Operating instructions AC010S Compact AS-i E-STOP safety module Sachnr. 7390636_/00 05/2007
Contents Safety instructions............................. 3 Installation / Setup............................ 4 Installation / Electrical connection................ 6 Operation.................................... 7 Consideration of the residual error probability.......8 Technical data................................ 9 Scale drawing............................... 10 2
Safety instructions Follow the operating instructions. Non-observance of the instructions, operation which is not in accordance with use as prescribed below, wrong installation or handling can affect the safety of people and the plant. For mounting and prescribed use of the product the notes in the operating instructions must be carefully observed and the applicable technical standards relevant for the application have to be considered. In case of non-observance of notes or standards, specially when tampering with and/or modifying the product any liability is excluded. The unit must be installed, connected and put into operation by a qualified electrician trained in safety technology. After set-up the system has to be subjected to a complete function check. Disconnect the unit externally before handling it. Also disconnect any independently supplied relay load circuits. For installation the requirements according to EN60204-1 must be observed. In case of malfunction of the unit please contact the manufacturer. Tampering with the unit can seriously affect the safety of people and the plant. This is not permitted and leads to an exclusion of liability and warranty. 3
Installation/Setup Only qualified staff is allowed to mount, connect and set up the modules. Applications: The compact AS-i E-STOP safety module (AC010S) is used to detect safety-related switching states. For this purpose a code table is transferred via the AS-i system with 8 x 4 bits which is evaluated by the safety monitor (e.g. AC001S... AC004S). When operated correctly, the system can be used in applications up to the control category 4 according to EN 954-1 or IEC 61508/SIL3 (see notes electrical connection). Attention! Depending on the safety components used the complete safety system can also be classified in a lower safety category! Function and electrical connection: Please refer to all information in the description of the configuration software (E7030S) and the installation instructions of the unit. These documents provide all required instructions concerning installation, configuration, operation and maintenance of the compact AS-i E-STOP safety module. Information on the parameterizable safety functions of the compact AS-i E-STOP safety module can be found in the chapter "Monitoring devices" (two positively-driven NC contacts) of the configuration software manual. Important note: The products described herein are designed to be components of a customized machinery safety-oriented control system. A complete safety-oriented control system may include safety sensors, evaluators, actuators and signalling components. It is the responsibility of each company to conduct its own evaluation of the effectiveness of the safety system. The manufacturer of the compact AS-i E-STOP safety module, his subsidiaries and 4
affiliates are not in a position to evaluate all of the characteristics of a given machine or product. The manufacturer of the AS-i safety module, his subsidiaries and affiliates are not in a position to evaluate all of the characteristics of a machine or product which was not designed by him. The warranty contained in the contract of sale is the sole warranty. Any statements contained herein do not create new warranties or modify existing ones. Maintenance requirement It is a compulsory requirement that the safety function must undergo an operational test at least once a year! Compliance with the complete description of the configuration software, the installation instructions of the AS-i safety monitor and operating instructions of the compact AS-i emergency-stop safety module is mandatory! Operating and indicating elements 4 fixing screws (upper part of the housing) UUU U M12 connector LEDs Emergencystop switch illuminated LED 4 mounting holes Fool-proof emergency-stop switch in accordance with ISO 13850 / EN 418, pull to reset. 5
Mounting Mount the compact AS-i E-STOP safety module on a mounting device. The upper part of the housing must be fixed to the lower part using all four screws! Electrical connection Connect the compact AS-i E-STOP safety module via the M12 connector to the AS-i system. The supply comes from the AS-i system. Do not connect the AS-i potential to an external potential. M12 connector M12 connector 3 AS-i - 2 4 5 1 AS-i + M12 connector Pin AS-i + 1 AS-i - 3 UUU 1 U LED red/led green (cannot be seen when the housing is closed) LED red alarm output 1 Do not change the electrical connections! Data bits Data bit D3 D2 D1 D0 In/Out SI-2 SI-2 SI-1 SI-1/O-1 Activated input channel SI-1 XX00 SI-2 00XX SI-1 und SI-2 0000 none XXXX Bit sequence D3-D0 Activated alarm output Bit sequence D3-D0 O-1 XXX1 X = don't care 6
The code words 0000, XX00 and 00XX cause the AS-i safety monitor to switch the installation into the safe state. For details on the effect of the corresponding data bits on the transmission sequence please refer to the configuration software manual (see the chapter "Monitoring devices"). Addressing When mounted the compact AS-i E-STOP safety module can be addressed via the M12 connector and the jumper cable, e.g. EVC011 using the addressing unit AC1144. Assign a free address between 1 and 31. At the factory the address is set to 0. Addressing via the M12 connector is only allowed when disconnected. Operation Check the safe functioning of the unit. Indication by LEDs on the PCB: LED green: LED red is lit: LED red flashes: LED yellow: LED alarm red: Voltage supply o.k. AS-i communication error, slave does not participate in the "normal" exchange of data, e. g. slave address 0 Periphery fault, e.g. sensor supply overloaded or shorted Inputs switched Alarm output O-1 (unsafe) (Through the host system the alarm output LED can be set as a static or dynamic output) Overload and short circuit of the input supply are signalled to the AS-i master (version 2.1) via the "periphery fault" flag in the status register. Accessories (optional) E-STOP label in four languages (German, English, French, Italian), order no. E7003S. 7
Consideration of the residual error probability to IEC 61508 To calculate the PFD (probability of a dangerous failure) of a safetyrelated function the PFD values of all components used in this function must be taken into account. The probability of a dangerous failure (PFD) is 7,9 x 10-6. The maximum service life (T) is 10 years. The test interval (T 1 ) for this unit corresponds to the maximum life time (T). The unit meets the requirements for SIL 3. Explanation of the abbreviations: PFD = Probability of a dangerous failure SIL = Safety integrity level T = Life time (= service life) T 1 = Test interval (between life testing of the safety function) The PFD values of the other components, especially of the AS-i safety monitor, can be found in the corresponding documentation. 8
Technical data Electrical design Operating voltage Current consumption Inputs Wiring Voltage supply Voltage range Short-circuit protection Input current high/low LED output Supply via AS-i Short-circuit protection Integrated Watchdog Max. current load output LED Operating temperature Protection rating AS-i interface / extended address mode possible AS-i profile I /O configuration ID code AS-i certificate Maximum number of compact AS-i E-STOP modules EMC Housing materials Housing dimensions Connection 9 2 safe inputs/ 1 unsafe LED output 26.5...31.6 V DC < 50 ma DC PNP via AS-i 20 V DC 4 ma - 10 ma red -25...60 C IP 67 version 2.1 / no S-7.B.E 7 [Hex] B.E [Hex] 74601 31 EN 50081-2; EN 50295 PC-GF20 (polycarbonate) 80 x 72 x 105 mm (HxWxD) M12x1 connector
Scale drawing 93,5 58,5 M12x1 72 56 105 66,5 80 10