTD RSET Test F-Test occurs ENBL TEST PWR Modular Block System: Hydraulic Presses 6-79

142 Standard Function Blocks SB070 SB070: Initialisation of administration data block DB015 Block header SB 070 INIT_MBS B - KoSy B - RRFK B - KU_S B - KU_R W - MaZy B - RBWS W - RVen Input parameters KoSy: RRFK: KU_S: KU_R: MaZy: RBWS: RVen: Contact synchronisation time of 2 N/O or N/C contacts Reaction time feedback loop contactor Contact switchover time N/O / N/C on buttons Contact switchover time N/O / N/C on relays Machine cycle time for cycling ESPE/AOPD ESPE/AOPD reaction time Valve switchover time Function Reads in the preset minimum scan time from DB002 A minimum scan time must always be configured if you are using MBS blocks. Please refer to the section entitled Minimum scan time in Chapter 5. Calculates the cycles using the times transferred in the parameters Enters the values into global parameters DW DW1007 of administration data block DB Modular Block System: Hydraulic Presses

143 Table for setting the global parameters: Input Parameters in Limits Suggested parameters Admin.-DB in [ms] values in [ms] KoSy DW RRFK DW KU_S DW KU_R DW MaZy DW , conforming to EN A.8.4/C.6.2 RBWS DW , conforming to EN RVen DW None DW 1008 DW 1009 Reserved DW 1010 DW 1011 DW 1012 DW 1013 DW 1014 Reserved DW 1015 DW 1016 DW 1017 DW 1018 DW 1019 Reserved DW 1020 Reserved DW 1021 Reserved DW 1022 Min. scan time DB002/DW0002 Reserved DW 1023 INFORMATION All times must be entered in ms. The values suggested are default values. If working with these values produces nuisance errors, you can determine which values would be suitable as follows: - Start from the default value - Increase this value in stages until the nuisance errors stop. Modular Block System: Hydraulic Presses 6-81

144 Standard Function Blocks SB070 Please note: Entering excessively high time values for monitoring operations will reduce the safety level of your machine. If you are using type 2 ESPE/AOPD devices, a maximum value of 150 ms may be entered for parameter RBWS (EN ). The number of cycles calculated is rounded down and transmitted to the data words in administration data block DB 015. The SB must be called up once only when the PSS is started up (e.g. in OB120). Error messages None Blocks required OB120 DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access Modular Block System: Hydraulic Presses

145 Notes Modular Block System: Hydraulic Presses 6-83

146 Standard Function Blocks SB071 SB071: Initialisation of administration data blocks Block header SB071 INIT_MBS B - CoSy B - RFbL B - CS_B B - CS_R W - MaCy B - ESPE Input parameters CoSy: RFbL: CS_B: CS_R: MaCy: ESPE: Contact synchronisation time of 2 N/O or N/C contacts Reaction time feedback loop contactor Contact switchover time N/O / N/C on buttons Contact switchover time N/O / N/C on relays Machine cycle time for cycling ESPE/AOPD ESPE/AOPD reaction time Function Reads in the preset minimum scan time from DB002 A minimum scan time must always be configured if you are using MBS blocks. Please refer to the section entitled Minimum scan time in Chapter 5. Calculates the cycles using the times transferred in the parameters Enters the values into global parameters DW DW1023 of the administration data blocks Modular Block System: Hydraulic Presses

147 Table for setting the global parameters: Input Parameters in Limits Suggested parameters Admin.-DB in [ms] values in [ms] CoSy DW RFbL DW CS_B DW CS_R DW MaCy DW , conforming to EN A.8.4/C.6.2 ESPE DW , conforming to EN Reserved DW 1007 DW 1008 DW 1009 Reserved DW 1010 DW 1011 DW 1012 DW 1013 DW 1014 Reserved DW 1015 DW 1016 DW 1017 DW 1018 Reserved DW 1019 Administration Reserved DW 1020 Reserved DW 1021 Reserved DW 1022 Min. scan time DB002/DW0002 Reserved DW 1023 INFORMATION All times must be entered in ms. The values suggested are default values. If working with these values produces nuisance errors, you can determine which values would be suitable as follows: - Start from the default value - Increase this value in stages until the nuisance errors stop. Modular Block System: Hydraulic Presses 6-85

148 Standard Function Blocks SB071 Please note: Entering excessively high time values for monitoring operations will reduce the safety level of your machine. If you are using type 2 ESPE/AOPD devices, a maximum value of 150 ms may be entered for parameter ESPE (EN ). The number of cycles calculated is rounded down and transmitted to the data words in the administration data blocks. The SB must be called up once only when the PSS is started up (e.g. in OB120). Error messages None Blocks required OB120 DB015/DB016/DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words. The data blocks must have READ/WRITE access Modular Block System: Hydraulic Presses

149 Notes Modular Block System: Hydraulic Presses 6-87

150 Standard Function Blocks SB072 SB072: Temporary suspension of safety functions (ESPE/AOPD muting) Block header SB 072 MUTING B - SSNR X - NO_1 X - NO_2 X - MS1 X - MS2 X - MP1 X - MP2 W - TS12 W - TPSy W - TInt W - TMut W - TOPD X - TOff X - AuSt X - SMd2 W - THlp X - RSET ENBL - X MAct - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). NO_1: N/O contact 1 of ESPE/AOPD NO_1 = 0: Protected field broken NO_1 = 1: Protected field clear NO_2: N/O contact 2 of ESPE/AOPD NO_2 = 0: Protected field broken NO_2 = 1: Protected field clear MS1: N/O contact of Muting signal Serial 1 MS1 = 0: Not operated (muting signal off) MS1 = 1: Operated (muting signal on) 6-88 Modular Block System: Hydraulic Presses

151 MS2: N/O contact of Muting signal Serial 2 MS2 = 0: Not operated (muting signal off) MS2 = 1: Operated (muting signal on) MP1: N/O contact of Muting signal Parallel 1 MP1 = 0: Not operated (muting signal off) MP1 = 1: Operated (muting signal on) MP2: N/O contact of Muting signal Parallel 2 or (inverted) N/C contact with sensors (please refer to Safety guidelines in the SB description) MP2 = 0: Not operated (muting signal off) MP2 = 1: Operated (muting signal on) TS12: Time Sequential This setting determines the maximum time that can elapse between the operation (0/1-pulse edge) of MS1 and MS2. Permitted value range: Format: Word Time unit: ms TPSy : Timer Parallel Synchronisation This setting determines the maximum time (synchronisation time) that can elapse between the operation (0/1-pulse edge) of MP1 and MP2. Permitted value range: Format: Word Time unit: ms TInt: Timer Interrupt This setting determines: - the maximum permitted release time of the ESPE/AOPD or - the maximum interrupt time of MP1 or MP2 during active muting Permitted value range: Format: Word Time unit: ms While muting is activated in sequential mode and MS2 = MP1 = 1 (MS1 and MP2 irrelevant), the ESPE/AOPD may be released without the muting function being switched off (e.g. during gaps in the load). If only MS2 = 1 (MP1 = 0, MS1 and MP2 irrelevant), the ESPE/AOPD may only be released for the time stated under TInt. Sequential muting will be switched off when Modular Block System: Hydraulic Presses 6-89

152 Standard Function Blocks SB072 TMut : TOPD: TOff : AuSt: - the ESPE/AOPD for t > TInt is released or - before TInt has elapsed, if there are no more muting signals. When parallel muting is activated, a parallel muting signal (MP1 or MP2) may be released for the time TInt. The released signal must be re-operated within the time specified under TInt, or the other signal must also be released. Parallel muting is switched off when: - the ESPE/AOPD for t > TInt is released (when MP1 = MP2 = 0) or - MP1 and MP2 are released when the ESPE/AOPD has already been released (when the muting signal is arranged in a cross/star formation) In general, muting is switched off when there are no more muting signals. Timer Muting This setting determines the maximum permitted muting time. Permitted value range: (^= 8.5 minutes) Format: Word Time unit: s Timer (active) Optoelectronic Protective Device This setting determines the maximum time permitted between: Muting ON and ESPE/AOPD interrupted and: Muting sensor exited and ESPE/AOPD released. The time elapsing between the start of muting and the interruption of the ESPE/AOPD must not exceed t = TOPD. The time elapsing between exiting the last muting switch and the enabling of the ESPE/AOPD must not exceed t = 2 x TOPD. Permitted value range: Format: Word Time unit: ms Halt all muting timers TOff = 0: Muting timer active TOff = 1: Halt all muting timers For example, this input parameter could be connected to the signal Conveyor stopped. Start-up disabler on PSS start-up AuSt = 0: Start-up disabler (reset required on PSS start-up) AuSt = 1: Automatic reset 6-90 Modular Block System: Hydraulic Presses

153 Wiring the input parameters SMd2: Sequential Mode 2 SMd2 = 0: For Muting ON, MS2 must be operated after MS1 and then MS1 be released again. SMd2 = 1: For Muting ON, MS2 must be operated after MS1. THlp: Auxiliary timer A flag word should be entered at this input parameter. The flag word must be exclusively reserved for this block. This means that this flag word, or any individual bit from this flag word, must not be used elsewhere in the program, nor be influenced from anywhere else within the program, even by interrupt processing. RSET: Reset button (N/O contact) for error reset and start-up enable. A key switch should be used for the reset button. RSET = 0/1-pulse edge: reset occurs INFORMATION The SB monitors the maximum time values stated. If parameters are set for a time value that exceeds the maximum permitted value, the SB will automatically restrict the time by blanking out the higher-value figures. No error message will appear in this case. Please note: This may mean that times are reduced to values which are considerably lower than the permitted limits. Type 4 ESPE/AOPD devices with semiconductor outputs can be connected to DI 2 inputs (e.g. input module PSS(1) DI 2) in order to meet the requirements of category 4. Output parameters ENBL: MAct: Enable flag bit ENBL = 0: Error detected (e.g. ESPE/AOPD interrupted) ENBL = 1: The enable will occur if: - the ESPE/AOPD is clear or muting is active and - no error has been detected. Display muting status (for LED) MAct = 0: No muting (ESPE/AOPD active) MAct = 1: Muting active (ESPE/AOPD suspended) Modular Block System: Hydraulic Presses 6-91

154 Standard Function Blocks SB072 Wiring the output parameters Muting must be displayed through an LED (output parameter MAct). This LED must be safely monitored to ensure it functions correctly (EN Section 7.1, 06/98). For this reason the muting LED should be connected to a dual-pole output (e.g. PSS DI2O Z module) or use standard function block SB097. Operating modes Terminology Muting ON Muting ON is the switch condition for switching on the muting function. If muting is switched on, the output parameter MAct will be high and time monitoring will be running (input parameter TMut / TOPD). Muting OFF Muting OFF is the switch condition for ending the muting function. When the muting function is ended the output parameter MAct will be low. Muting Start-Up Muting Start-Up is the switch condition for switching on the muting function when the PSS is cold-started or reset using the key switch (input parameter RSET) Modular Block System: Hydraulic Presses

155 Sequential muting mode (Muting when entering the danger area) A B C C MS1 MS2 ESPE/ AOPD MP1 W Transport Vehicle Danger Area ESPE/ AOPD MP2 Fig. 6-1: Entering the danger area (sequential muting mode) Muting signal arrangement Position MS1/MS2 and distance A/B: Distance B should be as long as possible, but shorter than the length of transport vehicle W. Required: W > B and W > A Position MS2 and distance C: MS2 must be located as close as possible to the ESPE/AOPD, i.e. distance C should be as short as possible. Position MP1: Requires muting signal MP1. Position MP2: Muting signal MP2 is optional and is used to detect vehicles leaving the danger area (please refer to Parallel mode ). If the muting signal MP2 is used, it must be operated at the same time as MP1. If muting signal MP2 is not being used, the input parameter MP2 should be assigned RLO-0 (M ). Modular Block System: Hydraulic Presses 6-93

156 Standard Function Blocks SB072 INFORMATION Important additional information on the use of sensors and contacts can be found under Safety guidelines at the end of this SB description. Switch conditions in sequential mode Muting ON Smd2 = 0: Muting signals MS1 and MS2 must be operated consecutively. MS1 must then be released while MS2 remains operated. The time between the operation of MS1 and MS2 must be at least the length of one PSS cycle. The time between the operation of MS1 and the release of MS1 (while MS2 is operated) must be less than the value set at input parameter TS12. The timer monitoring this time (input parameter TS12) is started by the 0/1-pulse edge at input parameter MS1. Smd2 = 1: Muting signals MS1 and MS2 must be operated consecutively. The time between the operation of MS1 and MS2 must be at least the length of one PSS cycle and less than the value set at input paramter TS12. The timer monitoring this time (input parameter TS12) is started by the 0/1-pulse edge at input parameter MS1. Muting OFF The suspension of the safety function is lifted as soon as: - the ESPE/AOPD is released and - the set interrupt time (input parameter TInt) has elapsed (the interrupt time is started when the ESPE/AOPD is released) or - the ESPE/AOPD is released and there are no more muting signals (i.e. MP1/MP2). Muting Start-Up MS2 or MP1 (or MP2, if present) must be operated if a vehicle is within the range of the ESPE/AOPD Modular Block System: Hydraulic Presses

157 Parallel muting mode (muting when leaving the danger area) A C C MS1 MS2 ESPE/ MP1 AOPD W Transport Vehicle Danger Area ESPE/ AOPD MP2 Fig. 6-2: Muting when leaving the danger area (parallel muting mode) Muting signal arrangement Position MP1/MP2: - Muting signals MP1 and MP2 must be positioned at the same height to the left and right of the vehicle and: - the length of the vehicle W must > A - distance C must be as short as possible. Position MS1: Muting signal MS1 is optional and is used to detect vehicles entering the danger area. If muting signal MS1 is not being used, the input parameter MS1 should be assigned RLO-0 (M ). Position MP2: Requires muting signal MP2. INFORMATION Important additional information on the use of sensors and contacts can be found under Safety guidelines at the end of this SB description. Modular Block System: Hydraulic Presses 6-95

158 Standard Function Blocks SB072 Switch conditions Muting ON Muting signals MP1 and MP2 must be operated consecutively. The maximum value for the synchronisation time between the MP1 and MP2 signals is: t = TPSy (input parameter TPSy). Muting OFF The switch condition for Muting OFF is fulfilled when input parameter: - MP1 = 0 and - MP2 = 0 and - the ESPE/AOPD is released for the time t > interrupt time (input parameter TInt) or - the ESPE/AOPD is released and there are no more muting signals (i.e. MS1/MS2). Muting Start-Up Muting signals MP1 or MP2, or MS2, must be operated if a vehicle is within the range of the ESPE/AOPD Modular Block System: Hydraulic Presses

159 Parallel muting mode (muting when entering and leaving the danger area) MP1 ESPE/ AOPD Transport Vehicle Danger Area MP2 ESPE/ AOPD Fig. 6-3: Muting when entering and leaving the danger area (parallel muting mode) Muting signal arrangement Position MP1/MP2: Muting signals may come from reflective or send and receive light barriers, for example. The beams must intersect within the danger area. INFORMATION The overall dimensions stated below must be maintained. MS1/MS2: Muting signals MS1 and MS2 are not used. The inputs of input parameters MS1 and MS2 should be assigned RLO-0 (M ). INFORMATION Important additional information on the use of sensors and contacts can be found under Safety guidelines at the end of this SB description. Modular Block System: Hydraulic Presses 6-97

160 Standard Function Blocks SB072 Light curtain access security Muting signal max cm min. 20 cm Intersection of muting signal beams Muting signal Danger area Muting signal Fig. 6-4: Muting signal arrangement (side and plan view) Switch conditions Muting ON Muting signals MP1 and MP2 must be operated consecutively. The maximum synchronisation time between the MP1 and MP2 signals is: t = TPSy (input parameter TPSy) Modular Block System: Hydraulic Presses

161 Muting OFF The switch condition for Muting OFF is fulfilled when muting signals MP1 and MP2 are reactivated. Muting Start-Up Muting signals MP1 or MP2 must be operated if a vehicle is within the range of the ESPE/AOPD. Safety guidelines WARNING! The following information must be heeded! Failure to comply with these guidelines could result in serious injury or death. Refer to EN , 06/98 when setting parameters for SB072 and when designing and operating the muting facility. Muting switches should be positioned so that it is impossible for a person to trigger the muting function. The transport vehicle should be designed to make it impossible for people to ride on it. Limit the size of the entry area by applying appropriate safety measures. People must not be able to enter the danger area during the muting phase. Consider the total duration of the muting phase if various transport speeds are to be in operation. Remember that a new muting phase can only be introduced once the previous phase has been completed. Maintenance gates should be provided if equipment is protected via a muting signal. Remember that the plant must be brought to a stop if the maintenance gates are opened. Using muting signals provided by switch contacts These contacts should use test pulses. Using sensors as muting signals MP1 and MP2 Pulsing is not possible when using sensors. For fault detection, therefore, you should use a N/O contact as sensor MP1 and a N/C contact as sensor MP2. Modular Block System: Hydraulic Presses 6-99

162 Standard Function Blocks SB072 Please note: In this case, the inverted signal from MP2 must be stored in an auxiliary flag. This auxiliary flag should be assigned to input parameter MP2. Example: L Exx.xx (input to which sensor MP2 is connected) =N Myy.yy (Auxiliary flag; must not be used elsewhere in the program) Please note: The auxiliary flag must be reserved exclusively for this application and must not be used elsewhere in the program. Not even interrupt processing should be able to amend this flag. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Synchronisation time for NO_1/NO_2 (of the ESPE/AOPD) exceeded Remedy: Check ESPE/AOPD, cable, input card and all conditions, then reset - Bit 01: NO_1 or NO_2 on ESPE/AOPD had not dropped out Remedy: This error can only be cleared by a further interruption to the ESPE/AOPD (function control), followed by pressing the reset button (input parameter RSET). - Bit 02: Simultaneous 0/1-pulse edge at input parameters MS1 and MS2, or input parameter MS2 = 1 during a 1/0-pulse edge at input parameters MP1 and MP2 and the ESPE/AOPD has not been interrupted (MS2 sticking ). Remedy: Check muting inputs, cable, input card and all conditions, and then reset. - Bit 03: Input parameter MS1 or MS2 has changed, while input parameter Toff = 1 Remedy: Check ESPE/AOPD, cable, input card and all conditions, and then reset Modular Block System: Hydraulic Presses

163 - Bit 04: Input parameter MP1 or MP2 has changed, while input parameter Toff = 1 Remedy: Check muting inputs, cable, input card and all conditions, and then reset. - Bit 05: Muting signal MP1 or MP2 was not in its start position Remedy: Check muting inputs, cable, input card and all conditions, and then reset. - Bit 06: Synchronisation time (input parameter TPSy) for MP1/MP2 exceeded Remedy: Check muting inputs, cable and input card, then reset (input parameter RSET). - Bit 07: Max. interrupt time (input parameter TInt) for MP1/MP2 exceeded Remedy: Check muting inputs, cable, input card and all conditions, and then reset. - Bit 09: Time from input parameter TS12 exceeded The time between the operation of muting signals MS1 and MS2 or the time between the operation of muting signals MS1 (MS2) and the release of MS1 has been exceeded. Remedy: Check muting inputs, cable, input card and all conditions, and then reset. - Bit 10: ESPE/AOPD interrupted Remedy: Clear protected field and then reset. - Bit 11: Muting time exceeded (input parameter TMut) Remedy: Check the run time required for the vehicle to travel through the muting zone. - Bit 12: TOPD exceeded The time from Muting Start to ESPE/AOPD interrupted or the time from Muting Signal ended to ESPE/AOPD clear has been exceeded. There are a number of potential reasons for this, for example: - Vehicle stationary within muting zone - ESPE/AOPD not reacting Remedy: Depends on the error. - Bit 13: 1/0-pulse edge from MS2 while MS1 = 1 (MS2 returning to sequential mode) Remedy: Check muting inputs, cable, input card and all conditions, and then reset. Modular Block System: Hydraulic Presses 6-101

164 Standard Function Blocks SB072 - Bit 14: RSet input constantly high or set too early Remedy: Check switch, cable, input card and all conditions, and then reset. - Bit 15: ESPE/AOPD is clear, confirm with RSET. Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB DW1001: Contact synchronisation time of 2 N/O contacts (NO_1 and NO_2 of the ESPE/AOPD) - DW1022: Minimum PSS scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access Modular Block System: Hydraulic Presses

165 Cycle diagrams Legend for diagrams: Signal level: 1-Signal 0-Signal Parallel muting cycle MS2* MP1 TInt MP2 MAct NO_1 NO_2 TInt 2xTOPD TInt TOPD TPSy If the muting signals are arranged in star Output parameter MAct switches off before the interrupt time (TInt) elapses, if no further muting signals are present (i.e. includes MS1/MS2). TInt TMut TMut * MS2 is not required in parallel muting mode when the muting signal is arranged in a cross/star formation. Modular Block System: Hydraulic Presses 6-103

166 Standard Function Blocks SB072 Sequential muting cycle MP1 MS1 MS2 MAct SMd2=0 NO_1 NO_2 TOPD TInt TS12 TMut 2xTOPD Output parameter MAct switches off before the interrupt time (TInt) elapses, if no further muting signals are present (i.e. includes MP1/ MP2) Modular Block System: Hydraulic Presses

167 Notes Modular Block System: Hydraulic Presses 6-105

168 Standard Function Blocks SB075 SB075: Controlling and monitoring safety gates with guard locking Block header SB075 GRD_LCK W - SSNR X - GRP X - S1 X - S2 X - LCKD W- SyTi X - MRun X - STPD X - RQST X - ARSt X - AuSt X - NoFT X - BLNK X - RSET ENBL - X UNLK - X SGrd - X SLck - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Word constants KF KF (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). GRP: I/O-Group status flag (SafetyBUS p) containing the inputs S1, S2, LCKD and STPD (M for I/O-Group 0 to M for I/O-Group 31) If the SB is being used without SafetyBUS p, the input parameter must be assigned RLO-1 S1: Gate switch: Signal 1 If the gate is closed, both gate S2: Gate switch: Signal 2 switches must supply a 1-signal Modular Block System: Hydraulic Presses

169 WARNING! To guarantee safety, the mechanical arrangement of the gate switches must comply with the requirements of EN 1088 Interlocking devices associated with guards. If these requirements are not met, the safety of the guard will be lost, which may lead to serious injury and death! The following example shows the arrangement of two mechanical gate switches. In this case, one of the switches (on the left in this example) must have a N/O contact which is actuated by the gate in positive mode, while the other switch (on the right in this example) should have a N/C contact which is actuated by the gate in non-positive mode. Fig. 6-5: Mechanical arrangement of the gate switches LCKD: SyTi: Guard locking monitoring circuit: Gate locked LCKD = 0: Gate unlocked LCKD = 1: Gate locked Synchronisation time between S1 and S2 Permitted value range: Time unit: ms SyTi = 0: The synchronisation time is infinite, i.e. monitoring is switched off SyTi < 0 Synchronisation time monitoring has no tolerance, i.e. when the gate closes, the signals on the gate switches must supply a 1-signal simultaneously (i.e. within one PSS cycle), otherwise an error message will occur. Modular Block System: Hydraulic Presses 6-107

170 Standard Function Blocks SB075 MRun: STPD: RQST: ARSt: INFORMATION The purpose of synchronisation time monitoring is to detect mechanical errors on the gate switches when the gate closes. The synchronisation time should be set to a time within which the signals from the gate switches should both supply a 1- signal when closing. If this time is exceeded, it is an indication that the gate switches are no longer switching synchronously when closing, due to mechanical reasons. Machine is running MRun = 0: Machine is still MRun = 1: Machine is running MRun = 1/0 pulse edge: Function test must be performed. This parameter can force the operator to carry out a function test of the gate (gate open/closed). With a 1/0 pulse edge, the enable is reset and a function test must be performed. Hazardous machine functions are stopped. STPD = 0: Hazardous machine functions are not stopped STPD = 1: Hazardous machine functions are stopped. WARNING! The signal Hazardous machine functions are stopped (STPD) must be formed safely. It must correspond to the category of the safety device. This can be guaranteed by checking the 2 signals from 2 diverse standstill monitors for feasibility, for example. This feasibility check can be performed using the approved block SB063 E-STOP, for example. Request to open/lock the gate. RQST = 0: No request RQST = 1: Request to open/lock the gate Automatic restart/reset lock ARSt = 0: Reset lock (reset is required) ARSt = 1: Automatic restart/no reset lock (see also under Operating modes ) Modular Block System: Hydraulic Presses

171 AuSt: NoFT: BLNK: RSET: Automatic start/start-up disabler AuSt = 0: Start-up disabler (initial reset is required) AuSt = 1: Automatic start/no start-up disabler on PSS cold/ warm start or when starting the I/O-Group (see also under Operating modes ) WARNING! A plant or machine may only be operated with an automatic restart or automatic start if the risk analysis of the plant or machine has guaranteed this will not cause a hazard. An automatic restart may not be set, for example, if it is possible to access the safety gate from behind. Function test on the gate NoFT = 0: Function test required on the gate when the PSS is cold/warm started, when the I/O-Group is started or each time the gate is unlocked NoFT = 1: No function test required (see also under Operating modes ) Flash mode for status indicator (see Output parameters SGrd and SLck) Reset input RSET = 0/1 pulse edge: - Reset errors or - Reset start-up disabler or - Reset reset lock Modular Block System: Hydraulic Presses 6-109

172 Standard Function Blocks SB075 Input circuitry Connect the input parameters S1, S2 and LCKD as follows: If you are using 2 gate switches and a guard locking monitoring circuit: Assign the relevant input parameters as specified in the section entitled Input parameters. If you are using one gate switch and one combined gate switch/guard locking monitoring circuit: Assign the input parameters S1 and S2 to the signal from the gate switch (both input parameters to the same signal). Assign the input parameter LCKD to the signal from the combined gate switch/guard locking monitoring circuit: Input parameter S1 Input parameter S2 Input parameter LCKD : Gate switch : Gate switch : Gate switch/guard locking monitoring circuit WARNING! The gate switch signal and the signal from the combined gate switch/guard locking monitoring circuit must not be connected in series. Output parameters ENBL: UNLK: Enable flag bit ENBL = 0 : Error detected (e.g. gate opened) ENBL = 1 : The enable is given if the gate is closed and locked and no error has been detected Controlling the guard locking (electromagnet) UNLK = 0 : Lock gate UNLK = 1 : Unlock gate WARNING! The guard locking device must operate to normally energised mode, i.e. the gate must be unlocked when operating voltage is applied (UNLK = 1)! Use of a guard locking device that operates to normally de Modular Block System: Hydraulic Presses

173 energised mode, i.e. the gate is locked when operating voltage is applied (UNLK = 1), is not permitted! WARNING! If a short circuit occurs between the guard locking device control and 24 V, the gate will be unlocked, even if hazardous machine functions are still being performed! The guard locking device should therefore be driven via a dual-pole output (e.g. via the PSS(1) DI2OZ). The dual-pole output will detect a short circuit with 24 V and shut down safely. The gate will not be unlocked. If it is not possible to use a dual-pole output, this error will need to be excluded by using a separate multicore cable for controlling the guard locking device, for example. SGrd: Status display on the gate SGrd = 0 : The machine is not enabled (ENBL = 0) SGrd flashing: Reset required SGrd = 1 : Machine is enabled (ENBL = 1) SLck: Status display on the guard locking device SLck = 0 : Gate is locked SLck flashing: After a request to open the gate, waiting until the hazardous machine functions have stopped or: After a 1/0 pulse edge at MRun, waiting until the hazardous machine functions have stopped or: Gate is closed, waiting for a request to lock the gate SLck = 1 : Gate is unlocked INFORMATION Flashing on the output parameters SGrd and SLck is determined via the input parameter BLNK. This input should be assigned a flashing flag. Modular Block System: Hydraulic Presses 6-111

174 Standard Function Blocks SB075 Operating modes Start-up disabler (input parameter AuSt) If the start-up disabler is active (AuSt = 0), you will need to reset after each PSS warm start PSS cold start or SafetyBUS p: I/O-Group start (input parameter GRP must be assigned the status flags of the relevant I/O-Groups) Only then can the enable be given. If a function test is also required (see input parameter NoFT), this must first be completed without error and then reset. If no other errors are present, the enable will be set. If the start-up disabler is not active (AuSt = 1), the enable will be set directly if no more errors are present. If a function test is required (see input parameter NoFT), this must first be completed without error. Start-up disabler (AuSt) Function test required (NoFT) Status of gate on start-up Close gate Request (RQST) Open gate Close gate Request (RQST) Reset (RSET) Yes No Yes No Yes No open x x x x x x shut - x x x x x open x x shut x open x x x x x - shut - x x x x - open x shut Note: This procedure is independent of the status of the input parameter ARSt Modular Block System: Hydraulic Presses

175 Reset lock (input parameter ARSt) If the reset lock is active (ARSt = 0), you will need to reset after each Opening and subsequent closing/locking of the gate (not applicable if the gate was not opened between unlocking and locking) Function test Error Only then can the enable be given. If no other errors are present, the enable will be set. If the reset lock is not active (ARSt = 1), the enable will be set directly, without a reset, after the above situations. Reset lock (ARSt) Yes No Function test required (NoFT) Yes No Yes No Request (RQST) x x x x Open gate x o x o Close gate x o x o Request (RQST) x x x x Reset (RSET) x / - - Note: This procedure is independent of the status of the input parameter AuSt Key: x: Action must be performed o: Action can be performed / : Action does not need to be performed if the gate was not open Modular Block System: Hydraulic Presses 6-113

176 Standard Function Blocks SB075 Function test on the gate (input parameter NoFT) If a function test is required on the gate (NoFT = 0), a function test must be performed on the gate after each Unlocking of the gate PSS warm start PSS cold start or SafetyBUS p: I/O-Group start (input parameter GRP must be assigned the status flags of the relevant I/O-Groups) Whether or not a reset is required after performing the function test is defined via the input parameters ARSt or AuSt (after each PSS cold/warm start or I/O-Group start) Modular Block System: Hydraulic Presses

177 Procedures Unlock If a request is made to open the gate (RQST = 0/1 pulse edge) when the gate is locked, the request will not be performed until the hazardous machine functions have stopped (STPD = 0/1 pulse edge). Only then will the enable output be reset (if it was set) and the gate unlocked (UNLK = 1). The gate can then be opened. Lock If a request is made to lock the gate (RQST = 0/1 pulse edge) when the gate is closed but not yet locked, the gate will be locked (UNLK = 0). When the gate is locked (LCKD = 1), the enable will be set directly (ARSt = 1) or after a reset (ARSt = 0), provided no other errors are present. If a request is made to lock the gate (RQST = 0/1 pulse edge) when the gate is still open, the gate will remain unlocked and an error message will be triggered (see section entitled Error messages ). Machine halted (input parameter MRun) A function test can be triggered via this parameter: When the machine is halted (MRun = 1/0 pulse edge), the enable is reset directly. As soon as the hazardous machine functions have stopped, the gate is unlocked (UNLK = 1) and the operator is prompted to carry out a function test (see section entitled Error messages ). This function is independent of the input parameter NoFT. Modular Block System: Hydraulic Presses 6-115

178 Standard Function Blocks SB075 Function test on the gate The conditions for requiring a function test are described in the sections entitled Operating modes, Procedures and Error messages. The function test is always prompted by the appropriate error message (see section entitled Erorr messages ). During a function test the gate must be opened and then closed again. The signals at the gate switch (S1, S2) must switch from '1' to '0' (on opening) or from '0' to '1' (on closing). During this process synchronisation time monitoring is active, as during a normal closing operation. If the gate is still open before starting the test, it must first be closed. If the prompt to carry out a function test is received while the gate is still locked, it must first be unlocked (see section entitled Procedures ). Whether or not a reset is required after performing the function test is defined via the input parameter ARSt. Additional safety guidelines WARNING! The following information must be heeded! Failure to comply with these guidelines could result in serious injury or death. The safety gate, gate switch and guard locking device and the way in which they are arranged must comply unreservedly with EN 1088 Interlocking devices associated with guards. If you are using a gate switch and a combined gate switch/guard locking monitoring circuit, certain errors cannot be detected. In this case it will be necessary to carry out a function test on the gate as part of each cycle, i.e. the gate must be opened and closed regularly. You can meet this requirement by activating the function test cyclically through a 1/0 pulse edge at the MRun input (e.g. each time the machine stops), so that it is only possible to restart the machine after the gate has been opened and closed. If all these conditions are met, this configuration can achieve Category 2 at best in accordance with EN Modular Block System: Hydraulic Presses

179 To achieve Category 4 in accordance with EN you will need to use 2 separate gate switches, which are operated independently. The signals from these gate switches must be used with test pulses. Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of the administration data block (1st data block), until the fault has been fully dealt with. Error messages in the administration data block - Bit 00: Gate open (S1 open) Remedy: Close gate - Bit 01: Gate open (S2 open) Remedy: Close gate - Bit 02: Gate open (S1 and S2 open) Remedy: Close gate - Bit 03: Synchronisation time between S1 and S2 exceeded Remedy: Carry out a function test - Bit 04: Function test not carried out Remedy: Carry out a function test - Bit 05: Gate closed, S1 was not open Remedy: Carry out a function test - Bit 06: Gate closed, S2 was not open Remedy: Carry out a function test - Bit 07: Error on the guard locking device The guard locking control (UNLK) does not match the signal from the monitoring circuit (LCKD) Remedy: Check monitoring circuit, control, guard locking device, cable, input/output card and all conditions and then reset (when ARSt = 0) Modular Block System: Hydraulic Presses 6-117

180 Standard Function Blocks SB075 - Bit 09: Hazardous machine functions have not stopped Although the hazardous machine functions were stopped and the enable reset, the machine functions are still running. Remedy: Check standstill monitoring, cable, input card and all conditions and then reset (when ARSt = 0) - Bit 10: Request to lock safety device when it is still open. A request was made to lock the gate while the gate was still open. Remedy: Close gate or reset (when ARSt = 0) - Bit 11: Gate unlocked Remedy: Activate guard locking on gate - Bit 12: I/O-Group stop triggered while PSS is in RUN mode Remedy: Start I/O-Group - Bit 13: Reset pressed too early The reset button was operated (RSET) although at least one error was still not rectified Remedy: Press reset button again - Bit 14: Reset required Remedy: Reset Error messages on the CPU-display E003: Administration data block has not been initialised Remedy: Call SB071 in OB Modular Block System: Hydraulic Presses

181 Global parameters used in the administration blocks Global parameters are set in OB120 using SB071. DW 1022: Minimum PSS scan time Blocks required DB015, DB016, DB017: Administration data blocks The data blocks must consist of their total length of 1024 data words and have READ/WRITE access (see section entitled Administration data blocks in Chapter 5). SB071: Initialisation of global parameters in DB015, DB016 and DB017 SB255: For calling up the operating system Modular Block System: Hydraulic Presses 6-119

182 Standard Function Blocks SB086 SB086: Overrun control on linear-driven presses Block header SB086 OVERRUN B - SSNR X - RQST X - STRT X - ETP X - TLS W- MTi X - RSET ENBL - X OK - X Input parameters SSNR: RQST: STRT: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (See sections entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR in the operating manual for the MBS block package). Signal to request an overrun measurement. RQST = 0/1 pulse edge, request an overrun measurement. The request will only be accepted if overrun measurement is not currently running. Removing a request (RQST = 0) made during an overrun measurement will not affect how this measurement is performed. Start signal to set the enable ( ENBL ). If no error is present, the start signal is simply passed to the ENBL output until the test cam (TLS) is reached. STRT = 0: No start signal is present; (stop overrun measurement) STRT = 0/1-pulse edge: Start overrun measurement STRT = 1: Perform overrun measurement Modular Block System: Hydraulic Presses

183 ETP: TLS: MTi: Extreme top position of press ETP = 0: Press not at extreme top position ETP = 1: Press at extreme top position Test limit switch, signal from the overrun test cam on the press TLS = 0: Test cam reached TLS = 1: Test cam free The length of the test cam corresponds to the permitted overrun on the press. Overrun measuring period in ms Permitted time range: ms Format: Word constants KF KF 4095 If you enter a value less than 200 ms, the block will operate internally with a measuring period of 200 ms. A value greater than 4095 will be limited to The time entered here will be started when the test cam (TLS) is reached. Once the MTi time has elapsed, a test is carried out to check if the test cam was passed. The time must be defined so that the press comes to a standstill within the stated time. CAUTION! Please note that, due to imprecisions on the internal timer, the actual measuring period may be up to one PSS scan time shorter than the value stated at the input parameter MTi. This is particularly significant with low MTi values. If necessary, increase the parameter value for MTi. RSET: Reset input for resetting error bits 00, 10, 11, 12 (see Error messages) RSET = 0/1 pulse edge: Trigger reset Modular Block System: Hydraulic Presses 6-121

184 Standard Function Blocks SB086 Output parameters Procedures ENBL: OK: Enable for the test closing stroke on the press ENBL = 0: No enable for the test closing stroke ENBL = 1: Enable for the test closing stroke Press overrun is in order This signal acts as the enable for normal operation after the test stroke; if OK=1, the press may start production, because the machine's overrun is in order. OK = 0: Press overrun not in order or overrun measurement not yet performed OK = 1: Press overrun in order or overrun measurement performed successfully 1. Use the UP button to move the press to the extreme top position (ETP) 2. Start the overrun measurement via a two-hand circuit, for example (0/1 pulse edge at STRT -> ENBL = 0/1 pulse edge) 3. Hold down the two-hand buttons (STRT = 1 -> ENBL = 1) 4. Press reaches the test cam, upward movement is stopped (ENBL = 0) and the MTi time is started 5. Release the two-hand buttons (STRT = 0) 6. Once the MTi time has elapsed, a test is carried out to check if the test cam (TLS) was passed: - If no: Overrun is in order (OK = 1) - If yes: Overrun is too long, press is disabled (OK = 0). No further downward movement is permitted on the press -> Use the UP button to move the press to ETP, check all the conditions and repeat the overrun measurement Please note: The block must be incorporated into the PSS user program for the press in such a way that the measurement is effective in terms of the respective requirements of the machine s safety concept, e. g. it must be run when the controller is switched on, so that the initital stroke on starting the machine is a test stroke Modular Block System: Hydraulic Presses

185 The overrun measurement must be performed when the press is operating at its maximum possible speed. The overrun measurement must be started from the extreme top position of the press. The length of the test cam corresponds to the permitted overrun of the press. The permitted overrun is determined by the press manufacturer, for example. The length of the test cam must then be derived from this. ETP Test cam Press slide s = Permitted overrun TSL Test limit switch Fig. 6-6: Start position for the test stroke Modular Block System: Hydraulic Presses 6-123

186 Standard Function Blocks SB086 ETP Press movement is complete Press slide Test cam TSL Test limit switch Fig. 6-7: Measurement complete: overrun is in order ETP Test limit switch Press movement is complete Press slide TSL s = Permitted overrun Test cam Fig. 6-8: Measurement complete: Overrun is not in order (too long) Modular Block System: Hydraulic Presses

187 Timing diagram RQST STRT ETP TLS MTi ENBL OK Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Bit 00: Bit 01: Bit 02: Bit 03: Bit 04: Bit 08: Press is not at the extreme top position (ETP) when the overrun measurement is started. Remedy: Move press to extreme top position (ETP); check all conditions, then reset (input parameter: RSET), error resets automatically at ETP Overrun measurement is missing Overrun measurement is running Test cam (TLS: test limit switch) reached, withdraw START command Evaluation of overrun measurement is running, i.e. test cam (TLS) reached, START command withdrawn and MTi time not yet elapsed Reset button constantly pressed or pressed too early. Remedy: Release reset button, check all conditions (input parameter: RSET) Modular Block System: Hydraulic Presses 6-125

188 Standard Function Blocks SB086 Bit 09: Bit 10: Bit 11: Bit 12: Error can only be reset at the extreme top position (ETP) of the press. Remedy: Move press to extreme top position (ETP); check all conditions, error resets automatically at ETP Press overrun is too long, i.e. the test cam (TLS) was passed on the overrun measurement; the press is disabled. Remedy: Move press to extreme top position (ETP); check all conditions, then reset (input parameter: RSET), repeat overrun measurement The signal from the test cam (TLS) is missing when starting the overrun measurement from the extreme top position (ETP). Remedy: Check all conditions, then reset (input parameter RSET) Test cam (TLS) reached and the extreme top position (ETP) is still free. Remedy: Move press to extreme top position (ETP); check all conditions, then reset (input parameter: RSET) Global parameters used in the administration blocks Global parameters are set in OB120 using SB071. DW 1022: Minimum PSS scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words and have READ/WRITE access (see section entitled Administration data blocks in Chapter 5) Modular Block System: Hydraulic Presses

189 Notes Modular Block System: Hydraulic Presses 6-127

190 Standard Function Blocks SB087 SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve) Block header SB087 H_VALV_S B - SSNR X - ON X - S W - TOn W - TOff X - VTyp X - RSET ENBL - X Y - X ERR - X Input parameters SSNR: ON: S: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: No error found Start signal for Operate valve ON = 0: Valve switched off ON = 0/1 pulse edge: Switch valve on ON = 1: Valve switched on ON = 1/0 pulse edge: Switch valve off The valve cannot be switched on if the block has detected a fault (reset lock). The valve can only be switched on if it is in its start (off) position (see input parameter S). Acknowledgement of valve position S = 1: Valve in its start position (valve de-energised, acknowledgement from valve is present) INFORMATION If the valve is acknowledged via a switch, the supply to this switch must be from test pulses Modular Block System: Hydraulic Presses

191 TOn: Maximum permitted reaction time for switching on the valve (in ms) TOn = KF KF 350 when VTyp = 0 (directional control valve) TOn = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff TOff: VTyp: RSET: Maximum permitted reaction time for switching off the valve (in ms) TOff = KF KF 350 when VTyp = 0 (directional control valve) TOff = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff Type of valve to be monitored VTyp = 0: Monitoring a directional control valve VTyp = 1: Monitoring a poppet valve (see also under Function ). Error reset RSET = 0/1 pulse edge: Reset fault It will only be possible to reset an existing fault if the valve is in its start (off) position (valve deenergised and acknowledgement from valve is present) and no start signal is present (ON 1). Output parameters ENBL: Enable flag bit ENBL = 0: No enable issued When the valve is switched off (input parameter ON = 1/0 pulse edge), the enable is locked until the valve returns to its start position (input parameter S = 1). This is not an error. The block will cancel the enable immediately if it detects a fault. ENBL = 1: Enable The block will set the enable if no fault has been found and the valve is either in operation or is in its start position. Modular Block System: Hydraulic Presses 6-129

192 Standard Function Blocks SB087 Y: ERR: Output parameters for operating a valve Y = 0: Valve off Y = 1: Valve on This output parameter is set as soon as a fault is discovered. ERR = 0: No fault found ERR = 1: Fault found Function Switches on the valve in its start position only (input parameter S = 1, valve de-energised, acknowledgement from valve is present). Monitors position through acknowledgement of the valve's position (input parameter S) within a maximum reaction time. The reaction time for switch on and switch off may be selected individually: - Reaction time when switching on the valve: When switched on, the valve must leave its start position within a maximum time (reaction time). The maximum reaction time when switching on the valve can be set via the input parameter TOn. If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and the valve will switch off immediately (output parameter Y = 0). A reset will be necessary (see also under Error messages ). - Reaction time when switching off the valve: When switched off, the valve must reach its start position within a maximum time (reaction time). The maximum reaction time when switching off the valve can be set via the input parameter TOff. If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and a reset will be necessary (see also under Error messages ). Monitors position through acknowledgement of the valve's position (input parameter S), without setting a maximum reaction time (input parameter TOn = 0 and TOff = 0). When monitoring the position of a valve without monitoring the reaction time, SB087 checks that it leaves its start position (valve de-energised, acknowledgement present) at least once in each working cycle (valve switching on and off). If this is not the case, SB087 will register an error (output parameter ENBL = 0 and ERR = 1) and the valve will switch off immediately (output parameter Y = 0). A reset will be necessary (see also under Error messages ) Modular Block System: Hydraulic Presses

193 Monitoring the position of directional control valves: With directional control valves, the position of the valve is monitored as it is being operated. The valve must not register its start position while it is being operated. If a directional control valve is correctly energised (input parameter ON = 1) and registers its start position while the valve output is switched on (output parameter Y = 1), SB087 immediately switches off the valve output (output parameter Y = 0) and registers a fault (output parameter ENBL = 0 and ERR = 1). A reset will be necessary (see also under Error messages ). INFORMATION Directional control valves may only be operated where the position of the valve is monitored by acknowledging the valve's position within a maximum reaction time. VTyp = 0 TOn = KF KF 350 TOff = KF KF 350 Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff Registers an error when the valve is in the wrong position If an error occurs, the valve will be switched off immediately; it will not be possible to reset the valve (reset disabled). After an error, a reset will only be possible if the error has been rectified, the valve is in its start position (valve de-energised, acknowledgement from valve is present) and no start signal is present (input parameter ON 1). Modular Block System: Hydraulic Presses 6-131

194 Standard Function Blocks SB087 Safety guidelines for input parameters TOn and TOff The reaction time (input parameters TOn and TOff) must not adversely affect the availability of the press. Please note that pressure and temperature fluctuations can vary the valve's reaction times. Please note that the clearance distance from the machine must be calculated in accordance with the values established by measuring the overrun on the press. Please note that the overrun of the machine will be determined by the reaction time of the valve. If the switching times of the valves increase during the lifetime of a machine, the overrun distance will also increase. This means that the safety distance will need to be increased. Always check that the reaction times are set correctly (input parameters TOn and TOff). This is the only way in which SB087 can sensibly monitor the reaction times on which the safety distance is based, detect the valve's increased reaction times and therefore switch the valve to a safe condition (start position). Reaction times should be set as short as possible (input parameter TOn and TOff). WARNING! If the time values entered for TOn and TOff are too long, serious injuries could result should the danger zone be accessed during operation. The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. Reaction times should be included in the calculation of the safety distance if the time values you are setting for the parameters TOn and TOff are significantly higher than the actual valve reaction times. Please note: - With directional control valves (input parameter VTyp = 0), the reaction time when the valve switches on and off must always be monitored (see under Settings for the parameters TOn and TOff). - With poppet valves, the reaction time when the valve switches on and off may be monitored (see under Settings for the parameters TOn and TOff ) Modular Block System: Hydraulic Presses

195 Settings for the parameters TOn and TOff Poppet valves I/P Parameter TOff = 0 0<TOff<TOff max VTyp = 1 TOn = 0 Reaction time is not Reaction time is monitored monitored when the valve when the valve is switches on or off switched off 0<TOn<TOn max Reaction time is Reaction time is monitored when the valve monitored when the valve is switched on is switched on and off Directional control valves I/P Parameter VTyp = 0 0<TOn<TOn max 0<TOff<TOff max Reaction time is monitored when the valve is switched on and off Setting reaction times Reaction times (entered under input parameters TOn and TOff) may be set as follows: Select a low value (e.g. 10 ms) Increase the value step by step (max. 10 ms steps), until it is clear that the valve operates safely and correctly. This will ensure that reaction times correspond to the actual values of the valve. Modular Block System: Hydraulic Presses 6-133

196 Standard Function Blocks SB087 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 01: Valve acknowledgement input parameter S remains high after the valve is switched on. Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 02: Valve acknowledgement input parameter S remains low after the valve is switched off. Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) INFORMATION If no reaction time has been set for switching off the valve (TOff = 0), Bit 02 will remain set until the valve returns to its start position. This is not a fault, but is important to bear in mind. - Bit 03: Valve acknowledgement input parameter S goes to its start position during operation (input parameter S goes high while output parameter Y = 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 04: Valve not in its start position (off) when switched on (input parameter S 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 08: Reset input constantly high, set too early, or EIN = 1 or S = 0 Remedy: Release reset button and press it again. If this does not work, check switch, cable, input card and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses

197 - Bit 12: No signal change has been detected from input parameter S. During the valve's working cycle (valve switching on and off), the valve has retained its start position (valve de-energised, acknowledgement present). Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 14: Invalid time entered under input parameter TOn Remedy: Enter a permitted value (for details of value range see input parameter TOn). - Bit 15: Invalid time entered under output parameter TOff Remedy: Enter a permitted value (for details of value range see input parameter TOff). Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: PSS scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Modular Block System: Hydraulic Presses 6-135

198 Standard Function Blocks SB088 SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve) Block header SB088 H_VALV_D B - SSNR X - ON X - S1 X - S2 W - TOn W - TOff X - Y1On X - Y2On X - VTyp X - RSET ENBL - X Y1 - X Y2 - X ERR - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: No error found ON: Start signal for drive valves (Y1 and Y2) ON = 0: Valves switched off ON = 0/1 pulse edge: Switch valves on ON = 1: Valves switched on ON = 1/0 pulse edge: Switch valves off The valves cannot be switched on if the block has detected a fault (reset lock). The valves can only be switched on if they are in their start (off) position (see input parameters S1 and S2). S1: Acknowledgement of valve position (valve 1) S1 = 1: Valve in its start position (valve de-energised, acknowledgement from valve is present) S2: Acknowledgement of valve position (valve 2) S2 = 1: Valve in its start position (valve de-energised, acknowledgement from valve is present) Modular Block System: Hydraulic Presses

199 INFORMATION If valves Y1 and Y2 are acknowledged via switches, the supply to these switches must be from test pulses. If valves Y1 and Y2 are acknowledged via proximity switches which cannot be pulsed, the signal lines of the proximity switches must be laid in different multicore cables within the duct. This will ensure that a short cannot occur between the two signal lines. This safety precaution will not be necessary if you use proximity switches with diverse signals. TOn: TOff: Y1On: Y2On: Maximum permitted reaction time for switching on both valves (in ms) TOn = KF KF 350 when VTyp = 0 (directional control valve) TOn = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff Maximum permitted reaction time for switching off both valves (in ms) TOff = KF KF 350 when VTyp = 0 (directional control valve) TOff = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff Operate valve for overrun measurement Y1On = 0: Switch off valve Y1 for external overrun measurement Y1On = 1: Enable valve Y1 In normal operation, Y1On should be assigned RLO-1 (M110.01). (see also under Function ) Operate valve for overrun measurement Y2On = 0: Switch off valve Y2 for external overrun measurement Y2On = 1: Enable valve Y2 In normal operation, Y2On should be assigned RLO-1 (M110.01). (see also under Function ) Modular Block System: Hydraulic Presses 6-137

200 Standard Function Blocks SB088 VTyp: RSET: Type of valve to be monitored VTyp = 0: Monitoring a directional control valve VTyp = 1: Monitoring a poppet valve (see also under Function ) Error reset RSET = 0/1 pulse edge: Reset fault It will only be possible to reset an existing fault if the valve is in its start (off) position (valve deenergised and acknowledgement from valve is present) and no start signal is present (ON 1). Output parameters ENBL: Y1: Y2: ERR: Enable flag bit ENBL = 0: Enable locked When the valves are switched off (input parameter ON = 1/0 pulse edge), the enable is locked until the valves return to their start position (input parameter S1 = 1 and S2 = 1). This is not an error. The block will cancel the enable immediately if it detects a fault. ENBL = 1: Enable The block will set the enable if no fault has been found and the valves are either in operation or in their start position. Output parameters for operating valve Y1 Y1 = 0: Valve Y1 off Y1 = 1: Valve Y1 on Output parameter for operating valve Y2 Y2 = 0: Valve Y2 off Y2 = 1: Valve Y2 on This output parameter is set as soon as a fault is discovered. ERR = 0: No fault found ERR = 1: Fault found Modular Block System: Hydraulic Presses

201 Function The valves can only be switched on if both valves are in their start position (input parameter S1 = 1 and S2 = 1, valve de-energised, acknowledgement from the valves is present) and input parameter Y1On = 1 and Y2On = 1. The valves can be switched off individually to enable external overrun measurement. Overrun measurement for Y1: - Input parameter Y1On and Y2On = 1 - Switch on valves via input parameter ON - Switch off valve Y1 via input parameter Y1On = 0 to enable overrun for Y1 to be measured - Switch off valve Y2 via input parameter ON = 0 Overrun measurement for Y2: - Input parameter Y1On and Y2On = 1 - Switch on valves via input parameter ON - Switch off valve Y2 via input parameter Y2On = 0 to enable overrun for Y2 to be measured - Switch off valve Y1 via input parameter ON = 0 Key to settings at Y1On and Y2On Y1On = 0 Y1On = 1 Y2On = 0 Invalid combination Overrun measurement Error Y2 switched off Y2On = 1 Overrun measurement Normal Y1 switched off working mode In order to detect shorts, valve Y2 is switched on one PSS-cycle after valve Y1. Both valves are switched off simultaneously. Monitors position through acknowledgement of the valves' position (input parameters S1 and S2) within a maximum reaction time. The reaction time for switch on and switch off may be selected individually. - Reaction time when switching on the valve: When switched on, the valves must leave their start position within a Modular Block System: Hydraulic Presses 6-139

202 Standard Function Blocks SB088 maximum time (reaction time). The maximum reaction time when switching on the valves can be set via the input parameter TOn (for both valves). If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and the valves will switch off immediately (output parameter Y1 = 0 and Y2 = 0). A reset will be necessary (see also under Error messages ). - Reaction time when switching off the valve: When switched off, the valves must reach their start position within a maximum time (reaction time). The maximum reaction time when switching off the valves can be set via the input parameter TOff (for both valves). If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and a reset will be necessary (see also under Error messages ). INFORMATION SB088 is designed for dual valves. You can assume that these will have a similar switching characteristic. This means that the reaction time for switching on (off) both valves can be monitored through the input parameters TOn (TOff). Position is monitored via acknowledgement of the valve's position (input parameters S1 and S2), without setting a maximum reaction time (input parameter TOn = 0 and TOff = 0). When monitoring the position of a valve without monitoring the reaction time, SB088 checks that the valves leave their start position (valve deenergised, acknowledgement present) at least once in each working cycle (valve switching on and off). If this is not the case, SB088 will register an error (output parameter ENBL = 0 and ERR = 1) and the valves will switch off immediately (output parameter Y1 = 0 and Y2 = 0). A reset will be necessary (see also under Error messages ). Monitoring the position of directional control valves With directional control valves, the position of the valves is monitored as they are being operated. The valves must not register their start position while they are being operated. If the directional control valves are correctly energised (input parameter ON = 1) and their start position is registered while the valve output is switched on (output parameter Y1 = 1 and Y2 = 1), SB088 immediately switches off the valve output (output parameter Y1 = 0 and Y2 = 0) and registers a fault (output parameter ENBL = 0 and ERR = 1). A reset will be necessary (see also under Error messages ) Modular Block System: Hydraulic Presses

203 INFORMATION Directional control valves may only be operated where the position of the valve is monitored by acknowledging the valve's position within a maximum reaction time. VTyp = 0 TOn = KF KF 350 TOff = KF KF 350 Ensure you follow the guidelines given below under Safety guidelines for input parameters TOn and TOff Registers an error when the valves are in the wrong position If an error occurs, the valves will be switched off immediately; it will not be possible to reset the valves (reset lock). After an error, a reset will only be possible if the error has been rectified, the valves are in their start position (valve de-energised, acknowledgement from valve is present), the input parameter Y1On = 1 and Y2On = 1, and no start signal is present (input parameter ON 1). Safety guidelines for input parameters TOn and TOff The reaction time (input parameters TOn and TOff) must not adversely affect the availability of the press. Please note that pressure and temperature fluctuations can vary the valves' reaction times. Please note that the safety distance from the machine must be calculated in accordance with the values established by measuring the overrun on the press. Please note that the overrun of the machine will be determined by the reaction time of the valve. If the switching times of the valves increase during the lifetime of a machine, the overrun distance will also increase. This means that the safety distance will also need to be increased. Always check that the reaction times are set correctly (input parameters TOn and TOff). This is the only way in which SB088 can sensibly monitor the reaction times on which the safety distance is based, detect the valves' increased reaction times and therefore switch the valves to a safe condition (start position). Reaction times should be set as short as possible (input parameter TOn and TOff). Modular Block System: Hydraulic Presses 6-141

204 Standard Function Blocks SB088 WARNING! If the time values entered for TOn and TOff are too long, serious injuries could result should the danger zone be accessed during operation. The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. Reaction times should be included in the calculation of the safety distance if the time values set for the parameters TOn and TOff are significantly higher than the actual valve reaction times. Please note: - With directional control valves (input parameter VTyp = 0), the reaction time when the valve switches on and off must always be monitored (see under Settings for the parameters TOn and TOff ). - With poppet valves, the reaction time when the valve switches on and off may be monitored (see under Settings for the parameters TOn and TOff ) Modular Block System: Hydraulic Presses

205 Settings for the parameters TOn and TOff Poppet valves I/P Parameter TOff = 0 0<TOff<TOff max VTyp = 1 TOn = 0 Reaction time is not Reaction time is monitored monitored when the valve when the valve is switches on or off switched off 0<TOn<TOn max Reaction time is Reaction time is monitored when the valve monitored when the valve is switched on is switched on and off Directional control valves I/P Parameter VTyp = 0 0<TOn<TOn max 0<TOff<TOff max Reaction time is monitored when the valve is switched on and off Setting reaction times Select a low value (e.g. 10 ms) Increase the value step by step (max. 10 ms steps), until it is clear that the valve operates safely and correctly. This will ensure that the reaction times correspond to the actual values of the valve. Modular Block System: Hydraulic Presses 6-143

206 Standard Function Blocks SB088 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Invalid operation of input parameter Y1On or Y2On Remedy: See section entitled Function. Once the error has been rectified, reset (input parameter RSET) - Bit 01: Valve acknowledgement input parameter S1 remains high after the valve is switched on Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 02: Valve acknowledgement input parameter S1 remains low after the valve is switched off Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) INFORMATION If no reaction time has been set for switching off the valve (TOff = 0), Bit 02 will remain set until the valve returns to its start position. This is not a fault, but is important to bear in mind. - Bit 03: Valve acknowledgement input parameter S1 goes to its start position during operation (input parameter S1 goes high while output parameter Y1 = 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 04: Valve Y1 not in its start position (off) when switched on, i.e. signal at input parameter S1 1 Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses

207 - Bit 05: Valve acknowledgement input parameter S2 remains high after the valve is switched on Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 06: Valve acknowledgement input parameter S2 remains low after the valve is switched off Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) INFORMATION If no reaction time has been set for switching off the valve (TOff = 0), Bit 06 will remain set until the valve returns to its start position. This is not a fault, but is important to bear in mind. - Bit 07: Valve Y2 not in its start position (off) when switched on, i.e. signal at input parameter S2 1 Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 08: Reset input constantly high, set too early, or EIN = 1 or S1 = 0 or S2 = 0 Remedy: Release reset button and press it again. If this does not work, check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 09: Valve acknowledgement input parameter S2 goes to its start position during operation (input parameter S2 goes high while output parameter Y2 = 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 12: No signal change detected from input parameter S1. During the working cycle of valve Y1 (valve switching on and off), the valve has retained its start position (valve de-energised, acknowledgement present). Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses 6-145

208 Standard Function Blocks SB088 - Bit 13: No signal change detected from input parameter S2. During the working cycle of valve Y2 (valve switching on and off), the valve has retained its start position (valve de-energised, acknowledgement present). Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 14: Invalid time entered under input parameter TOn Remedy: Enter a permitted value (for details of value range see input parameter TOn). - Bit 15: Invalid time entered under input parameter TOff Remedy: Enter a permitted value (for details of value range see input parameter TOff). Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: PSS scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access Modular Block System: Hydraulic Presses

209 Notes Modular Block System: Hydraulic Presses 6-147

210 Standard Function Blocks SB089 SB089: Sequential driving/monitoring the position of two hydraulic valves (poppet and directional control valves) Block header SB089 H_VALV_P B - SSNR X - StEn X - S1 X - S2 W - TOn W - TOff X - Y1On X - Y2On X - VTyp X - RSET ENBL - X Y1 - X Y2 - X ERR - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: No error found StEn: Static enable for operating the valve StEn = 0: Valve operation disabled StEn = 1: Valve operation enabled S1: Valve 1: Acknowledgement of position S1 = 1: Start position of valve (valve de-energised, acknowledgement from valve is present) S2: Valve 2: Acknowledgement of position S2 = 1: Start position of valve (valve de-energised, acknowledgement from valve is present) INFORMATION If valves Y1 and Y2 are acknowledged via switches, the supply to these switches must be from test pulses Modular Block System: Hydraulic Presses

211 INFORMATION If valves Y1 and Y2 are acknowledged via proximity switches which cannot be pulsed, the signal lines of the proximity switches must be laid in different multicore cables within the duct. This will ensure that a short cannot occur between the two signal lines. This safety precaution will not be necessary if you use proximity switches with diverse signals. TOn: Maximum permitted reaction time for switching on both valves (in ms) TOn = KF KF 350 when VTyp = 0 (directional control valve) TOn = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff TOff: Maximum permitted reaction time for switching off both valves (in ms) TOff = KF KF 350 when VTyp = 0 (directional control valve) TOff = KF KF 350 when VTyp = 1 (poppet valve) Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff Y1On: Start signal for Operate valve Y1 Y1On = 0/1 pulse edge: Switch on valve Y1 Y1On = 1/0 pulse edge: Switch off valve Y1 Y2On: Start signal for Operate valve Y2 Y2On = 0/1 pulse edge: Switch on valve Y2 Y2On = 1/0 pulse edge: Switch off valve Y2 INFORMATION The input parameters Y1On and Y2On are interlocked with respect to each other. This guarantees that only one valve can be operated at a time. Neither of the valves can be switched on while the block detects an error (reset lock). It is only possible to switch on one valve if both valves are in their start position (see input parameters S1 and S2). Modular Block System: Hydraulic Presses 6-149

212 Standard Function Blocks SB089 VTyp: RSET: Type of valve to be monitored VTyp = 0: Monitoring a directional control valve VTyp = 1: Monitoring a poppet valve (see also under Function ) Error Reset RSET = 0/1 pulse edge: Reset fault It will only be possible to reset an existing fault if the valve is in its start position (valve de-energised and acknowledgement from valve is present) and no start signal is present (Y1On = 0, Y2On = 0). Output parameters ENBL: Y1: Y2: ERR: Enable flag bit ENBL = 0: Enable locked When the valve is switched off (input parameter Y1On / Y2On = 1/0 pulse edge), the enable is locked until the valve returns to its start position (input parameter S1 = 1 / S2 = 1). This is not an error. The block will cancel the enable immediately if it detects a fault. ENBL = 1: Enable The block will set the enable if no fault has been found and the valves are either in operation or in their start position. Output parameters for operating valve Y1 Y1 = 0: Valve Y1 off Y1 = 1: Valve Y1 on Output parameters for operating valve Y2 Y2 = 0: Valve Y2 off Y2 = 1: Valve Y2 on The output parameter is set as soon as a fault is detected. ERR = 0: No fault detected ERR = 1: Fault detected Modular Block System: Hydraulic Presses

213 Function It is only possible to switch on one valve (Y1 or Y2) if both valves are in their start position (input parameter S1 = 1 and S2 = 1, valve deenergised, acknowledgements from the valves are present) and input parameter StEn = 1. Key to settings at Y1On and Y2On Y1On = 0 Y1On = 1 Y2On = 0 Both valves are Valve Y1 is switched off switched on Y2On = 1 Valve Y2 is Invalid combination switched on Monitors position through acknowledgement of the valves' position (input parameter S1 / S2) within a maximum reaction time. The reaction time for switch on and switch off may be selected individually. - Reaction time when switching on the valve: When switched on, the valve must leave its start position within a maximum time (reaction time). The maximum reaction time when switching on the valve can be set via the input parameter TOn (for both valves). If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and the relevant valve will switch off immediately (output parameter Y1 = 0 / Y2 = 0). A reset will be necessary (see also under Error messages ). - Reaction time when switching off the valve: When switched off, the valve must reach its start position within a maximum time (reaction time). The maximum reaction time when switching off the valve can be set via the input parameter TOff (for both valves). If the maximum reaction time is exceeded, an error message will be issued (output parameter ENBL = 0 and ERR = 1) and a reset will be necessary (see also Error messages ). INFORMATION Both valves are monitored using the same parameter for switch-on and switch-off. If you are using structurally separated valves you must make sure that these have a similar switching characteristic. Modular Block System: Hydraulic Presses 6-151

214 Standard Function Blocks SB089 Monitors position through acknowledgement of the valve's position (input parameter S1 / S2), without setting a maximum reaction time (input parameter TOn = 0 and TOff = 0). When monitoring the position of a valve without monitoring the reaction time, SB089 checks that the valve leaves its start position (valve deenergised, acknowledgement present) at least once in each working cycle (valve switching on and off). If this is not the case, SB089 will register an error (output parameter ENBL = 0 and ERR = 1) and the valve will switch off immediately (output parameter Y1 = 0 / Y2 = 0). A reset will be necessary (see also under Error messages ). Monitoring the position of directional control valves With directional control valves, the position of the valve is monitored as it is being operated. The valve must not register its start position while it is being operated. If a directional control valve is correctly energised and registers its start position while the valve output is switched on (output parameter Y1 = 1 / Y2 = 1), SB089 immediately switches off the valve (output parameter Y1 = 0 / Y2 = 0) and registers an error (output parameter ENBL = 0 and ERR = 1). A reset will be necessary (see also under Error messages ). INFORMATION Directional control valves may only be operated where the position of the valve is monitored by acknowledging the valve's position within a maximum reaction time. VTyp = 0 TOn = KF KF 350 TOff = KF KF 350 Ensure you follow the guidelines given under Safety guidelines for input parameters TOn and TOff. If an error occurs, the valves will be switched off immediately; it will not be possible to reset the valve (reset lock). After an error, a reset will only be possible if the error has been rectified, both valves are in their start position (valve disabled, acknowledgement from valve is present) and no start signal is present (input parameter Y1On = 0 / Y2On = 0) Modular Block System: Hydraulic Presses

215 Safety guidelines for input parameters TOn and TOff The reaction time (input parameters TOn and TOff) must not adversely affect the availability of the press. Please note that pressure and temperature fluctuations can vary the valve's reaction times. Please note that the safety distance from the machine must be calculated in accordance with the values established by measuring the overrun on the press. Please note that the overrun of the machine will be determined by the reaction time of the valve. If the switching times of the valves increase during the lifetime of a machine, the overrun distance will also increase. This means that the safety distance will also need to be increased. Always check that the reaction times are set correctly (input parameter TOn and TOff). This is the only way in which SB089 can sensibly monitor the reaction times on which the safety distance is based, detect the increased reaction times from the valve and therefore switch the valve to a safe condition (start position). Reaction times should be set as short as possible (input parameter TOn and TOff). DANGER! If the time values entered for TOn and TOff are too long, serious injuries could result should the danger zone be accessed during operation. The reaction time of the safety valve determines the stopping time of the press on an emergency stop. The stopping time determines the safety distance to the tool. Reaction times should be included in the calculation of the safety distance if the time values set for the parameters TOn and TOff are significantly higher than the actual valve reaction times. Modular Block System: Hydraulic Presses 6-153

216 Standard Function Blocks SB089 Please note: - With directional control valves (input parameter VTyp = 0), the reaction time when the valve switches on and off must always be monitored (see under Settings for the parameters TOn and TOff ). - With poppet valves, the reaction time when the valve switches on and off may be monitored (see under Settings for the parameters TOn and TOff ). Settings for the parameters TOn and TOff Poppet valves I/P Parameter TOff = 0 0<TOff<TOff max VTyp = 1 TOn = 0 Reaction time is not Reaction time is monitored monitored with the valve when the valve switches switches on or off off 0<TOn<TOn max Reaction time is Reaction time is monitored when the valve monitored when the valve switches on switches on and off Directional control valves I/P Parameter VTyp = 0 0<TOn<TOn max 0<TOff<TOff max Reaction time is monitored when the valve switches on and off Setting reaction times Select a low value (e.g. 10 ms) Increase the value step by step (max. 10 ms steps), until it is clear that the valve operates safely and correctly. This will ensure that reaction times correspond to the actual values of the valve Modular Block System: Hydraulic Presses

217 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 01: Valve acknowledgement input parameter S1 remains high after the valve is switched on. Remedy: Check switch, cable, input card and all conditions, and then reset (input parameter RSET) - Bit 02: Valve acknowledgement input parameter S1 remains low after the valve is switched off. Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) INFORMATION If no reaction time has been set for switching off the valve (TOff = 0), Bit 02 will remain set until the valve returns to its start position. This is not a fault, but is important to bear in mind. - Bit 03: Valve acknowledgement input parameter S1 goes to its start position during operation (input parameter S1 goes high while output parameter Y1 = 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 04: Valve Y1 not in its start position (off) when switched on (input parameter S1 = 0) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 05: Valve acknowledgement input parameter S2 remains high after the valve is switched on Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) Modular Block System: Hydraulic Presses 6-155

218 Standard Function Blocks SB089 - Bit 06: Valve acknowledgement input parameter S2 remains low after the valve is switched off Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) INFORMATION If no reaction time has been set for switching off the valve (TOff = 0), Bit 06 will remain set on switch-off until the valve returns to its start position. This is not a fault, but is important to bear in mind. - Bit 07: Valve Y2 not in its start position (off) when switched on, i.e. signal at input parameter S2 = 0 Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 08: Reset input constantly high, set too early, or EIN = 1 or S1 = 0 or S2 = 0 Remedy: Release reset button and press it again. If this does not work, check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 09: Valve acknowledgement input parameter S2 goes to its start position during operation (input parameter S2 goes high while output parameter Y2 = 1) Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 10: Input parameter StEn is not high when switching on via Y1On / Y2On. This message disappears automatically as soon as input parameter StEn = 1. This is not an fault, but is important to bear in mind. - Bit 11: Invalid combination:y1on = 1 and Y2On = 1 Remedy: Check switch, cable, input card and all conditions. Check the software to ensure both valves cannot be driven simultaneously (see and 4-109) and then reset (input parameter RSET) Modular Block System: Hydraulic Presses

219 - Bit 12: No signal change detected from input parameter S1. During the working cycle of valve Y1 (valve switching on and off), the valve has retained its start position (valve deenergised, acknowledgement present). Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 13: No signal change detected from input parameter S2. During the working cycle of valve Y2 (valve switching on and off), the valve has retained its start position (valve deenergised, acknowledgement present). Remedy: Check switch, cable, input card and all conditions and then reset (input parameter RSET) - Bit 14: Invalid time entered under input parameter TOn Remedy: Enter a permitted value (for details of value range see input parameter TOn). - Bit 15: Invalid time entered under input parameter TOff Remedy: Enter a permitted value (for details of value range see input parameter TOff). Error messages on the CPU-display - None Global parameters used in administration data block DB015 Global parameters may be set in OB120 using SB070. DW1022: PSS scan time Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Modular Block System: Hydraulic Presses 6-157

220 Standard Function Blocks SB092 SB092: Enable switch Block header SB 092 ENBL_DEV B - SSNR X - ON X - NC X - NO X - AuSt X - ARst X - RSET ENBL - X Input parameters SSNR: ON: NC: NO: AuSt: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 (see sections in Chapter 5 entitled Administration data blocks DB015, DB016 and DB017 and Input parameter SSNR ). Value of DW (SSNR) = 0: no error found Switch operating mode on/off (enable function) ON = 0: Operating mode switched off ON = 0/1 pulse edge: Switch on operating mode N/C contact (please refer to Switching diagrams ). N/O contact (please refer to Switching diagrams ). INFORMATION Both contacts NC and NO should be provided with different test pulse outputs (test pulses). Automatic start/start-up lock when the PSS starts up AuSt = 0: Start-up disabled when PSS starts up When the PSS starts up, a reset via the input parameter RSET is required. To set the start-up lock on the SB, the input parameter should be assigned RLO-0 (M ) Modular Block System: Hydraulic Presses

221 ARst: RSET: AuSt = 1: Automatic start when PSS starts up To set automatic start-up on the SB, the input parameter should be assigned RLO-1 (M ). Automatic restart/reset lock after the enable switch is released or unlatched from stage 3 ARst = 0: ARst = 1: Reset lock After the enable switch is released / unlatched, a reset via the input parameter RSET is required. To set the reset lock on the SB, the input parameter should be assigned RLO-0 (M ). Automatic restart after the enable switch is released / unlatched from stage 3 To set automatic restart for the SB, the input parameter should be assigned RLO-1 (M ). Error reset RSET = 0/1-pulse edge: Reset error Output parameters ENBL: Enable flag bit ENBL = 0: Not enabled i.e. no approval ENBL = 1: Enabled i.e. approval Modular Block System: Hydraulic Presses 6-159

222 Standard Function Blocks SB092 Function SB092 monitors a three-position enable switch designed to protect personnel where operating modes (setup) have safety devices suspended. It can be used for the following applications: For enable switches conforming to EN 1921, 10/95, VDE 2853, 07/87 For three-position switches conforming to EN 692 section , 08/96 and EN 693 section , 2001, for presses with automatic reset and a slow closing speed (10 mm/s) For the switching diagrams documented in the following pages. INFORMATION Please bear in mind the following points (EN 1921, 10/95): An enable switch approves a dangerous movement but does not actually trigger it. The enable switch alone must not be able to initiate a potentially hazardous situation. If an enable device is required, it must be connected to either a category 0 or category 1 stop. If the switching device is fed back from stage 3 through stage 2 to stage 1, the enable function in stage 2 will not occur. It is possible to set a start-up and reset lock after feedback from stage Modular Block System: Hydraulic Presses

223 Switching diagrams Type A Circuitry: - Input parameter NC: N/C contact - Input parameter NO: N/O contact Diagrams: not operated central position fully operated NC NO Stage 1 Stage 2 Stage 3 Fig. 6-5: Switching from stage 1 to stage 2 and back or switching from stage 2 to stage 3 not operated central position fully operated NC NO Stage 1 Stage 2 Stage 3 Fig. 6-6: Switching from stage 3 through stage 2 to stage 1 Contact closed Modular Block System: Hydraulic Presses 6-161

224 Standard Function Blocks SB092 Type B Circuitry: - Input parameter NC: N/C contact - Input parameter NO: N/O contact Diagrams: not operated central position fully operated NC NO Stage 1 Stage 2 Stage 3 Fig. 6-7: Switching from stage 1 to stage 2 and back or switching from stage 2 to stage 3 not operated central position fully operated NC NO Stage 1 Stage 2 Stage 3 Fig. 6-8: Switching from stage 3 through stage 2 to stage 1 Contact closed Modular Block System: Hydraulic Presses

225 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Enable switch is fully operated (E-STOP) Remedy: Release enable switch, check switch, cable, input card and all conditions, and then reset (input parameter RSET). - Bit 01: N/O contact on the enable switch is defective (input parameter NO) Remedy: Check switch, cable, input card and all conditions, and then reset (input parameter RSET). - Bit 08: RSET input constantly high or set too early Remedy: Check switch, cable, input card and all conditions, and then reset (input parameter RSET). - Bit 09: RSET input not yet operated, no reset present Remedy: Press reset button (input parameter RSET) Error messages on the CPU-display - None Global parameters used in administration data block DB015 None Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words DB015 must have READ/WRITE access. Modular Block System: Hydraulic Presses 6-163

226 Standard Function Blocks SB097 SB097: Monitoring muting lamps Block header SB097 MUT_LAMP B - SSNR X - GRP X - ON X - FbL1 X - FbL2 X - 1OUT X - RSET ENBL - X WARN - X LMP1 - X LMP2 - X Input parameters SSNR: Safety subroutine number Permitted value range: Format: Byte constants KB KB200 GRP: On SafetyBUS p applications: Assign the status flag of the I/O-Group containing inputs FbL1 and FbL2 (M for I/O-Group 0 to M for I/O-Group 31). On non-safetybus p applications:: Assign RLO-1 (M ) ON: Enable signal for muting lamps ON ON = 1: Switch on muting lamps ON = 0: Switch off muting lamps This input should be assigned the output signal MAct from SB 072 (Muting). FbL1: Feedback input for monitoring filament 1 (Feedback Loop 1) FbL2: Feedback input for monitoring filament 2 (Feedback Loop 2) RSET: Input for acknowledging error messages (Reset) RSET = 0/1-pulse edge: Delete all error entries when the faults have been rectified Modular Block System: Hydraulic Presses

227 1OUT: Input for selecting whether both muting lamps are to be tested simultaneously or alternately. 1OUT =1: Lamps are tested simultaneously. If positiveswitching outputs are used, output parameters LMP1 and LMP2 can both be assigned the address of a single output. Two optocouplers will need to be connected to the PSS output. If negative-switching outputs are used, two PSS outputs will be needed. 1OUT= 0: Lamps are tested alternately. The output parameters LMP1 and LMP2 must be assigned two different addresses. Output parameters ENBL: WARN: Enable flag bit ENBL = 1: At least one filament is in order. ENBL = 0: Fault detected: A defect has been found on both filaments or on the optocouplers. Warning WARN = 1: One of the two filaments is defective. WARN = 0: Both filaments are in order. LMP1: Output for driving muting lamp 1 (Lamp 1) LMP1 = 1: Muting lamp 1 on LMP1 = 0: Muting lamp 1 off LMP2: Output for driving muting lamp 2 (Lamp 2) LMP2 = 1: Muting lamp 2 on LMP2 = 0: Muting lamp 2 off Modular Block System: Hydraulic Presses 6-165

228 Standard Function Blocks SB097 Wiring the output parameters Positive or negative-switching outputs can be used to drive the muting lamps. If positive-switching outputs are used, muting lamps must be switched with the aid of optocouplers (e.g. PHOENIX power couplers, type ST-0V-2, Art. No , 24 VDC/24 VDC 5 A). With negative-switching outputs (e.g. output xx.06 and xx.07 on the SafetyBUS p module PSS SB DI8O8), the muting lamps can be switched directly. See example: Monitoring muting lamps in Chapter 8. Wiring diagram 24 V DC Positiveswitching output LMP1 Input FbL1 Input FbL2 Positiveswitching output LMP2 0 V DC Fig. 6-9: Wiring diagram Function The block uses feedback inputs (input parameters FbL1 / FbL2) to monitor the filaments on two muting lamps (output parameters LMP1 / LMP2). Monitoring occurs in both the off state (input parameter ON = 0) and the on state (input parameter ON = 1). In the off state, 1-Potential must be present at the feedback input. In the on state, the output through which the muting lamp is driven will be switched off and checked. This happens every 12 seconds; the time is not adjustable. If the filament is in order, 1-potential is present at the feedback input. If the filament has blown, 0- potential will be present Modular Block System: Hydraulic Presses

229 A warning is issued (output parameter WARN) when a filament has blown. Only the second filament will then be tested every 12 seconds. If the second filament blows, the enable will be removed (output parameter ENBL). The defective muting lamp can be exchanged during operation once the warning has been issued. When it has been exchanged, the warning must be acknowledged via the input parameter RSET. The input parameter 1OUT can be used to determine whether both muting lamps are to be tested simultaneously or alternately. Guidelines for the design and layout of the muting lamps Muting lamps should be positioned in such a way that the machine operator can see the muting lamps from any standard position, whenever the muting function is being performed. We therefore recommend the use of signals which emit light all round; these are available in different designs from various manufacturers. These signal lights can often be combined in a modular structure to form multilevel signal systems, with lights in various colours. With a three-stage signal system, both muting lamps and the warning lamp for displaying a failed lamp could be combined, for example. INFORMATION Muting lamps that use LEDs for illumination cannot be monitored using SB097. Modular Block System: Hydraulic Presses 6-167

230 Standard Function Blocks SB097 Error messages Any fault that is detected will be stored in the corresponding error data word (SSNR) of DB015 (1st data block), until the fault has been fully dealt with. Error messages in DB015 - Bit 00: Broken filament, wiring error or optocoupler fault on muting lamp 1 Remedy: Change muting lamp, then reset. If the error is still present: Check the cabling, then reset. If the error is still present and an optocoupler has been used: Check the optocoupler, then reset - Bit 01: Broken filament, wiring error or optocoupler fault on muting lamp 2 Remedy: Change muting lamp, then reset. If the error is still present: Check the cabling, then reset. If the error is still present and an optocoupler has been used: Check the optocoupler, then reset - Bit 02: Fault on logic element of muting lamp 1 (e.g. defective optocoupler) Remedy: Check cabling, then reset. If the error is still present: Check the optocoupler and output module, then reset - Bit 03: Fault on logic element of muting lamp 2 (e.g. defective optocoupler) Remedy: Check cabling, then reset. If the error is still present: Check the optocoupler and output module, then reset Modular Block System: Hydraulic Presses

231 - Bit 04: Fault driving the muting lamps / external power source at the feedback inputs Remedy: Check the cabling, optocoupler and output module, then reset - Bit 05: I/O-Group in STOP (SafetyBUS p) Remedy: Clarify reason for I/O-Group stop, then start I/O- Group Error messages on the CPU-display - None Global parameters used in administration data block DB 015 None Blocks required DB015: Administration data block DB015 must consist of its total length of 1024 data words. DB015 must have READ/WRITE access. Modular Block System: Hydraulic Presses 6-169

232 Standard Function Blocks Timing diagrams I/O-Group status flag = 1 (GRP = 1) Normal operation without lamp failure 1 ON 1 FbL1 1 FbL2 1 1OUT 1 RSET 1 ENBL 1 WARN 1 LMP1 1 LMP2 Switch-off tests Fig. 6-10: Normal operation without lamp failure Lamp failure 1 ON 1 FbL1 1 FbL2 1 1OUT 1 RSET 1 ENBL 1 WARN 1 LMP1 1 LMP2 Fig.6-11: Lamp failure Fault lamp 1 Fault lamp 2 Switch-off tests Lamps replaced Modular Block System: Hydraulic Presses

233 Link Blocks Check list Safety regulations - Which safety regulations need to be met? - Aid: Relevant standards and regulations. Selecting standard function blocks - Which safety devices or process functions need to be supported? Aid: Consult plant and machinery plans. - Which standard function blocks should be used? Aid: Consult sample programs in Chapter 8. - Is the contact arrangement on the operator elements suitable for the standard function blocks? - Does the PSS have the correct I/O arrangement? Start up the failsafe section of the programming device - Enter password. Load project into programming device - Aid: Use Change Project from the project menu. Import all the blocks you need into the project - Aid: Use Import from the project menu. Link the project allocation table to the block allocation table - Aid: Use Import from the project menu. - Does the allocation table contain all the operands and tags? Tip: Logic signals may be linked symbolically. Adapt the allocation table to the wiring plan - Adapt the I/Os in the allocation table. Aid: Allocation table editor. - Keep reserved flags free (do not use for your own applications). Configure system - Call up the configurator - Enter the set layout configuration - Enter the test pulse allocation - Enter preliminary run times for test purposes. Modular Block System: Hydraulic Presses 7-1

234 Link Blocks These can be optimised during commissioning. - Enter a minimum scan time. - If test pulses are to be connected to the 3 ms inputs (E x E x.31): Make sure the DI test time is set correctly. Establish the sequence in which the blocks will be called up - MBS blocks must be run through as part of each cycle. - Aid: Flow chart and listing. Create a supervisory (master) block - The master block should be either a PB or an FB (if parameters are required: FB). - Call up the blocks in the correct sequence and set parameters for them Assign a different number to each block SSNR ( ) Document the SSNR you have used If necessary, combine the enable output parameters (FG/ENBL) into suitable groups by means of a logic AND-operation. - Remember to take into account any links which have already been made. - Enter details on the operation of the selected fault indicator Import / set up DB015 or DB015/DB016/DB017 in the project - DB015/DB016/DB017 must always contain 1024 data words - DB015/DB016/DB017 must have READ/WRITE status Create OB120 If necessary, add SB070 or SB071 call. 7-2 Modular Block System: Hydraulic Presses

235 Create OB101 - Reset all enable flags (FG/ENBL) at the start of the OB or at the start of the cycle. This way you can be sure that the FG flags are indeed set. INFORMATION On some blocks (e.g. E-STOP) the input parameter SSNR is monitored (see the description of the relevant SB in Chapter 6). These blocks must be run through as part of each PSS cycle. The following commands should therefore be entered once only at the end of OB101: DB015 DW1015 A I - Call up the E-STOP standard function blocks directly in OB101 or, for example, global call in an FB. - Check: Have all the blocks required for the application been called up? Things to note when starting up the program Tip: - On start up, the PSS clears all the flag words, outputs, timers and counters in the FS section. All the necessary constants should therefore be set when starting up the program. Link Project INFORMATION - All safety devices should be checked to ensure they operate correctly. - Short-circuits and open circuits should be simulated. Modular Block System: Hydraulic Presses 7-3

236 Link Blocks Notes 7-4 Modular Block System: Hydraulic Presses

237 Examples Applications and parameters of individual blocks The following examples are designed to show the application and parameters of individual standard function blocks. The voltage supply to the PSS and the reset input E 0.31 are not shown in the wiring diagrams for the sake of clarity. Many of the following diagrams state the category for which the circuitry is designed, in accordance with EN 954-1, 03/97. For details of how this relates to the corresponding AK requirement class (DIN V , 05/94), please refer to the table in the Appendix. NOTICE It is important to note that the categories stated refer exclusively to the PSS circuitry and the parameters set on the SBs. To achieve the corresponding category throughout the whole system, all safety-related components/devices (e.g. E-STOP button, safety limit switch etc.), plus the whole of the application program must be considered in the assessment (approved SBs do not need to be tested). Pilz cannot accept responsibility for classifying installations into particular categories. Modular Block System: Hydraulic Presses 8-1

238 Examples Emergency stop monitoring with manual start (start-up and operation), category 4 Block used: SB061/NA_1 INFORMATION The E-STOP in this example is designed for category V E-STOP 1 2 Reset E0.01 E0.02 E0.03 E0.04 E0.31 PSS pulsed outputs A1.00 A1.01 Fig. 8-1: Wiring diagram 8-2 Modular Block System: Hydraulic Presses

239 1 E E E E E M PSS- START Fig. 8-2: Timing diagram Program: KB E 0.31.START - E 0.01.E-STOP1 - E 0.02.E-STOP1 - M RLO-1 - M RLO-0 - SB061 NA_1 B - SSNR X - EIN X - S1_Ö X - S2_Ö X - QAnf X - QAut FG - X - M NA_1 KB E 0.31.START - E 0.03.E-STOP2 - E 0.04.E-STOP2 - M RLO-1 - M RLO-0 - SB061 NA_1 B - SSNR FG - X X - EIN X - S1_Ö X - S2_Ö X - QAnf X - QAut Insert the following additional commands: : L M80.00.NA_1 : U M80.01.NA_2 : = M80.02.NA_GES - M NA_2 Insert the following additional commands at the end of OB101: : A DB015 : I DW1015 Modular Block System: Hydraulic Presses 8-3

240 Examples Emergency stop monitoring with automatic start-up, manual start (operation) and function test, category 4 Block used: SB063/E-STOP INFORMATION The E-STOP in this example is operated to category V E-STOP 1 RSET E40.01 E40.02 E40.07 PSS pulsed outputs T0 T1 Fig. 8-3: Wiring diagram 8-4 Modular Block System: Hydraulic Presses

241 E E E M M PSS-Start Fig. 8-4: Timing diagram Program: KF M SBUS_Grp_01 E E-STOP1 - E E-STOP1 - M RLO-1 - M RLO-0 - M RLO-1 - E Reset - SB063 E-STOP W - SSNR X - GRP X - NC_1 X - NC_2 X - AuSt X - ARSt X - FTST X - RSET ENBL - X - M E-STOP_1 Modular Block System: Hydraulic Presses 8-5

242 Examples Feedback loop monitoring (shutdown with two contactors connected in series), category 4 Block used: SB065/FBL INFORMATION To achieve category 4, two independent shutdown routes must be available within the current path of the potentially dangerous drive. This can be achieved, for example, by connecting two contactors in series. Please note: The feedback loops must be wired inside the control cabinet. L1 24 V K-M1.1 FBL K-M1.1 FBL K-M1.2 M1 START K-M1.2 E0.01 E0.02 E0.08 PSS A1.00 A1.08 M1 M K-M1.1 K-M1.2 N Fig. 8-5: Wiring diagram 8-6 Modular Block System: Hydraulic Presses

243 PSS- START E0.01 E0.02 E0.08 E0.31 M72.01 A1.00 A Fig. 8-6: Timing diagram Program: SB065 FBL KF M RLO-1 - E 0.08.M1_ON - E 0.01.FbL-K-M1.1 - E 0.02.FbL-K-M1.2 - KF Mon.Time - E 0.31.Reset W - SSNR X - GRP X - ON X - FbL1 X - FbL2 W - TFbL X - RSET ENBL - X K1 - X K2 - X - M FG-M1 - A 1.00.K-M1.1 - A 1.08.K-M1.2 Modular Block System: Hydraulic Presses 8-7

244 Examples Feedback loop monitoring (shutdown with two main contactors connected in series and pulsed outputs), category 4 Block: SB067/RFK_K4 INFORMATION If wired outside the control cabinet, or if there is any possibility of a short circuit, the feedback loops must be allocated pulsed outputs (A0.16 and A0.17); this must be entered in the configurator (DB002). L1 24 V K-M1.1 RFK K-M1.1 RFK K-M1.2 M1 START K-M1.2 E0.01 E0.02 E0.08 PSS pulsed outputs + A A0.16 A0.17 M1 M K-M1.1 K-M1.2 N Fig. 8-7: Wiring diagram 8-8 Modular Block System: Hydraulic Presses

245 PSS- 1 START START0 E E0.010 E E E00.08 E E00.31 E M72.01 M A01.16 A Fig. 8-8: Timing diagram Program: SB 067 RFK_K4 KB 006 E 0.01.RFK-K-M1.1 - E 0.02.RFK-K-M1.2 - E 0.31.Reset - E 0.08.M1_START - B - SSNR X - RFK1 X - RFK2 X - RSet X - Ein FG - X K - X - M FG-M1 - A 1.16.K-M1.1/2 Modular Block System: Hydraulic Presses 8-9

246 Examples Feedback loop monitoring (selective shutdown), category 4 Block used: SB067/RFK_K4 WARNING! If only one contactor is used to switch a potentially dangerous drive, it must be possible to switch this contactor off via a group contactor situated within the current path. This group contactor must be controlled with the AND-linked FG-signals of the individual main contactors and must be monitored with a feedback loop. The subordinate main contactors may only switch on if the group contactor monitor FG = 1. The switch-on signal from the subordinate contactors must form an AND-connection with the FG-signal from the group contactor and must be assigned to the Ein-parameter of the main contactor monitor. If only one feedback loop is used, the feedback input will be connected to RFK1 and RFK2. Please note: The feedback loops must be wired inside the control cabinet. If this is not possible, the feedback loops must be pulsed. L1 24 V K-G1 RFK K-G1 M1.1 START RFK K-M1.1 M1.2 START RFK K-M1.2 K-M1.1 K-M1.2 E0.0 E0.8 E0.1 E0.9 E0.2 PSS + A A A M1.1 M1.2 M M K-G1 K-M1.1 K-M1.2 N 0 V Fig. 8-9: Wiring diagram 8-10 Modular Block System: Hydraulic Presses

247 Program: Motor 1.1 :Segment 01 : L A 1.16.K-G1 K-M1.1 switches on if K-G1 is 1 and : U E 0.08.M1.1_Start start command (here E 0.08) is 1. : = M K-M1.1_Start : CAL SB 067 SB 067 RFK_K4 KB 008 E 0.01.RFK-K-M1.1 - E 0.01.RFK-K-M1.1 - E 0.31.Reset - M K-M1.1_Start - B - SSNR X - RFK1 X - RFK2 X - RSet X - Ein FG - X K - X - M FG-M1.1 - A 1.17.K-M1.1 Motor 1.2 :Segment 02 : L A 1.16.K-G1 K-M1.2 switches on if K-G1 is 1 and : U E 0.09.M1.2_Start the start command (here E 0.09) is 1. : = M K-M1.2_Start : CAL SB 067 SB 067 RFK_K4 KB 009 E 0.02.RFK-K-M1.2 - E 0.02.RFK-K-M1.2 - E 0.31.Reset - M K-M1.2_Start - B - SSNR X - RFK1 X - RFK2 X - RSet X - Ein FG - X K - X - M FG-M1.2 - A 1.18.K-M1.2 Group 1 :Segment 03 : L M FG-M1.1 K-G1 can only switch on if K-M1.1 and : U M FG-M1.2 K-M1.2 are error-free. : = M K-M1.2_Start Modular Block System: Hydraulic Presses 8-11

248 Examples : CAL SB 067 SB 067 RFK_K4 KB 010 E 0.00.RFK-K-G1 - E 0.00.RFK-K-G1 - E 0.31.Reset - M FG - B - SSNR X - RFK1 X - RFK2 X - RSet X - Ein FG - X K - X - M FG-G1 - A 1.16.K-G Modular Block System: Hydraulic Presses

249 Notes Modular Block System: Hydraulic Presses 8-13

250 Examples E-STOP monitoring with monitoring of feedback loop, category 4 Block used: SB061/NA_1 and SB067/RFK_K4 WARNING! When a safety-related device provides a start or restart signal, the start or restart shall take place automatically only if a hazardous situation cannot exist (EN 954, 03/97). L1 24 V K-M1.1 K-M1.2 E-STOP Reset E0.01 E0.02 E0.03 E0.06 PSS A A pulsed outputs A1.00 A1.01 M1 M K-M1.1 K-M1.2 N Feedback loop Fig. 8-10: Wiring diagram 8-14 Modular Block System: Hydraulic Presses

251 PSS- 1 START 1 E E M E E M A1.16 Fig. 8-11: Timing diagram Program: SB 061 NA_1 KB M RLO-1 - E 0.01.E-STOP - E 0.02.E-STOP - M RLO-0 - M RLO-1 - B - SSNR X - EIN X - S1_Ö X - S2_Ö X - QAnf X - QAut FG - X - M SB 067 RFK_K4 KB 012 E 0.03.F/back loop - E 0.03.F/back loop - E 0.06.Reset - M FG - B - SSNR X - RFK1 X - RFK2 X - RSet X - Ein FG - X K - X - M A 1.16 Modular Block System: Hydraulic Presses 8-15

252 Examples Safety gate monitoring with manual start and manual restart, category 2 Block used: SB066/ST_K4 Cyclical function test on the gate: The following application requires a cyclical function test of the safety gate (open/close gate). This requirement is met by carrying out a function test at appropriate intervals using a 1/0-pulse edge at the input parameter MEin. Set operating mode: The following operating mode is set for this application: ARSt = 0: NFkT = 0 AuSt = 0 Reset lock activated (manual reset) The operator has to reset each time the safety gate opens (input parameter Strt). A function test is required. When the PSS is started up or reset, the operator is forced to carry out a function test on the gate before starting. Start-up disabler activated (manual start) The operator must reset each time the PSS is started up or reset (input parameter Strt) Modular Block System: Hydraulic Presses

253 24 V Plant in operation Reset Close gate E0.00 pulsed output A1.00 E0.02 E0.03 PSS Fig. 8-12: Wiring diagram 1 PSS Start 1 E E E M80.00 Fig. 8-13: Timing diagram Modular Block System: Hydraulic Presses 8-17

254 Examples Program: SB 066 ST_K4 KB E 0.00.Gate switch 1 - E 0.00.Gate switch 1 - KF Sync. time - E 0.02.Machine running - E 0.03.Reset - M Reset lock - M Start-up disabler - M F-Test - B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M Modular Block System: Hydraulic Presses

255 Notes Modular Block System: Hydraulic Presses 8-19

256 Examples Safety gate monitoring with automatic start and manual restart, category 2 Block used: SB066/ST_K4 Cyclical function test on the gate: The following application requires a cyclical function test of the safety gate (open/close safety gate). This requirement is met by carrying out a function test using a 1/0-pulse edge at the input parameter MEin. Set operating mode: The following operating mode is set for this application: ARSt = 0: NFkT = 1 AuSt = 1 Reset lock activated (manual restart) The operator must reset each time the safety gate opens (input parameter Strt). No function test on safety gate when PSS starts up/resets Automatic start WARNING! When a safety-related device provides a start or restart signal, the start or restart shall take place automatically only if a hazardous situation cannot exist (EN 954, 03/97) Modular Block System: Hydraulic Presses

257 24 V Plant in operation Reset Close gate E0.00 pulsed output A1.00 E0.02 E0.03 PSS Fig. 8-14: Wiring diagram 1 PSS Start 1 E E E M80.00 Fig. 8-15: Timing diagram Modular Block System: Hydraulic Presses 8-21

258 Examples Program: SB 066 ST_K4 KB E 0.00.Gate switch 1 - E 0.00.Gate switch 1 - KF Sync. time - E 0.02.Machine running - E 0.03.Reset - M Reset lock - M Auto. start - M No F-Test B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M Modular Block System: Hydraulic Presses

259 Notes Modular Block System: Hydraulic Presses 8-23

260 Examples Safety gate monitoring with manual start and manual restart, category 4 Block used: SB064/S_GATE Cyclical function test on the gate: The following application does not require a cyclical function test on the gate. However, should you wish to use this function, you should assign the Machine running signal to the input parameter MEin. Set operating mode: The following operating mode is set for this application: ARSt = 0: NFkT = 1 AuSt = 0 Reset lock activated (manual restart) The operator must reset each time the safety gate opens (input parameter Strt). No function test on safety gate when PSS starts up/resets Start up disabler activated (manual start) The operator must reset each time the PSS is started up or resets (input parameter Strt) Modular Block System: Hydraulic Presses

261 24 V Reset Close gate E33.00 E33.01 E33.03 PSS SB DI8O8 Pulsed outputs T0 T1 Fig. 8-16: Wiring diagram PSS Start M E33.00 E33.01 E33.03 M Fig. 8-17: Timing diagram Modular Block System: Hydraulic Presses 8-25

262 Examples Program: SB064 S-GATE KF M SBUS_Grp_31 - E33.00.Gate-Switch 1 - E33.01.Gate-Switch 2 - KF Synch.-Time - M RLO-0 - M StartDisabler - M ResetLock - M No F-Test - E33.03.Reset - W - SSNR X - GRP X - S1 X - S2 W - SyTi X - MRun X - AuSt X - ARSt X - NoFT X - RSET ENBL - X - M Modular Block System: Hydraulic Presses

263 Notes Modular Block System: Hydraulic Presses 8-27

264 Examples Safety gate monitoring with automatic start and manual restart, category 4 Block used: SB066/ST_K4 Cyclical function test on the gate: The following application does not require a cyclical function test on the gate. However, should you wish to use this function you should assign the Machine running signal to the input parameter MEin. Set operating mode: The following operating mode is set for this application: ARSt = 0: NFkT = 1 AuSt = 1 Reset lock activated (manual restart) The operator must reset each time the safety gate opens (input parameter Strt). No function test on safety gate when PSS starts up/resets Automatic start WARNING! When a safety-related device provides a start or restart signal, the start or restart shall take place automatically only if a hazardous situation cannot exist (EN 954, 03/97) Modular Block System: Hydraulic Presses

265 24 V Reset Close gate E0.00 E0.01 PSS Pulsed outputs A1.00 A1.01 E0.03 Fig. 8-18: Wiring diagram 1 PSS Start 1 E E E M80.00 Fig. 8-19: Timing diagram Modular Block System: Hydraulic Presses 8-29

266 Examples Program: SB 066 ST_K4 KB E 0.00.Gate switch 1 - E 0.01.Gate switch 2 - KF Sync. time - M RLO-0 - E 0.03.Reset - M Reset lock - M Auto. start - M No F-Test - B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M Modular Block System: Hydraulic Presses

267 Notes Modular Block System: Hydraulic Presses 8-31

268 Examples Safety gate monitoring with manual start and manual restart, category 4 Block used: SB066/ST_K4 Cyclical function test on the gate: The following application does not require a cyclical function test on the gate. However, should you wish to use this function you should assign the Machine running signal to the input parameter MEin. Set operating mode: The following operating mode is set for this application: ARSt = 0: NFkT = 1 AuSt = 0 Reset lock activated (manual restart) The operator must reset each time the safety gate opens (input parameter Strt). No function test on safety gate when PSS starts up/resets Reset disabler activated (manual start) The operator must reset each time the PSS is started up or restarted (input parameter Strt) Modular Block System: Hydraulic Presses

269 24 V Reset Reset E0.00 E0.01 E0.04 E0.05E0.06 E0.03 PSS Pulsed outputs A1.00 A1.01 Close gate Close gate Fig. 8-20: Wiring diagram Modular Block System: Hydraulic Presses 8-33

270 Examples 1 PSS Start 1 E E E M E E E M M80.02 Fig. 8-21: Timing diagram 8-34 Modular Block System: Hydraulic Presses

271 Program: SB 066 ST_K4 KB E 0.00.Gate switch E 0.01.Gate switch KF Sync. time - M RLO-0 - E 0.03.Reset - M Reset lock - M Start-up disabler - M No F-Test - B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M FG_ST1 SB 066 ST_K4 KB E 0.04.Gate switch E 0.05.Gate switch KF Sync. time - M RLO-0 - E 0.06.Reset - M Reset lock - M Start-up disabler - M No F-Test B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M FG_ST2 :L M FG_ST1 :U M FG_ST2 := M FG_GES_ST Modular Block System: Hydraulic Presses 8-35

272 Examples Safety sensors PSEN 2.1p-10 and PSEN 2.1p-11 with block SB066 (ST_K4) This example explains some of the special features when incorporating the safety sensor PSEN 2.1p into the application program. In this case the safety sensor is assigned to the failsafe standard function block SB066. Please note the following safety guidelines: CAUTION! Block used: SB066/ST_K4 The safety sensor should only be operated in conjunction with an approved evaluation device (in this case the PSS with SB066)! The safety sensor should always be used dual-channel, irrespective of the required category! Cyclical function test on the gate: Set operating mode: The following application does not require a cyclical function test on the gate. However, if you need this requirement, the Machine running signal should be assigned to the input parameter MEin. The following operating mode is set in this application: ARSt = 0: NFkT = 1 AuSt = 0 Reset lock activated (manual restart) The operator must acknowledge each opening of the safety gate (input parameter Strt). No function test of the safety gate on PSS cold start/warm start Start-up disabler activated (manual reset) The operator must acknowledge each PSS cold start/warm start (input parameter Strt) Modular Block System: Hydraulic Presses

273 24 V Safety sensor not operated E0.00 E0.01 (E33.00) (E33.01) (T/p 1) A1.00 (T/p 2) A1.01 Reset PSS E0.03 (E33.03) pulsed outputs Fig. 8-22: Circuit diagram (descriptions in brackets only for the SafetyBUS p example) 1 PSS Start 1 E E E M80.00 Fig. 8-23: Timing diagram (E 33.03, M and M only for the SafetyBUS p example) Modular Block System: Hydraulic Presses 8-37

274 Examples Program PSS 3000/3100 example INFORMATION As the input circuit between sensor connections 3 and 4 is designed as an unoperated N/C contact, this input signal must be inverted before calling SB 066. LN E0.00 PSEN_CH1 Safety gate contact channel 1 = M MPSENCH1 Flag for safety gate signal channel 1 CAL SB066 SB066 ST_K4 KB003 - M99.00.MPSENCH1 - E0.01.PSEN_CH2 - KF03000.Syn.Time - M RLO_ZERO - E0.03.Reset - M RLO_ZERO - M RLO_ZERO - M RLO_ONE - B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M Modular Block System: Hydraulic Presses

275 SafetyBUS p example INFORMATION On decentralised DI inputs, input statuses are only available to the PSS after a group start has taken place. However, due to the inversion of the input signal between sensor connections 3 and 4, input parameter S1 will show RLO = 1 and input parameter S2 RLO = 0. The inverted input statuses will therefore need to be AND-linked to the respective group flags. LN E33.00 PSEN_CH1 Safety gate contact channel 1 U M SBp_IO-Group SBp Status-M I/O-Group 31 = M MPSENCH1 Flag for s/gate signal channel 1 L E33.01 PSEN_CH2 Safety gate contact channel 2 U M SBp_IO-Group SBp Status-M I/O-Group 31 = M MPSENCH2 Flag for s/gate signal channel 2 CAL SB066 SB066 ST_K4 KB003 - M99.00.MPSENCH1 - M99.01.MPSENCH2 - KF03000.Syn.Time - M RLO_0 - E0.03.Reset - M RLO_0 - M RLO_0 - M RLO_1 - B - SSNR X - S1 X - S2 W - SyTi X - MEin X - Strt X - ARSt X - AuSt X - NFkT FG - X - M Modular Block System: Hydraulic Presses 8-39

276 Examples ESPE/AOPD in guard mode with automatic function test (SB068) Block used: SB068/BWS_AOS Set operating mode: The following operating mode is set for this application: OFF = 0 ESPE/AOPD has guard function and reset lock GdO = 1 (Guard Only) SBrk = 0 The signal must come from a connected operating mode DBrk = 0 selector switch block (e.g. SB 051). SSeq = 0 Start-up disabler / function test ARSt = 0 Reset lock Automatic test in guard-only mode: The input parameter Test should be assigned the enable signal (UNsignal). With eccentric presses, this input should be assigned the output parameter UN from SB074, for example. Sequence: Test input (input parameter Test) = 0/1-pulse edge change at UN signal. A change in the pulse edge at the UN signal activates the automatic test of the ESPE/AOPD in each cycle. SB068 detects the change in the pulse edge SB068 detects the change in the pulse edge at the test input and sets the test output (output parameter TEST) from a 1-signal to a 0-signal. This switches off the ESPE/AOPD's emitter (test start). ESPE/AOPD's emitter switched off (significance) Switching off the ESPE/AOPD's emitter simulates access into the protected field. The ESPE/AOPD must react to this simulated access (refer also to Global parameter DW 1006 in Chapter 4). Reaction of the ESPE/AOPD Both the N/O contacts on the ESPE/AOPD (input parameter NO_1 and NO_2) must change from a 1-signal to a 0-signal. As soon as both input parameters (NO_1 and NO_2) show a 0-signal, the ESPE/AOPD's emitter will be switched back on via the test output (output parameter TEST: 0/1-pulse edge). The block enable output parameter ENBL will go to a 0-signal (no block enable) Modular Block System: Hydraulic Presses

277 Block enable - If the input parameters NO_1 and NO_2 return to a 1-signal within the maximum permitted reaction time, the block enable will be triggered (output parameter ENBL = 1). This means that the automatic function test of the ESPE/AOPD has been completed successfully. The maximum permitted duration of the whole test on Type 2 ESPE/ AOPDs is 150 ms (in accordance with EN Section 5.2.4, 06/ 98). - If the ESPE/AOPD does not react within the permitted time, the block enable on the ESPE/AOPD will remain locked (output parameter ENBL = 0). An error message will appear (see also under Error messages in the SB068 description). Setting the block parameters SB068 BWS_AOS KB1 ESPE-N/O1 ESPE-N/O2 OFF mode = 0 GdO mode = 1 SBrk mode = 0 DBrk mode = 0 Press-ON M (RLO-0) M (RLO-0) M (RLO-0) M (RLO-0) UN-signal Reset button - SSNR - NO_1 - NO_2 OFF GdO SBrk DBrk - RUN - CyRs - SSeq - ARSt - STyp - Test - RSET ENBL - ESPE enabled TEST - Test input of ESPE emitter RdCy - Ready to cycle PWR - Voltage supply to ESPE Modular Block System: Hydraulic Presses 8-41

278 Examples ESPE/AOPD in single break mode with cycle reset via a pulse at top dead centre (TDC) Block used: SB068/BWS_AOS Set operating mode: The following mode is set for this application: OFF = 0 ESPE/AOPD in single break mode GdO = 0 Enabled via a single interruption to the ESPE. SBrk = 1 The signal must come from a connected operating mode DBrk = 0 selector switch block (e.g. SB051). SSeq = 0 Start-up disabler / function test Cycle reset: In this example, the cycle is reset via a pulse at top dead centre. Sequence: Cycle reset Once the cycle is reset (resetting the cycle counter), the pulsed output (output parameter RdCy) will change from a 0-signal to a 1-signal. Start the next cycle If RdCy = 1, the next cycle can be started by accessing the protected field. DANGER! The reset lock must be active throughout the duration of the potentially dangerous movement. The input parameter ARSt should be assigned a static 0-signal (RLO-0). This will activate the reset lock if the protected field is accessed during a potentially dangerous movement Modular Block System: Hydraulic Presses

279 Program: Command L R LN R SPB L SPB S S LABEL Symbolic parameter Cycle reset Cycle reset Top dead centre Pulse edge flag cycle reset = LABEL Pulse edge flag cycle reset = LABEL Pulse edge flag cycle reset Cycle reset :Segment xx SB 068 BWS_AOS KB1 ESPE-N/O1 ESPE-N/O2 OFF mode = 0 GdO mode = 0 SBrk mode = 1 DBrk mode = 0 Press-ON Cycle reset M (RLO-0) M (RLO-0) M (RLO-0) M (RLO-0) Reset button - SSNR - NO_1 - NO_2 OFF GdO SBrk DBrk - RUN - CyRs - SSeq - ARSt - STyp - Test - RSET ENBL - ESPE enabled TEST - Test input of ESPE emitter RdCy - Ready to cycle PWR - Voltage supply to ESPE Modular Block System: Hydraulic Presses 8-43

280 Examples ESPE/AOPD in guard mode with automatic function test (SB069) Block used: SB069/AOPD_GDO Set operating mode: The following operating mode is set for this application: GRP = M (SafetyBUS p I/O-Group 0) GdOn = 1 ESPE/AOPD as guard function with SSeq = 0 start-up disabler/function test and ARSt = 0 reset lock The signal may come from a connected operating mode selector switch block (e.g. SB051). Sequence of automatic function test of the ESPE/AOPD in guard mode: A 0/1-pulse edge at the input parameter Test requests an automatic function test of the ESPE/AOPD. The output parameter TEST (ESPE/AOPD emitter) is switched off. As soon as both input parameters NO_1 and NO_2 (ESPE/AOPDoutputs) show a 0-signal, the output parameter TEST (ESPE/AOPD emitter) will be switched back on again (TEST = 1). The test is complete when both input parameters NO_1 and NO_2 (ESPE/AOPD outputs) show a 1-signal again, i.e. switched on. INFORMATION The block enable output parameter ENBL = 1 for the whole duration of the automatic function test of the ESPE/AOPD. The maximum permitted duration of the whole test on Type 2 ESPE/ AOPDs is 150 ms (in accordance with EN Section 5.2.4, 06/98) Modular Block System: Hydraulic Presses

281 Setting the block parameters: SB069 AOPD_GDO KF1 - SSNR M GRP ESPE-Signal1 - NO_1 ESPE-Signal2 - NO_2 GdOn mode = 1 GdOn KB MTD M (RLO-0) - SSeq M (RLO-0) - ARSt Test requirement - Test Reset button - RSET ENBL - ESPE enabled TEST - Test input of ESPE emitter PWR - Voltage supply to ESPE Modular Block System: Hydraulic Presses 8-45

282 Examples Monitoring muting lamps Blocks used: SB072/MUTING and SB097/MUT_LAMP In this example, the ESPE/AOPD, muting sensor and muting lamps are connected to the SafetyBUS p module PSS SB DI808. The muting lamps can either be driven via the negative-switching outputs (A32.06 and A32.07) or via the positive-switching outputs (A32.02 and A32.03) in conjunction with optocouplers. 24 V Muting Lamp 1 Muting Lamp 2 Reset Lamps Reset Muting E32.04 A32.06 E32.05 A32.07 E33.00 E33.01 PSS SB DI8O8 E32.00 E32.01 E32.02 E32.03 E32.06 E32.07 Muting sensor A32.02 E32.04 A32.03 E V Muting Lamp 1 AOPD Muting Lamp 2 0 V Fig. 8-24: Monitoring muting lamps 6-46 Modular Block System: Hydraulic Presses

283 Block parameters: Muting Lamp: Segment 00 SB097 MUT_LAMP KB002 M SBp-Group_01 M Muting_Active E FL1 E FL2 M RLO-0 E Reset-Lamps - SSNR - GRP - ON - FbL1 - FbL2-1OUT - RSET ENBL - M EnableLamps WARN - M Lamp def. LMP1 - A Lamp 1 (A 32.02) LMP2 - A Lamp 2 (A 32.03) Muting: Segment 01 SB072 MUTING KB001 E AOPD-NO 1 E AOPD-NO 2 E Muting-sensor S1 E Muting-sensor S2 E Muting-sensor P1 E Muting-sensor P2 KF KF KF KF KF M RLO-0 M RLO-0 M RLO-1 MW Aux.Value E Reset-Muting - SNR - NO_1 - NO_2 - MS1 - MS2 - MP1 - MP2 - TS12 - TPSy - TInt - TMut - TOPD - TOff - AuSt - SMd2 - THlp - RSET ENBL - M EnableMuting MAct - M Muting_Active Safety: Segment 02 :L M EnableMuting :U M EnableLamps := M EnableWhole Modular Block System: Hydraulic Presses 6-47

284 Examples Safety gate monitoring with guard locking, automatic start and manual restart, category 4 Block used: SB075/GRD_LCK Cyclical function test on the gate: The following application does not require a cyclical function test on the gate. However, if you need this requirement, the Machine running signal should be assigned to the input parameter MRun. Set operating mode: The following operating mode is set in this application: ARSt = 0: NoFT = 1 AuSt = 1 Reset lock activated (manual restart) The operator must acknowledge each opening of the safety gate (input parameter RSET). No function test on the gate when the PSS is cold/warm started, when the I/O-Group is started or each time the gate is unlocked No start-up disabler (automatic start) WARNING! When a safety-related device provides a start or restart signal, the start or restart shall take place automatically only if a hazardous situation cannot exist (EN 954, 03/97) Modular Block System: Hydraulic Presses

285 24 V Request Reset Standstill signal E0.00 E0.01 E0.02 E0.04 E0.05 E0.08 E0.09 PSS SB DI8O8 Close gate Pulsed outputs A1.16 A pole output A2.16 A1.00 A V Gate status Gd_Lock status Guard locking Modular Block System: Hydraulic Presses 8-49

286 Examples PSS Start E 0.00 E 0.01 E 0.02 E 0.08/E 0.09 E 0.04 E 0.05 M A 2.16 A 1.00 A Key: 1) Hazardous machine movement 2) Request to open 3) Hazardous machine movements stopped. Unlocked 4) Gate open 5) Gate closed 6) Request to lock 7) Reset 8) As Modular Block System: Hydraulic Presses

287 Program: OB101 Zyklisch :A DB 002 :L KF :: DW 0002 :< MW :SPB = Change :I MW :SPA = Next Change : Segment 00 Generate flashing (example): :L M Flashing :=N M Flashing :L KF :T MW Modular Block System: Hydraulic Presses 8-51

288 Examples Next : Segment :CAL SB 063 KF W- SSNR M RLO_ONE - X - GRP E 0.08.Standstill 1 - X - NC_1 E 0.09.Standstill 2 - X - NC_2 M RLO_ONE - X - AuSt M RLO_ONE - X - ARSt M RLO_ONE - X - FTST E 0.05.Reset - X - RSET SB063 E-STOP ENBL - X - M Machine stopped :CAL SB 075 SB075 GRD_LCK KF M RLO_ONE - E 0.00.Gate switch 1 - E 0.01.Gate switch 2 - E 0.02.Gate locked - KF M RLO_ONE - M Machine stopped - E 0.04.Request - M RLO_ZERO - M RLO_ONE - M RLO_ONE - M Flashing - E 0.05.Reset - W - SSNR X - GRP X - S1 X - S2 X - LCKD W- SyTi X - MRun X - STPD X - RQST X - ARSt X - AuSt X - NoFT X - BLNK X - RSET ENBL- UNLK- SGrd - SLck - X - M Enable X - A2.16. Guard locking X - A1.00. Gate status X - A1.01. Gd_Lock status :BE : 8-52 Modular Block System: Hydraulic Presses

289 Appendix Assignment table: category and requirement class In process engineering, safety requirements must conform to DIN V , 01/89 (Basic Safety Requirements for Measurement and Control Protection Devices). Requirement classes in accordance with DIN V , 01/89 may be referred to the categories as per EN 954-1, 11/94. Assignment as per requirements Assignment as per safety measures Risk Class VDI/VDE 2180 I II *2 Requirement Class DIN V Safety Integrity Level IEC *1 *1 *1 Category of Control EN B Fig. 9-1: Assignment table *1 This assignment cannot be definitive. It depends on the system and/or product. *2 Depending on the anticipated extent of damage, requirement class 1 may either be category 1 or may have no safety requirement. Modular Block System: Hydraulic Presses 9-1

290 Appendix Standard function blocks: current versions INFORMATION This manual is intended exclusively for use with the standard function block versions listed below. Older SB versions may differ from the description given in this manual. A description of the changes which have taken place when versions have been upgraded can be found later in the chapter under Changes to the standard function blocks. The version number can be determined from the information stated in the block header of the SB (date and CRC). SB No. Name Date CRC Version Approval to SB051 BA_1AUS F4 1.1 EN954-1 SB052 BA_2AUS BF EN954-1 SB059 2_HAND E1C 1.3 EN954-1 SB061 NA_ D4F9 1.1 EN954-1, IEC EN SB063 E-STOP AB5 1.0 EN954-1, IEC EN SB064 S-GATE F 1.0 EN954-1 SB065 FBL EN954-1 SB066 ST_K EN954-1 SB067 RFK_K A5 1.1 EN954-1 SB068 BWS_AOS EN954-1 SB069 AOPD_GDO E11E 2.0 EN954-1, IEC EN SB070 INIT_MBS D 1.2 EN954-1 SB071 INIT_MBS DF EN954-1 SB072 MUTING CAF3 1.1 EN954-1 SB075 GRD_LCK CDD 1.0 EN954-1, IEC EN SB086 OVERRUN D VBG 7n SB087 H_VALV_S D EN954-1 SB088 H_VALV_D D3F2 1.0 EN Modular Block System: Hydraulic Presses

291 SB No. Name Date CRC Version Approval to SB089 H_VALV_P E8CA 1.0 EN954-1 SB092 ENBL_DEV C9CA 1.0 EN954-1 SB097 MUT_LAMP EN954-1 INFORMATION Always use the current version of the relevant standard function block for your application program. Changes to the standard function blocks INFORMATION When imported into existing projects, new parameters must be set for standard function blocks in which input or output parameters have been amended (additional I/O parameters, notation changed, description changed etc.). Please note: STOP An SB version marked with this symbol can only replace the previous SB version in an existing application program if new parameters are set for it once imported. SB051: Operating mode selector switch, 1 from 8 Version Date CRC E F4 STOP Changes from Version 1.0 to Version 1.1 Name changed from BA_1aus8 to BA_1AUS8 Addition of input parameter TIME. This input parameter enables you to adjust the contact switchover time on the operating mode selector switch. Permitted value range for the contact switchover time: ms Modular Block System: Hydraulic Presses 9-3

292 Appendix Addition of output parameter RSET. This output parameter signals a change in operating mode through a 1- signal for the length of one PSS cycle. SB052: Operating mode selector switch, 2 from 6 Version Date CRC B BB6F STOP BF70 Changes from Version 1.0 to Version 1.1 Name changed from BA_1aus6 to BA_1AUS6 Addition of input parameter TIME. This input parameter enables you to adjust the contact switchover time on the operating mode selector switch. Permitted value range for the contact switchover time: ms Addition of output parameter RSET. This output parameter signals a change in operating mode through a 1- signal for the length of one PSS cycle. Changes from Version 1.1 to Version 1.2 Input parameter TIME Maximum permitted contact switchover time increased from 255 ms to 1023 ms 9-4 Modular Block System: Hydraulic Presses

293 SB059: Two-hand monitoring Version Date CRC A STOP E1C STOP Changes from Version 1.0 to Version 1.1 Name changed from 2_Hand to 2_HAND Addition of input parameter Off. This input parameter allows you to deselect two-hand monitoring or the console. Addition of output parameter OFF. This output parameter indicates whether two-hand monitoring or the console have been deactivated. OFF = 1: Two-hand monitoring/console correctly deselected Changes from Version 1.1 to Version 1.2 Fixed contact synchronisation time implemented. Extended monitoring on PSS start-up/reset when two-hand monitoring / console deselected. Changes from Version 1.2 to Version 1.3 Introduction of input parameter KU_S This input parameter enables you to enter a maximum contact switchover time between the N/O and N/C contacts on pushbuttons. Monitoring on PSS start-up/reset when two-hand monitoring or console is de-selected has been optimised. Modular Block System: Hydraulic Presses 9-5

294 Appendix SB061: Emergency stop monitoring Version Date CRC AC D4F9 Changes from Version 1.0 to Version 1.1 If automatic reset is selected (input parameter EIN = 1 and QAut = 1), the application program no longer locks up if the E-STOP button is pressed and then released in quick succession. Previously this could only be rectified by switching the controller off and then on again. SB063: Emergency stop monitoring Version Date CRC AB5 SB064: Safety gate monitoring Version Date CRC F SB065: Feedback loop monitoring (RFK) Version Date CRC SB066: Safety gate monitoring Version Date CRC Modular Block System: Hydraulic Presses

295 Changes from Version 1.0 to Version 1.1 Transposition of error bit 12 and 13 rectified Automatic start now possible when PSS cold/warm starts i.e. no start-up disabler, no function test and no reset required. SB067: Feedback loop monitoring (RFK) Version Date CRC F A5 STOP Changes from Version 1.0 to Version 1.1 Transposition of error bits 04 and 05 rectified Transposition of error bits 06 and 07 rectified Notation of input parameter SSNr changed to SSNR. SB068: Monitoring ESPE/AOPDs with guarding function Version Date CRC E A3A0 STOP STOP Changes from Version 1.0 to Version 1.1 Name changed from BWS_ÜW to BWS_AOS When the protected field is clear, the SB now expects two 1-signals from the ESPE/AOPD (version 1.0: one 0-signal and one 1-signal) This means that input parameters BWSö and BWSs have been replaced by input parameters NO_1 and NO_2. Modular Block System: Hydraulic Presses 9-7

296 Appendix Each operating mode now has its own individual input parameter. Selection of operating mode is therefore uncoded, i.e. input parameters BA_1 and BA_2 have been replaced by input parameters OFF, GdO, SBrk and DBrk. Addition of input parameter RUN. Function: Static enable for operation of ESPE (RUN = 0: No enable) Input parameter TLÖK renamed CyRs. This parameter is only effective in cycle mode. The input parameter now has no function when an automatic function test of the ESPE occurs. Input parameter TKFG renamed CyEn. Single-channel instead of dual-channel reset, i.e. input parameters QT_1 and QT_2 have been replaced by input parameter RSET. Input parameter AuAL renamed AuSt. Input parameter AQSP renamed ARLk. This input parameter has an important function in cycle mode. The input parameter ARLk gives the signal to the block that the press is carrying out a dangerous movement (closing stroke). Input parameter Swed renamed STyp. Addition of input parameter Test. A 0/1-pulse edge at this input parameter requests an automatic function test of the ESPE/AOPD. This function is only effective in guard only mode (input parameter GdO). Output parameter FG renamed ENBL. Output parameter Test renamed TEST. Output parameter Takt renamed RdCy. Addition of output parameter PWR. This output parameter enables the supply voltage to the ESPE/AOPD to be switched directly via the SB. This has the advantage that the ESPE/ AOPD is separated from the supply in OFF mode and the operator is not lulled into a false sense of security. Cycle mode has been revised. 9-8 Modular Block System: Hydraulic Presses

297 Changes from Version 1.1 to Version 1.2 Sequence of the automatic function test of the ESPE/AOPD has been revised. The output parameter RdCy now signals to the user when the SB is expecting an interruption to the protected field in cycle mode. (input parameter RdCy = 1: SB waiting for protected field to be interrupted). Input parameter CyEn has been removed Input parameter AuSt renamed SSeq Input parameter ARLk renamed ARSt. The function of the input parameter has been inverted. Cycle mode has been revised. Changes from Version 1.2 to Version 1.3 Start-up procedure on STyp=1 has been revised when the cycle time is exceeded. SB069: Monitoring ESPE/AOPDs with guarding function Version Date CRC C E11E STOP Changes from Version 1.0 to Version 2.0 Value range for input parameter SSNR expanded to (Format: Word) New input parameter GRP SB070: Initialisation of administration data block (DB015) Version Date CRC C D640 STOP D STOP Modular Block System: Hydraulic Presses 9-9

298 Appendix Changes from Version 1.0 to Version 1.1: Input parameter SSDB removed Input parameter KUs renamed KU_S Input parameter KURe renamed KU_R Input parameters RVen, SPSV, RPSV, WBan, WBim introduced. Changes from Version 1.1 to Version 1.2: Input parameters SPSV, RPSV, WBan, WBim removed SB071: Initialisation of administration data blocks (DB015/DB016/DB017) Version Date CRC DF40 SB072: Temporary suspension of safety functions (ESPE/AOPD muting) Version Date CRC F0A CAF3 Changes from Version 1.0 to Version 1.1: Monitoring times - TMut Timer Muting - TS12 Time Sequential - TOPD Timer (active) Optoelectronic Protective Device can no longer be deactivated. The value 0 which previously led to deactivation is now interpreted as a time value of 0 ms. When using input parameter TOff (condition: TOff is not statically set to 0), it was previously possible for the control system to switch to a STOP condition with error message F-0C, if SB 072 detected an error at the muting station during parallel muting. This no longer happens. Now, the enable ENBL from SB 072 is reset and the corresponding error bit is set Modular Block System: Hydraulic Presses

299 On parallel muting with sensors (i.e. no star arrangement of MP1 and MP2), it was previously possible for the enable ENBL from SB 072 to be reset and error bit 02 to be set, if gaps in the load occurred when the ESPE/AOPD was released. This no longer happens. Reset with sequential muting If an error occurred (e.g. TS12 elapsed, TMut elapsed, MS1 and MS2 simultaneously) after the start-up of MS1 (ESPE clear) or MS1 and MS2 (ESPE interrupted), previously, a reset was only possible if MS1 was released. Releasing MS1 was often not possible with muting channels, because reverse travel was technically impossible and further forward travel was prevented as there was no enable from SB 072. The enable, however, is only triggered after a reset. Now, a reset is also possible in these cases, so that the enable from SB072 can again be accessed. Gaps in the load with sequential muting When reaching sequential muting mode, muting was previously aborted if the ESPE/AOPD was released for longer than the time stated under TInt. There is now no time limit on the release of the ESPE, provided both muting signals MS2 and MP1 are used with the vehicle. If just one of the muting signals is used, e.g. on entering and leaving, the gaps may not be longer than TInt, as previously. SB075: Controlling and monitoring safety gates with guard locking Version 1.0 Date CRC 9CDD SB085: Driving and monitoring a hydraulic directional control valve SB085 is no longer included in the MBS Hydraulic Press package from Version 2.0. It has been replaced by SB087. Modular Block System: Hydraulic Presses 9-11

300 Appendix SB086: Overrun control on linear-driven presses Version 1.0 Date CRC 5D85 SB087: Driving/monitoring the position of a single hydraulic valve (poppet and directional control valve) Version Date CRC D675 SB088: Driving/monitoring the position of a dual hydraulic valve (poppet and directional control valve) Version Date CRC D3F2 SB089: Driving/monitoring the position of two hydraulic valves (poppet and directional control valves) Version Date CRC E8CA SB092: Enable switch Version Date CRC C9CA 9-12 Modular Block System: Hydraulic Presses

301 SB097: Monitoring muting lamps Version Date CRC Modular Block System: Hydraulic Presses 9-13

302 Appendix Notes 9-14 Modular Block System: Hydraulic Presses

303 Changes to the operating manual Changes from Version III to Version IV The status of standards has been updated throughout the manual. Old New Change page page Feedback loop monitoring SB Information on input circuitry SB Information on input circuitry SB Information on input circuitry SB Information on safety query from E-STOP buttons S SSeq= Danger note, input parameter RLO=0 (M110.00) Information note amended to Warning Wiring for category Function test CyRs=0/1-pulse edge Reset hardware error Other messages Bit 10, Bit Function of SB Table for setting global parameters Use of type 2 ESPE/AOPD for parameter RBWS Wiring the input parameter Set operating mode ARSt= Danger note, potentially dangerous movement Setting the block parameters M (RLO-0) -ARSt Danger note, potentially dangerous movement Setting the block parameters M (RLO-0) -ARSt Danger note, potentially dangerous movement Setting the block parameters M (RLO-0) -ARSt Modular Block System: Hydraulic Presses 9-15

304 Appendix Changes from Version IV to Version V The operating manual was revised. The functionality of SB059, SB072 and SB080 has changed and SB062 was newly incorporated into the package. Other amendments are listed in the table below. Old New Change page page Not to use temporary flags as output parameters 4-6 Assignment of input and output parameters Description of input parameter CyRs Information on NC and NO added Block diagram: FG on SB 074 now goes directly to the static enable StFG 6-4 Example for SB 062 added 6-38 Example ESPE/AOPD in double break mode with cycle reset via the enable signal (on press return) deleted Changes from Version V to Version VI The operating manual was revised and the chapters restructured. New: Chapter 2 Overview and Chapter 5 MBS Basics. Standard function blocks SB063, SB064, SB065 and SB071 have been added to the block package. Changes in Version The operating manual was revised. The functionality of SB 069 was changed. The blocks SB075 and SB086 were newly incorporated into the package Modular Block System: Hydraulic Presses

305 Allocation of safety subroutine numbers enable flags Recommended use of enable flags when working with a Pilz error evaluation package: MW Bit Beispiel: Für SSNR 75 76= ist 78 der 79Merker 80 81M zu verwenden Example: Use flag M77.20 for SSNR = 245 Modular Block System: Hydraulic Presses 9-17

306 Appendix Notes 9-18 Modular Block System: Hydraulic Presses

307

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