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Safety Controller User`s Manual

1. 68 MELSEC WS Technical data Table 41 Example for the calculation of the response time of Path 1 of a MELSEC WS safety controller Occurrence Digital inputs Digital outputs General C4000 response time 14 0 ms Robot response time 40 0 ms General Input processing time 6 5 ms Output processing time 4 5 ms When On Off filter 8 0 ms When X1 to X8 is connected at the test output Logic a Safety mats and Switching rails b Testable sensors Type 4 e g L41 2 C All other sensors Total E1 20 5 ms Total A1 44 5 ms Evaluation Response time of the considered input in Path 1 E1 20 5 ms 2 x logic execution time 8 0 ms Response time of logic Delay through logic application Response time of the considered output in Path 1 A1 44 5 ms Total response time 73 0 ms Table 42 Example for the calculation of the response time of Path 2 of a MELSEC WS safety controller Occurrence Message transmitter Digital outputs If EFI functions Response time of the EFI 12 0 ms Robot response time 40 0 ms are used via data source C4000 EFl compatible receiver stand alone Logic devices Constant C4000 1 5 ms Output processing time 4 5 ms Total E2 13 5 Total A2 44 5 ms ms Evaluation Response time of the considered input in Path 2 E2 13 5 ms Response tiie oficale 2 x logic execution time 8 0 ms Delay
2. ssssssssse 31 3 8 WS0 4RO safety relay output module sseee 32 3 8 1 Description ie EH edet dE ede o eub Leo odd 32 3 8 2 Display elements and terminal description sssssssuse 33 4 4 1 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 6 4 1 7 4 2 4 2 1 4 2 2 4 2 3 43 4 3 1 4 3 2 4 3 3 4 4 4 5 4 6 4 6 1 5 1 5 1 1 5 1 2 5 1 3 5 1 4 5 2 5 2 1 5 2 2 6 1 6 2 Connecting DEVICES cic cececcceeeeccceeeeecceeeteecceeeeneceenenecedenenecaeeteneeeeenensees 35 Safety command devices and electro mechanical safety switches 37 Emergency stop pushbuttons e g SICK ES21 sssss 37 Electro mechanical safety switches with and without interlock e g SICK 110 1100 and 11000 38 Enabling switch e g SICK E100 sse 39 Twoshand control 2 iR DH ee ee 40 Safety malts n Deor eene 40 Operating mode selector switch seeene 41 Floating Contacts eb e ee RC ee RD eed 41 Non contact safety sensors sssssssssseeene enne 42 Magnetic safety switches e g SICK RE eeeeese 42 Inductive safety switches e g SICK IN4000 IN40 Direct 43 Transponder e g SICK T4000 Compact T40 Direct 43 Testable single beam photoelectric safety switches 44 Testable Type 2 single beam photoelectric safety switches e g
3. Mount the modules in accordance with EN 50274 The modules are located in a 22 5 mm wide modular system for 35 mm DIN rails to EN 60715 Mounting Dismantling MELSEC WS Figure 15 Mounting the module onto the DIN rail Figure 16 Installing the end clips Make sure that the voltage supply of the MELSEC WS safety controller is switched off Hang the device onto the DIN rail 1 Ensure that the earthing spring contact is positioned correctly 2 The earthing spring contact of the module must contact the DIN rail securely to allow electrical conductivity Latch the module onto the DIN rail by pressing it lightly in the direction of the arrow 3 lf there are several modules slide the modules together individually in the direction of the arrow until the side plug connection latches in Install the end clips on the right and left The following steps are necessary after mounting Completing the electrical connections Configuration See the Safety Controller Setting and Monitoring Tool Operating Manual Checking the installation 54 MELSEC WS Mounting Dismantling 6 2 Steps for dismantling the modules Figure 17 Removing the removable terminals Figure 18 Disconnecting the plug connections lf there are several modules slide the modules away from each other individually in the direction of the arrow until the side plug
4. 3 Limits on Damages a MELCO S MAXIMUM CUMULATIVE LIABILITY BASED ON ANY CLAIMS FOR BREACH OF WARRANTY OR CONTRACT NEGLIGENCE STRICT TORT LIABILITY OR OTHER THEORIES OF RECOVERY REGARDING THE SALE REPAIR REPLACEMENT DELIVERY PERFORMANCE CONDITION SUITABILITY COMPLIANCE OR OTHER ASPECTS OF THE PRODUCTS OR THEIR SALE INSTALLATION OR USE SHALL BE LIMITED TO THE PRICE PAID FOR PRODUCTS NOT AS WARRANTED b Although MELCO has obtained the certification for Product s compliance to the international safety standards IEC61508 and EN954 1 18013849 1 from TUV Rheinland this fact does not guarantee that Product will be free from any malfunction or failure The user of this Product shall comply with any and all applicable safety standard regulation or law and take appropriate safety measures for the system in which the Product is installed or used and shall take the second or third safety measures other than the Product MELCO is not liable for damages that could have been prevented by compliance with any applicable safety standard regulation or law c MELCO prohibits the use of Products with or in any application involving power plants trains railway systems airplanes airline operations other transportation systems amusement equipments hospitals medical care dialysis and life support facilities or equipment incineration and fuel devices handling of nuclear or hazardous materials or chemicals mining and drilling and oth
5. NWARNING Do not touch any terminal while power is on Doing so will cause electric shock Shut off the external power supply for the system in all phases before cleaning the module or retightening the terminal screws Failure to do so may result in electric shock Tighten the terminal screw within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction Safety oriented devices must be suitable for safety related signals A function interruption of safety outputs results in a loss of the safety functions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the safety outputs Wire the MELSEC WS safety controller so that 24 V DC signals cannot unintentionally contact safety outputs Connect the GND wires of the power supply to earth so that the devices do not switch on when the safety output line is applied to frame potential Use suitable components or devices that fulfill all the applicable regulations and standards Actuators at the outputs can be wired single channeled In order to maintain the respective Safety Integrity Level the lines have to be routed in such a manner that cross circuits to other live signals can be excluded for example by routing them within protected areas such as in a control cabinet or in separate sheathed cables N C
6. The Setting and Monitoring Tool and the WSO MPL memory plug are required to configure the MELSEC WS safety controller Configuration and verification of devices that are connected to the safety controller is generally not carried out by using the Setting and Monitoring Tool even if they can be addressed via an RS 232 interface of a MELSEC WS module These devices have their own mechanisms for configuration and verification The exception is formed by the EFI sensors connected to the WSO CPU1 module EFI elements from the elements window These sensors can be configured directly in the Setting and Monitoring Tool by double clicking the icon or alternatively configured and verified locally at the sensor via the RS 232 interface The SICK configuration and diagnostics software CDS is used to this purpose The SICK configuration and diagnostics software CDS included in Setting and Monitoring Tool is the product of SICK For the CDS please contact your local SICK representative see Annex Section 14 5 http Awww sens control com The system configuration of the complete MELSEC WS module with the exception of the EFI compatible devices is only stored in the memory plug This offers the advantage when terminal modules are replaced that the system does not have to be reconfigured The data stored in the memory plug are retained when the voltage supply is interrupted Transfer of configuration information via the EFI interface po
7. 10 to 95 non condensing Climatic conditions to EN 61131 2 55 C 95 rel humidity No corrosive gases Rigidity 5 Hz to 500 Hz tested to EN 61131 2 Enclosure rating to EN IEC 60529 Terminals IP 20 Housing IP 40 Electromagnetic compatibility EN 61000 6 2 EN 55011 Class A Protection class System connection Power input via FLEXBUS without currents to X1 to X8 Two tier tension spring terminals Max 3 3 W Cross circuit of connecting wires Single core or finely stranded 1 x 0 14 to 2 5 mm or 2 x 0 14 to 0 75 mm Finely stranded with ferrules to EN 46228 1 x 0 25 to 2 5 mm or 2 x 0 25 to 0 5 mm Dimensions W x H x D Weight 22 5 x 106 5 x 120 8 mm 150g Input circuit 11 to I8 Input voltage HIGH 13 V DC to 30 V DC Input voltage LOW 5 V DC to 5 V DC Input current HIGH 2 4 mA to 3 8 mA Input current LOW 2 5 mA to 2 1 mA Switching current with mechanical 14 4 mA at 5 V contacts 3mAat 24V Discrepancy times 4 ms to 30 s configurable Number of inputs 8 Technical data Test outputs X1 to X8 MELSEC WS Number of outputs 8 with 2 test pulse generators Output type PNP semiconductor short circuit protected cross circuit monitoring Output voltage 16 V DC to 30 V DC Output current Max 120 mA at each of the two test signal generators X1 X3 X5 X7 or X2 X4 X6 X8 This means
8. 1Hz Valid but unverified Verify configuration with the Setting and configuration Monitoring Tool Yellow Valid and verified configuration Table 6 Assignment Pin assignment of the Plug socket Pin Signal Colour PC sided RS 232 RS 232 interface SubD 9 pins 1 Reserved Brown 2 RxD White Pin 3 GND Internally electrically Blue Pin 5 3 connected with connection A2 of the CPU module 4 TxD Black Pin2 3 5 CPU module WS0 CPU1 3 5 4 Description The WSO CPU1 module has the same functions as the WSO CPUO Please Observe the notes in Section 3 4 In addition this module has 2 EFI interfaces If intelligent SICK sensor equipment is connected a functional extension at the sensors is then possible by simple means For further information about a functional extension refer to the manual for intelligent SICK sensor equipment For further information about EFI interfaces refer to Section 5 1 Transferring the configuration from the Setting and Monitoring Tool to the memory plug and to the connected EFI compatible devices Uploading the configuration from the memory plug and the connected EFI compatible devices to the Setting and Monitoring Tool Diagnostics of the MELSEC WS safety controller with the Setting and Monitoring Tool Note The maximum permissible cable length is 3 m The screen has to be shielded and connected at suitable points to the FE Avoid ground loops between the GN
9. MELSEC Q Operating ambient temperature ambient temperature 25to550 to 55 C 0t59C O to 55 C Operating ambient humidity 10 to 95 RH 5 to 95 RH Storage ambient temperature 25 to 70 C 25 to 75 C Storage ambient humidity 10 to 95 RH 5 to 95 RH 1 When the WS0 GCC100202 is included in the system operating ambient temperature will be 0 to 55 C 2 For the MELSEC QS series programmable controller storage ambient temperature will be 40 to 75 C EMC standards that are applicable to the products differ MELSE MELSEC WS SAN MELSEC PEE EMC standards standards EN61000 6 2 EN55011 6 2 EN55011 ENeM312 2 e SAFETY PRECAUTIONS Read these precautions before using this product Before using this product please read this manual the relevant manuals and the safety standards carefully and pay full attention to safety to handle the product correctly In this manual the safety precautions are classified into two levels NWARNING and NCAUTION Indicates that incorrect handling may cause hazardous conditions resulting WARNING b in death or severe injury Indicates that incorrect handling may cause hazardous conditions resultin NCAUTION gna 9 in minor or moderate injury or property damage Under some circumstances failure to observe the precautions given under A CAUTION may lead to serious consequences Observe the precautions of both levels because they
10. SICK Wx12 18 24 27 ssssssssssseeseeee enne 44 Testable Type 4 single beam photoelectric safety switches 45 Information for mounting testable single beam photoelectric safety SWITCHES ascetur LN E aed eI EVA Ns ite cae et a e 46 Electro sensitive protective equipment ESPE ssssss 48 OUtpults tetto etui inh sur 48 EEI deVIGeS 5i th eee ut ee t teet ud 49 EFI communication and EMC sssssssssesee 49 Special functions edere e ede re pd dns 50 Enhanced Function Interface EFI 50 Definitionen vtta iet md 50 Properties oae id cet Eie end Ld s D e deed 50 FUMGUONS tente oeste ieu studi even hn teh ser LOAD ae ea 51 Bene tits ie cb p tmt tents 51 MUIIFIG tst mere RARE ANNUM i ta ie 52 General description i eei e tad rt ota beoe a aeea eee 52 SICK muting sensors erdia nadari aa A i AE AE 52 Mounting Dismantling eene enn 53 Steps for mounting the modules sssseeen 53 Steps for dismantling the modules sssse 55 Electrical installation ssssssseeeeeme 57 Configuration uuu ee eroe ue dee e ce d d es 59 10 11 9 Commilssioning eak eiir tuac et eaten qe teque edv aun 60 9 1 Full approval of the application 60 9 2 Tests before the initial commissioning eeee 61 10 BEP m 62 10 1 In the event of faults or errors eene 62 10
11. or Off delay function block Response time of the considered output in the signal path Total response time A1 or A2 or A3 from above table 1 Take values from the corresponding manual 2 The update rate between the CPU and a network module depends on the amount of data to be transferred and the number of network module used in the system Take the values from the report in the Setting and Monitoring Tool 3 Time values have a tolerance of 10 ms i e for each selected value 10 ms must be considered additionally for the response time E g for a 10 ms Off delay 20 ms must be used for the calculation 67 Technical data MELSEC WS Example Calculation of the response time for a MELSEC WS safety controller consisting of a WS0 CPU1 and a WSO XTIO Figure 21 Example of a MELSEC WS safety 2omm controller I J InjOut Summary Page y Page 1 Configuration Digital inputs XTIO 1 1516 C4000 One C4000 safety light curtain Digital outputs XTIO 1 Q3Q4 Robot Robot dual channel EFI message transmitter EFI 1 1 OSSD OSS One C4000 receiver stand alone safety light curtain with high resolution for hazardous point hazardous area and access protection at machines 2 paths have to be considered and calculated separately Figure 22 Response times within a MELSEC WS safety controller Digital input EF message transmitter C4000 stand alone receiver Digital output
12. 4 LED has turned off When the K1 2 or K3 4 LED has turned off Annex Figure 46 Flowchart when the PWR LED has turned off 2 When the PWR LED has turned off Refer to the following flowchart when the PWR LED of the safety relay output module has turned off at power on or during operation of the MELSEC WS safety controller PWR LED has turned off Is power supplied to the CPU module Is the safety relay output module securely connected to the module on the left Replace the safety relay output module Supply power How is the PWR LED Connect the safety relay output module to module on the left securely How is the PWR LED MELSEC WS Completed 102 MELSEC WS Figure 47 Flowchart when the K1 2 or K3 4 LED has turned off 103 K1 2 or K3 4 LED has turned off Annex 3 When the K1 2 or K3 4 LED has turned off Refer to the following flowchart when the K1 2 or K3 4 LED of the safety relay output module has turned off at power on or during operation of the MELSEC WS safety controller Are the outputs Supply the outputs from the WSO XTIO input to the from the WSO XTIO B1 or B2 terminal of the to the B1 or B2 terminal WS0 4RO of the WS0 4RO How is the K1 2 or K3 4 LED Replace the safety relay output module Completed 14 5 SICK contact MELSEC WS More representatives and agencies in all major industrialnations at www sick com Australia Phone
13. 8 W Single core or finely stranded 1 x 0 14 to 2 5 mm or 2 x 0 14 to 0 75 mm Finely stranded with ferrules to EN 46228 1 x 0 25 to 2 5 mm or 2 x 0 25 to 0 5 mm Internal bus FLEXBUS Dimensions W x H x D 22 5 x 106 5 x 120 8 mm Weight Power supply unit A1 A2 180 g Supply voltage 24 V DC 16 8 V DC to 30 V DC Type of supply voltage PELV or SELV The current of the power supply unit that supplies the CPU module has to be limited to a maximum of 4 A either by the power supply unit itself or by a fuse Power consumption Switch on time Max 96 W determined by the load at the outputs Q1 to Q4 Max 18s Short circuit protection 4 A gG with tripping characteristic B or C Technical data Input circuit 11 to I8 MELSEC WS Input voltage HIGH 13 V DC to 30 V DC Input voltage LOW 5 V DC to 5 V DC Input current HIGH 2 4 mA to 3 8 mA Input current LOW 2 5 mA to 2 1 mA Switching current with mechanical 14 4 mA at 5 V contacts 3 mA at 24 V Discrepancy times 4 ms to 30 s configurable Number of inputs 8 Test outputs X1 X2 Number of outputs 2 with 2 test pulse generators Output type PNP semiconductor short circuit protected cross circuit monitoring Output voltage 16 V DC to 30 V DC Output current Max 120 mA at a test output X1 or X2 This means that a maximum of 8 testable sensor casc
14. 8 mm 22 5 x 101 7 x 120 8 mm 100 g 110g Power supply A1 A2 via memory plug WSO MPL Supply voltage Type of supply voltage 24 V DC 16 8 V DC to 30 V DC PELV or SELV The current of the power supply unit that supplies the CPU module has to be limited to a maximum of 4 A either by the power supply unit itself or by a fuse Power consumption Max 2 5 W Switch on time Max 18s Short circuit protection 4 A gG with tripping characteristic B or C 70 MELSEC WS Table 44 Data sheet WSO XTIO 71 Technical data 12 2 2 WSO0 XTIO safety input output combined module Category Category 4 EN ISO 13849 1 Category 4 EN 954 1 Safety Integrity Level SIL3 IEC 61508 Performance Level PL e EN ISO 13849 1 PFHd 0 9E 09 1 h double channel 4 8E 09 1 h single channel TM service life 20 years Ambient temperature in operation Storage temperature 25 C to 55 C 25 C to 70 C Humidity 10 to 95 non condensing Climatic conditions Rigidity to EN 61131 2 55 C 95 rel humidity No corrosive gases 5 Hz to 500 Hz tested to EN 61131 2 Enclosure rating to EN IEC 60529 Electromagnetic compatibility Terminals IP 20 Housing IP 40 EN 61000 6 2 EN 55011 Class A Protection class Power input via FLEXBUS without currents to X1 X2 Cross circuit of connecting wires Data interface Ii Max 2
15. Chapter 12 in the sense of Section 2 2 It may only be used by specialist personnel and only at the machine at which it was mounted and initially commissioned by qualified safety personnel in accordance with the MELSEC WS manuals Mitsubishi Electric Corporation accepts no claims for liability if the equipment is used in any other way or if modifications are made to the device even in the context of mounting and installation The external voltage supply of the device must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204 The MELSEC WS safety controller may not start up normally when power is restored immediately after the external power supply has been shut off within 5 seconds To restore the power wait for 5 or more seconds after power off The modules of the MELSEC WS safety controller conform to Class A Group 1 in accordance with EN 55011 Group 1 encompasses all the ISM devices in which intentionally generated and or used conductor bound RF energy that is required for the inner function of the device itself occurs For UL CSA applications Use 60 C 75 C conductors The terminal tightening torque must be 5 to 7 Ibs in To used in a Pollution Degree 2 environment only Memory plug and CPU module shall be supplied by an isolating power source protected by an UL248 fuse rating 42 4VDC which is the maximum voltage requirements of UL508 The safety funct
16. Direct PN OSSD1 IN4000 at I3 with OSSD 4 2E OSSD2 IN4000 at 14 Function Notes Testing Necessary on IN4000 Series connection cascading IN40 direct cannot be cascaded IN4000 up to 6 sensors per input Observe max line resistance of 100 O and correct setting of the test impulse time Max off on delay through a complete chain may not exceed a maximum of 10 ms Further information is available in the manuals of the SICK inductive safety switches or in the manuals of devices used 4 2 3 Transponder e g SICK T4000 Compact T40 Direct Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO T4000 Compact ve n 24 V at LA 11 at LA without testing 24v 3 2 De 24Vat LB I2atLB T4000 Compact with X1 at LA I3 at LA x1 a I3 v testing X2 LR X2 at LB 14 at LB T40 Direct with 24 V at UB T40 I5 at OA 24V I5 aC OSSD 24V a amp E 24V at UB T40 I6 at OB Function Notes Testing Possible for T4000 Compact Not necessary for T40 Direct since self monitored Series connection Cascading T4000 Compact not cascadable Take the max line resistance of 100 Q into account at the T40 see Chapter 12 For further information refer to the manuals of the Transponder SICK T4000 Compact or T40 Direct or in the manuals of devices used Connecting devices Table 34 Connection of testable Type 2 single beam photoe
17. WS safety controller Figure 42 Flowchart when the MS LED has turned on red MS LED of the safety O module has turned on red Decrease the total number of safety I O modules to 12 or less Is the total number of safety 1 0 modules 12 or less On or flashing How is the MS LED Power off the MELSEC WS safety controller and then on Other than on red How is the MS LED On red Power off and then on repeatedly Other than on red How is the MS LED On red Narrow down the troubled module using the Setting and Monitoring Tool and replace the module Completed 98 MELSEC WS Annex 4 When the MS LED is flashing red Refer to the following flowchart when the MS LED of the safety I O module is flashing red at power on or during operation of the MELSEC WS safety controller Figure 43 Flowchart when the MS LED is flashing red MS LED of the safety I O module is flashing red Are all the LEDs for Q1 to Q4 of the safety I O modules within the system flashing Is power Supplied to the A1 and A2 terminals of the safety l O module Supply power to the A1 and A2 terminals of the safetyl O module On green or flashing green Check the input and output Flashing red lines connected to the safety I O module whose MS LED is flashing red How is the MS LED Check the power supply status with a circu
18. a reference for periodical tests 1 This checklist does not replace initial commissioning and regular tests by qualified safety Have the safety rules and regulations been observed in compliance with the directives standards applicable to the machine Are the applied directives and standards listed in the declaration of conformity Does the protective device comply with the required category Are the required protective measures against electric shock in effect protection class Has the protective function been checked in compliance with the test notes in this documentation Especially Functional check of the command devices sensors and actuators connected to the safety controller Testofall switch off paths Are you sure that the safety controller was tested fully for safety functionality after each configuration change personnel Yes Yes Yes Yes Yes Yes No No No No No No Annex MELSEC WS 14 3 Wiring examples 1 Wiring of the emergency stop pushbuttons start switches stop switches and reset switches 8 Dual channel wiring with test pulse outputs Connect emergency stop pushbuttons to the MELSEC WS safety controller as shown below Figure 25 24 V DC Wiring example of aa um emergency stop Connect an emergency stop pushbutton with dual channel equ
19. are elevated REVISIONS The manual number is given on the bottom left of the back cover Print date Manual number Revision September 2009 SH NA 080855ENG A First edition March 2010 SH NA 080855ENG B Addition of description on CC Link interface module Japanese manual version SH 080852 B This manual confers no industrial property rights or any rights of any other kind nor does it confer any patent licenses Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual 2009 MITSUBISHI ELECTRIC CORPORATION CONTENTS SAFETY PREGAUTIONS eir a teer e eae i suec egeta aues 1 CONDITIONS OF USE FOR THE PRODUCT sssssssssee ee 7 REVISIONS 4 dst tst tse dateien nta tentavit laa tte cae 8 CONTENTS idit scu de aa ie dec o AD du ad 9 GENERIC TERMS AND ABBREVIATIONS sss 12 1 About this doc ment iie d ee eee 13 1 1 Function of this document sssssssssssssseeeee 13 1 2 Target group ict etit peste inet ENE E RRN 14 1 3 Depth of information essssssssssesssee eene eene 15 1 4 SCOPE oO Lu E RU de e E e A eee EHE 15 1 5 Abbreviations sed teniente dai sec ad dea ze dedi 16 1 6 Symbols used epi o D n eerte 16 2 On Safety operan edu de I edet LET 17 2 1 Qualified safety personnel ssss
20. are important for personal and system safety Make sure that the end users read this manual and then keep the manual in a safe place for future reference Design Precautions e e NWARNING When the MELSEC WS safety controller detects a fault in the external power supply or itself it turns off the outputs Configure an external circuit so that the connected devices are powered off according to the output status off of the MELSEC WS safety controller Incorrect configuration may result in an accident When a load current exceeding the rated current or an overcurrent caused by a load short circuit flows for a long time it may cause smoke and fire To prevent this configure an external safety circuit such as a fuse For safety relays configure an external circuit using a device such as a fuse or breaker to protect a short circuit current When changing data and operating status and modifying program of the running MELSEC WS safety controller from the PC configure a safety circuit in the sequence program or external to the MELSEC WS safety controller to ensure that the entire system operates safely Before operating the MELSEC WS safety controller read the relevant manuals carefully and determine the operating procedure so that the safety can be ensured Furthermore before performing online operations for the MELSEC WS safety controller from the PC determine corrective actions to be taken for
21. are mounted alternatively ensure that the light beam of Sender S1 cannot be received by Receiver R3 and that the light beam of Sender S3 cannot be received by Receiver R1 Connecting devices MELSEC WS Table 38 Connection of ESPE Note ATTENTION 4 4 Electro sensitive protective equipment ESPE e g SICK C2000 C4000 M2000 M4000 S300 S3000 V300 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO C2000 C4000 OSSD1 receiver at I1 24V El n Ney M2000 M4000 S300 24 12 t OSSD2 receiver at I2 3000 V300 Further information is available in the manual of the corresponding SICK ESPE or in the manuals of devices used 4 5 Outputs Safety oriented devices must be suitable for safety related signals A function interruption of safety outputs results in a loss of the safety functions so that the risk of serious injury exists Do not connect any loads that exceed the rated values of the safety outputs Wire the MELSEC WS safety controller so that 24 V DC signals cannot unintentionally contact safety outputs Connect the GND wires of the power supply to earth so that the devices do not Switch on when the safety output line is applied to frame potential Use suitable components or devices that fulfil all the applicable regulations and standards Actuators at the outputs can be
22. connection is separated 55 Mounting Dismantling MELSEC WS Figure 19 Removing modules from the DIN rail Press the module downwards at the rear 1 and remove it from the DIN rail in the direction of the arrow while keeping it pressed down 2 56 MELSEC WS Electrical installation T Electrical installation 57 ATTENTION Note Switch the entire machine system off line The system could start up unexpectedly while you are connecting the devices The MELSEC WS safety controller fulfils the EMC requirements in accordance with the basic specification EN 61000 6 2 2005 for industrial use To ensure full electromagnetic compatibility EMC the DIN mounting rail has to be connected to functional earth FE The control cabinet or assembly casing of the MELSEC WS safety controller must comply at least with enclosure rating IP 54 Mount the modules in accordance with EN 50274 Electrical installation in accordance with EN 60204 1 The voltage supply of the devices must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204 1 The voltage supply has to fulfil the regulations for extra low voltages with safe separation SELV PELV in accordance with EN 60664 and DIN 50178 equipment of electrical power installation with electronic devices All connected pick ups and downstream controllers as well as wiring and installation must correspond to the required category in a
23. contact your local Mitsubishi representative When you send in a WSO MPL memory plug for repair or analysis it is returned in the state of delivery Therefore store the configuration s of your devices in the Setting and Monitoring Tool 10 3 Error display of the MS and CV status LEDs Error displays and error elimination are described in the individual modules see Section 3 4 to 3 8 62 MELSEC WS 63 Diagnostics 10 4 Additional error displays of EFl compatible devices EF l compatible devices see Section 5 1 have extended functions in connection with the WSO CPU1 module Error displays and error elimination are described in the manuals of the corresponding devices 10 5 Extended diagnostics The Setting and Monitoring Tool contains extended diagnostic possibilities If you cannot identify what kind of error is occurring or if you have serviceability problems it allows you to locate the error more accurately For detailed information refer to the Safety Controller Setting and Monitoring Tool Operating Manual Maintenance MELSEC WS 11 Maintenance The following sections inform about regular tests and the exchange of MELSEC WS modules Do not try to dismantle repair or modify the MELSEC WS modules This can lead to a loss of the safety function s In addition Mitsubishi accepts no claims for liability 11 1 Regular inspection of the protective device by qualified safety personnel Check the system at the in
24. is being carried out Red 1Hz Recoverable external Check the wiring of the flashing inputs and error outputs If all the output LEDs flash check the supply voltage at terminals A1 and A2 of this module Red Critical error in the Switch off the voltage supply of the CPU module and switch it on again If the error is not eliminated after multiple repetitions replace the module In order to narrow down the respective module use the diagnostics display in the Setting and Monitoring Tool Product description Table 10 Displays of the input output LEDs MELSEC WS Input LEDs I1 to I8 Output LEDs Q1 to Q4 Meaning O Input output is inactive Green Green 1 Hz synchronous with the red MS LED Input output is active Input output is inactive and there is a correctable error Green 1 Hz alternatively with the red MS LED Input output is active and there is a correctable error 30 MELSEC WS Figure 7 Display elements WSO0 XTDI 31 Note Product description 3 7 WSO0 XTDI safety input module 3 7 1 Description The WSO XTDI module is the input extension with 8 safe inputs It fulfills the following tasks Monitoring of the connected sensor equipment also refer to Chapter 4 Passing on the input information to the CPU module The WSO XTDI module cannot be used alone and always requires a WSO CPUO or WS0 CPU1 module See the Safety Controll
25. of their respective companies SH NA 080855ENG B MITSUBISHI ELECTRIC HEADQUARTERS EUROPEAN REPRESENTATIVES EUROPEAN REPRESENTATIVES EURASIAN REPRESENTATIVES MITSUBISHI ELECTRIC EUROPE B V German Branch Gothaer Strafe 8 D 40880 Ratingen Phone 4 49 0 2102 486 0 Fax 49 0 2102 486 1120 MITSUBISHI ELECTRIC EUROPE B V CZECH REPUBLIC Czech Branch Avenir Business Park Radlick 714 113a 2 158 00 Praha 5 Phone 420 251551470 Fax 420 251 551 471 MITSUBISHI ELECTRIC EUROPE B V French Branch 25 Boulevard des Bouvets F 92741 Nanterre Cedex Phone 33 0 1 55 68 55 68 Fax 33 0 1 55 68 57 57 MITSUBISHI ELECTRIC EUROPE B V Irish Branch Westgate Business Park Ballymount IRL Dublin 24 Phone 353 0 1 4198800 Fax 353 0 1 4198890 MITSUBISHI ELECTRIC EUROPE B V Italian Branch Viale Colleoni 7 1 20041 Agrate Brianza MB Phone 39 039 60 53 1 Fax 39 039 60 53 312 MITSUBISHI ELECTRIC EUROPE B V Poland Branch Krakowska 50 PL 32 083 Balice Phone 48 0 12 630 47 00 Fax 48 0 12 630 47 01 MITSUBISHI ELECTRIC EUROPE B V Spanish Branch Carretera de Rub 76 80 E 08190 Sant Cugat del Vall s Barcelona Phone 902 131121 34 935653131 Fax 34 935891579 MITSUBISHI ELECTRIC EUROPE B V UK UK Branch Travellers Lane UK Hatfield Herts AL10 8XB Phone 44 0 1707 27 6100 Fax 44 0 1707 27 86 95 MITSUBISHI
26. photoelectric safety switches Note 45 Connecting devices 4 3 2 Testable Type 4 single beam photoelectric safety switches Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO L41 xd Test input TE transmitter at X1 x1 n NC On Output Q receiver at 11 Route the transmitter and receiver lines outside the control cabinet in such a manner that cross circuiting between these lines can be excluded for example in separate sheathed cables or in protected areas Function Notes Testing Necessary Series connection Cascading Max 10 pairs per input Max power up delay of the cascade 12 ms otherwise the test gap will lead to switching off Take the max line resistance of 100 Q into account For further information refer to the manual of the testable Type 4 single beam photoelectric safety switches Connecting devices Note Figure 12 Minimum distance a to reflective surfaces correct mounting and alignment 4 3 3 Information for mounting testable single beam photoelectric safety switches Observe the information for mounting in the manuals of the respective sensors and in particular the following points Single beam photoelectric safety switches may only be used as access protection in accordance with EN 999 Usage as finger and hand protection is not permissible Observe the minimum distance to reflective surfa
27. retains sufficient spare parts for repairs of its Products for a period of four 4 years after production is discontinued MELCO generally announces discontinuation of Products through MELCO s Technical Bulletins Products discontinued and repair parts for them may not be available after their production is discontinued 1 repaired or altered by persons other than MELCO or its authorized engineers or FA Centers 2 subjected to negligence carelessness accident misuse or damage 3 improperly stored handled installed or maintained 4 integrated or used in connection with improperly designed incompatible or defective hardware or software 5 that fails because consumable parts such as relay batteries backlights or fuses were not tested serviced or replaced 6 operated or used with equipment production lines or systems that do not meet applicable and commensurate legal safety and industry accepted standards 7 operated or used in abnormal applications 8 installed operated or used in contravention of instructions precautions or warnings contained in MELCO s user instruction and or safety manuals technical bulletins and guidelines for the Products 9 used with obsolete technologies or technologies not fully tested and widely accepted and in use at the time of the Product s manufacture 10 subjected to excessive heat or moisture abnormal voltages shock excessive vibration physical damage or ot
28. that a maximum of 8 testable sensor cascades per module with max 30 mA each are possible The total current of the MELSEC WS safety controllers is limited to a maximum of 1 28 mA This corresponds to e g 32 inputs of testable sensors with 30 mA each and 64 inputs of WSO XTIO or WSO XTDI modules Test pulse rate 1 Hz to 25 Hz configurable Load capacity 1 uF for test pulse duration 4 ms 0 5 uF for test pulse duration 1 ms Cable resistance lt 1000 74 MELSEC WS Table 46 Data sheet WS0 4RO 75 Technical data 12 2 4 WS0 4RO safety relay output module Supply circuit Supply voltage 24 V DC 19 2 V DC to 30 V DC Safety extra low voltage If WSO 4RO is connected and loading of the output current paths U 25 V AC 60 V DC PELV U 25 V AC 60 V DC SELV PELV Power consumption Max 3 2 W Output circuit 13 14 23 24 33 34 43 44 Y1 Y2 Y3 Y4 Number of NO contacts 4 13 14 23 24 33 34 43 44 Number of NC contacts 2 Y1 Y2 Y3 Y4 Switching voltage 250 V AC 5 V AC to 275 V AC 230 V DC 5 V DC to 275 V DC B1 B2 to drop relay Switching current 10 mAat5V 2 mA at 24 V Max 6A Total current 12A Response time time from LOW at 30 ms Output type Volt free NO contacts positively driven 13 14 23 24 33 34 43 44 Volt free NC contacts positively driven Y1 Y2 Y3 Y4 Contact material
29. to such as an arc caused by switching the relays N CAUTION Use the MELSEC WS safety controller in an environment that meets the general specifications in this manual Failure to do so may result in electric shock fire malfunction or damage to or deterioration of the product Latch the module onto the DIN rail Incorrect mounting may cause malfunction failure or drop of the module To ensure full electromagnetic compatibility EMC the DIN mounting rail has to be connected to functional earth FE Ensure that the earthling contact is positioned correctly The earthling spring contact of the module must contact the DIN rail securely to allow electrical conductivity Shut off the external power supply for the system in all phases before mounting or removing the module Failure to do so may result in damage to the product Do not directly touch any conductive part of the module Doing so can cause malfunction or failure of the module The MELSEC WS safety controller is only suitable for mounting in a control cabinet with at least IP 54 degree of protection Failure to meet the installation method may cause the module to fail or malfunction due to the deposition of dust or the adhesion of water Wiring Precautions N WARNING Shut off the external power supply for the system in all phases before wiring Failure to do so may result in electric shock or damage to the product The sy
30. 12 MELSEC WS About this document 1 About this document Please read the SAFETY PRECAUTIONS Chapter 1 and Chapter 2 carefully before working with this documentation and the MELSEC WS safety controller 1 1 Function of this document For the MELSEC WS safety controller there are three manuals with clearly distinguished fields of application as well as User s Manuals Hardware for each module This manual describes all the MELSEC WS modules and their functions in detail Use this manual in particular to configure MELSEC WS safety controllers except for network modules The manual instructs the technical staff of the machine manufacturer and or of the machine operator on the safe mounting electrical installation commissioning as well as maintenance of the MELSEC WS safety controller The manual does not provide instructions for operating the machine in which the safety controller is or will be integrated Information of this kind will be found in the manuals for the machine The Safety Controller Setting and Monitoring Tool Operating Manual describes the software supported configuration and parameterization of the MELSEC WS safety controller In addition the manual contains the description of the diagnostics functions that are important for operation and detailed information for the identification and elimination of errors Use the manual in particular for the configuration commissioning and operation of MELSEC WS safety c
31. 2 Mitsubishi support sssssssssssseeeemereneen ene emere nennen 62 10 3 Error display of the MS and CV status LEDS 62 10 4 Additional error displays of EFl compatible devices 63 10 5 Extended diagnostics ssssssesssseeeee eene 63 11 Maintenance 2 2 rtc RP tet curte p ate Aaa 64 11 1 Regular inspection of the protective device by qualified safety personnel oio utili remate deste iof tubes 64 11 2 Device replacement sss eene 65 12 Technical data iie cie EL dee ed eina ce dae d 66 12 1 Response times of the MELSEC WS safety controller 66 12 2 Data sheet noe da eed ot 70 12 2 1 WSO0 CPUO and WSO CPU1 modules sse 70 12 2 2 WSO XTIO safety input output combined module 71 12 2 3 WSO XTDI safety input module ssseeeen 73 12 2 4 WS0 4RO safety relay output module see 75 12 3 Dimensional drawings essen nennen 77 12 3 1 WS0 CPU0 CPU1 module with memory plug seessss 77 12 3 2 WS0 XTIO module WSO XTDI module and WSO A4RO module TT 13 Ordering information esae E ene enrennn 78 13 1 Available modules and accessories ssssseeeeeee 78 14 Puno EE 79 14 1 EC declaration of conformity sse 79 14 2 Manufacturers checklist sss n
32. 25 15 800 E Mail sick sick fi Sverige Phone 46 10 110 10 00 E Mail info sick se Taiwan Phone 886 2 2375 6288 E Mail sales sick com tw Turkiye Phone 90 216 587 74 00 E Mail info sick com tr United Arab Emirates Phone 971 4 8865 878 E Mail info sick ae USA Canada M xico Phone 1 952 941 6780 1800 325 7425 tollfree E Mail info sickusa com 104 WARRANTY 2 Limits of Warranties a MELCO does not warrant or guarantee the design specify manufacture construction or installation of the materials construction criteria functionality use 1 Limited Warranty and Product Support a Mitsubishi Electric Company MELCO warrants that for a period of eighteen 18 months after date of delivery from the point of manufacture or one year from date of Customer s purchase whichever is less Mitsubishi Safety Controller the Products will be free from defects in material and workmanship b At MELCO s option for those Products MELCO determines are not as warranted MELCO shall either repair or replace them or issue a credit or return the purchase price paid for them For this warranty to apply 1 Customer shall give MELCO i notice of a warranty claim to MELCO and the authorized dealer or distributor from whom the Products were purchased ii the notice shall describe in reasonable details the warranty problem iii the notice shall be provided properties or other characteristics of the equipment sy
33. 3 positions with testing 24V 24V x2 MN Channel 1 V and l1 Channel 2 V and I2 Channel 3 and I3 Channel 4 and I4 Contact E13 between 24 Contact E23 between 24 Contact E31 between X1 Contact E41 between X2 Function Testing Possible Notes Series connection Not possible Discrepancy times Manual See the Safety Controller Setting and Monitoring Tool Operating Further information is available in the manual of the enabling switch SICK E100 or in the manuals of devices used Connecting devices Table 21 Connection of two hand control Note Table 22 Connection of safety mats Table 23 Functions of safety mats Note MELSEC WS 4 1 4 Two hand control Electrical connection Example from Setting and Monitoring Tool with WSO0 XTIO Type IIIA v Ba Channel 1 Contact between 24 V and 11 without testing 2V n uo Channel 2 Contact between X2 and I2 ate a Type IIIC av Ba nm w NC contact between 24 V and 11 13 without testing w ER 2 NC NO contact between 24 V and I2 I4 24V B NO 2v ge moe Type IIIA At Type IIIA two equivalent inputs NO contacts of the two two hand buttons are monitored A valid input signal is only generated if the ON state H level exists at both inputs within a period of 0 5 s synchronous change both two hand buttons pressed and if both were in the OFF state L level beforehand Typ
34. 30202 CPU module 2 EFI inputs Two tier spring terminals WS0 XT1084202 Safety I O combined module 8 inputs 4 outputs Two tier spring terminals WS0 XTDI80202 Safety input module 8 inputs Two tier spring terminals WS0 4RO4002 Safety relay output module 4 NO contacts and 2 24 V DC alarm signals Removable terminals WS0 C20R2 WS0 UC 232A Configuration cable 2 m M8 Sub D RS 232 USB converter RS 232 to USB WS0 GETH00200 Ethernet interface module for Ethernet WS0 GCC100202 CC Link interface module for CC Link WS0 TBC4 4 Two tier spring terminals for replacement WSO TBS4 4 screw terminals for replacement 78 MELSEC WS 14 Annex 79 14 1 EC declaration of conformity The MELSEC WS safety controller has been produced in accordance with the following standards Machinery Directive 2006 42 EC EMC Directive 2004 108 EC 14 2 Manufacturers checklist Table 48 Example of the checklist for installation of the MELSEC WS safety controller The specifications for the following items listed must be available at least for the initial commissioning They are dependent on the application whose requirement must be checked by the Checklist for the manufacturer installer for installation of the MELSEC WS safety controller manufacturer installer This checklist should be retained stored with the machine documentation so that you can use it as
35. 61 3 9497 4100 1800 33 48 02 tollfree E Mail sales sick com au Belgium Luxembourg Phone 32 0 2 466 55 66 E Mail info sick be Brasil Phone 55 11 3215 4900 E Mail sac sick com br Cesk Republika Phone 420 2 57 91 18 50 E Mail sick sick cz China Phone 7852 2763 6966 E Mail ghk sick com hk Danmark Phone 45 45 82 64 00 E Mail sick sick dk Deutschland Phone 49 211 5301 260 E Mail info sick de Espana Phone 34 93 480 31 00 E Mail info sick es France Phone 33 1 64 62 35 00 E Mail info sick fr GreatBritain Phone 44 0 1727 831121 E Mail info sick co uk India Phone 91 22 4033 8333 E Mail info sick india com Israel Phone 972 4 9990590 E Mail info sick sensors com Italia Phone 39 02 27 43 41 E Mail info sick it Japan Phone 81 0 3 3358 1341 E Mail support sick jp Nederlands Phone 31 0 30 229 25 44 E Mail info sick nl Norge Phone 47 67 81 50 00 E Mail austefjord sick no Osterreich Phone 43 0 22 36 62 28 8 0 E Mail office sick at Polska Phone 48 22 837 40 50 E Mail info sick pl Republic of Korea Phone 82 2 786 6321 4 E Mail kang sickkorea net Republika Slovenija Phone 386 0 1 47 69 990 E Mail office sick si Romania Phone 40356171120 E Mail office sick ro Russia Phone 7 495 775 05 34 E Mail info sick automation ru Schweiz Phone 41 41 619 29 39 E Mail contact sick ch Singapore Phone 65 6744 3732 E Mail admin sicksgp com sg Suomi Phone 358 9
36. 7 6431 Fax 31 0 180 44 23 55 TEXEL ELECTRONICS Ltd ISRAEL Koning amp Hartman b v BELGIUM Koning amp Hartman b v NETHERLANDS gt jj umanut P 0 B 6272 Woluwelaan 31 Haarlerbergweg 21 23 1L 42160 Netanya BE 1800 Vilvoorde NL 1101 CH Amsterdam Phone 972 0 9 863 39 80 Phone 32 0 2 2570240 Phone 31 0 20 5877600 Fax 972 0 9 885 2430 Fax 32 0 2 257 02 49 Fax 31 0 20 587 76 05 CEG INTERNATIONAL LEBANON INEA BH d o o BOSNIA AND HERZEGOVINA Beijer Electronics AS NORWAY Cebaco Center Block A Autostrade DORA Aleja Lipa 56 Postboks 487 Lebanon Beirut BA 71000 Sarajevo N0 3002 Drammen Phone 961 0 1 240 430 Phone 387 0 33 921164 Phone 47 0 32 243000 Fax 961 0 1 240 438 Fax 387 0 33 524 539 Fax 47 0 32 84 85 77 AKHNATON BULGARIA Sirius Trading amp Services srl ROMANIA 4 Andrej Ljapchev Blvd Pb 21 Aleea Lacul Morii Nr 3 BG 1756 Sofia R0 060841 Bucuresti Sector 6 AFRICAN REPRESENTATIVE Phone 359 0 2 817 6004 Phone 40 0 21 430 40 06 Fax 4 359 0 2 97 4406 1 Fax 40 0 21 430 4002 CBI Ltd SOUTH AFRICA INEA CR d o 0 CROATIA Craft Con amp Engineering d o o SERBIA Private Bag 2016 Losinjska 4a Bulevar Svetog Cara Konstantina 80 86 ZA 1600 Isando HR 10000 Zagreb SER 18106 Nis Phone 27 0 11 977 0770 Phone 385 0 1 36940 01 02 03 Phone 381 0 18 292 24 4 5 pes UT Fax 4 385 0 1 36 940 03 Fax 381 0 18 292 24 4 5 AutoCont C S s r o CZECH REPUB
37. AUTION Before performing online operations Force mode for the running MELSEC WS safety controller from the PC read the relevant manuals carefully and ensure the safety The online operations must be performed by qualified personnel following the operating procedure determined at designing Fully understand the precautions described in the Safety Controller Setting and Monitoring Tool Operating Manual before use Do not disassemble or modify the modules Doing so may cause failure malfunction injury or a fire Mitsubishi does not warrant any products repaired or modified by persons other than Mitsubishi or FA Center authorized by Mitsubishi Shutoffthe external power supply for the MELSEC WS safety controller in all phases before mounting or removing the module Failure to do so may cause the module to fail or malfunction After the first use of the product do not mount remove the module from to the DIN rail and the terminal block to from the module more than 50 times IEC 61131 2 compliant respectively Exceeding the limit of 50 times may cause malfunction Before handling the module touch a grounded metal object to discharge the static electricity from the human body Failure to do so may cause the module to fail or malfunction Disposal Precautions N CAUTION When disposing of this product treat it as industrial waste Disposal of the product should always occur in accordance with the applic
38. AgSnO with 1 um Au Output circuit fusing 6 A gG per current path Utilization category AC 15 Ue 250 V le 3A DC 13 Ue 24 V le 3A Output circuit Y14 Y24 Output type Non isolated NO contact positively driven current limited Number of NO contacts Y14 24 2 Output voltage 24 V DC 18 V DC to 30 V DC Output current Max 75 mA The total output current is limited The maximum total current of all the relay modules at Y14 or Y24 is 1 lt 80 mA Load capacity 200 nF General data Electrical isolation Supply circuit input circuit No Supply circuit output circuit Yes Input circuit output circuit Yes Weight without packaging 190 g Technical data Operating data MELSEC WS Ambient operating temperature 25 C to 55 C Storage temperature 25 C to 70 C Humidity 10 to 95 non condensing Climatic conditions to EN 61131 2 55 C 95 rel humidity No corrosive gases Mechanical strength Oscillation EN 61131 2 Vibration stability EN 60068 2 64 Electrical safety EN 50178 Rated impulse withstand voltage Vimp 5 500 Hz 5 grms 4kV Overvoltage category Pollution degree 2 inside 3 outside Rated voltage 300 VAC Enclosure rating to EN 60529 housing terminals Electromagnetic compatibility IP 40 IP 20 EN 61000 6 2 EN 55011 Class A Terminal and conn
39. Art no SH NA 080855 03201 0 afa MITSUBISHI ELECTRIC MELSEC WS Series Safety Controller User s Manual WSO CPUO WSO CPUT1 WSO XTD1 WSO XTIO WS0 4RO MITSUBISHI ELECTRIC NDUSTRIAL AUTOMATION This document is protected by the law of copyright whereby all rights established therein remain with the company Mitsubishi Electric Corporation Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law Alteration or abridgement of the document is not permitted without the explicit written approval of the company Mitsubishi Electric Corporation Precautions regarding warranty and specifications MELSEC WS series products are jointly developed and manufactured by Mitsubishi and SICK AG Industrial Safety Systems in Germany Note that there are some precautions regarding warranty and specifications of MELSEC WS series products Warranty The gratis warranty term of the product shall be for one 1 year after the date of delivery or for eighteen 18 months after manufacturing whichever is less The onerous repair term after discontinuation of production shall be for four 4 years Mitsubishi shall mainly replace the product that needs a repair t may take some time to respond to the problem or repair the product depending on the condition and timing Specifications General specifications of the products differ
40. D of the RS 232 interface and the connection A2 of the CPU module e g by using optocouplers 26 MELSEC WS Figure 5 Display elements WS0 CPU1 Table 7 Displays of the EFI LEDs 27 Product description 3 5 2 Display elements and terminal description The displays of the MS and CV LEDs as well as the RS 232 interface are identical with those of the WSO CPUO see Section 3 4 2 Memory plug RS 232 interface EFI1_A EFI1_B LED MS Module Status LED CV Configuration Verified EFI1 LED EFI2 LED EFI2_B EFI2 A EFI LED EFI1 or EFI2 Meaning Note O OK Red Error Waiting for integration of EFI devices after power up Red 1 Hz Error Integration check Check the wiring failed Product description MELSEC WS 3 6 WSO0 XTIO safety I O combined module 3 6 1 Description The WSO XTIO module is an input output extension with 8 safety inputs and 4 safety outputs It has two test signal generators One for test output X1 and one for test output X2 The WSO XTIO module fulfills the following tasks Monitoring of the connected sensor equipment also refer to Chapter 4 Passing on the input information to the CPU module Receiving the control signals from the CPU module and corresponding switching of the outputs Fast Shut Off Direct switching off of the actuators connected to the module possible This leads to a considerable reduction of the response t
41. DI 1 Troubleshooting flowchart The following shows the error description according to the types of events red and green When the MS LED has turned off When the MS LED has turned on red When the MS LED is flashing red When the MS LED is flashing red and green 96 MELSEC WS Annex 2 When the MS LED has turned off Refer to the following flowchart when the MS LED of the safety I O module has turned off at power on or during operation of the MELSEC WS safety controller Figure 41 Flowchart when the MS LED has turned off The MS LED of the safety VO module has turned off Is power supplied to Supply power to the the A1 and A2 terminals of A1 and A2 terminals the CPU module of the CPU module On or flashing How is the MS LED Check the power supply status with a circuit tester Is the power Hh supply voltage within Supply power within specifications the rated voltage On or flashing How is the MS LED Is the safety O module Connect the safety securely connected to the 1 O module to module module onthe left on the left securely On or flashing Completed How is the MS LED Replace the safety VO module 97 Annex MELSEC WS 3 When the MS LED has turned on red Refer to the following flowchart when the MS LED of the safety I O module has turned on red at power on or during operation of the MELSEC
42. EC WS safety controller into a machine commission it initially or who are in charge of servicing and maintaining the unit 14 MELSEC WS 15 Note About this document 1 3 Depth of information This manual contains information on the MELSEC WS safety controller in the following subjects Mounting Error diagnostics and remedying Electrical installation Part numbers Hardware commissioning Conformity and approval Maintenance Planning and using other company s protective devices also require specific technical skills which are not detailed in this documentation When operating the MELSEC WS safety controller the national local and statutory rules and regulations must be observed For the acquisition of Setting and Monitoring Tool please contact your local Mitsubishi representative The EFl compatible devices and SICK configuration and diagnostics software CDS are the products of SICK For details of the SICK products please contact your local SICK representative see Annex Section 14 5 http www sens control com 1 4 Scope This manual is valid for all modules of the MELSEC WS safety controller with the exception of the network modules This document is the original manual About this document MELSEC WS ESPE EDM EFI PFHD OSSD SIL SIL CL Recommendation Note OG Red ORed Green Action ATTENTION 1 5 Abbreviations used Electro sensitive protective
43. ELECTRIC CORPORATION Office Tower Z 14 F 8 12 1 chome Harumi Chuo Ku Tokyo 104 6212 Phone 813 622 160 60 Fax 81 3 622 160 75 MITSUBISHI ELECTRIC AUTOMATION Inc 500 Corporate Woods Parkway Vernon Hills IL 60061 Phone 1 847 478 2100 Fax 1 847 478 2253 EUROPE FRANCE IRELAND ITALY POLAND SPAIN JAPAN USA MITSUBISHI ELECTRIC GEVA AUSTRIA ALFATRADE Ltd MALTA Kazpromautomatics Ltd KAZAKHSTAN Wiener Stra e 89 99 Paola Hill Mustafina Str 7 2 AT 2500 Baden Malta Paola PLA 1702 KAZ 470046 Karaganda Phone 4 43 0 2252 85 55 20 Phone 4 356 0 21 697 816 Phone 7 7212 50 1150 Fax 4 43 0 2252 488 60 Fax 356 0 21 697 817 Fax 7 7212 50 1150 TEHNIKON BELARUS INTEHSIS srl MOLDOVA Oktyabrskaya 16 5 Off 703 711 bld Traian 23 1 BY 220030 Minsk MD 2060 Kishinev Phone 375 0 17 210 46 26 Phone 373 0 22 66 4242 MIDDLE EAST REPRESENTATIVES Fax 375 0 17 210 46 26 Fax 373 0 22 66 4280 LAN amp GAVISH Ltd ISRAEL ESCO DRIVES amp AUTOMATION BELGIUM HIFLEX AUTOM TECHNIEK B V NETHERLANDS 4 Shenkar St Kiryat Arie Culliganlaan 3 Wolweverstraat 22 1L 49001 Petah Tiqva BE 1831 Diegem NL 2984 CD Ridderkerk Phone 972 0 3 922 18 24 Phone 32 0 2 717 6430 Phone 31 0 180 46 60 04 Fax 972 0 3 924 0761 Fax 32 02 71
44. EN ISO 13849 1 and up to Safety Integrity Level SILCL3 in accordance with EN 62061 To this purpose take all the required marginal conditions and evaluate these for example in a failure analysis FMEA For further information that has to be taken into consideration during the electrical installation see Chapter 7 Loss of the safety function through an incorrect configuration Plan and carry out configuration carefully The configuration of safety applications must be carried out with the greatest accuracy and must match the status and the condition of the machine or system to be monitored Check whether the configured safety application monitors the machine or system as planned and whether the safety of a configured application is ensured at all times This must be ensured in each operating mode and partial application Document the result of this check n each case observe the instructions for commissioning and daily checking in the manuals of the protective devices integrated into the safety application Note the warnings and function descriptions of protective devices connected to the MELSEC WS safety controller Contact the respective manufacturer of the protective device if in doubt Take into account that the minimum switch off time of the connected sensors must be greater than the execution time of the logic see the chapter about the logic editor in the Safety Controller Setting and Monitoring Tool Oper
45. I General Information Type Code Serial number Version Hardware Firmware Address version version WS0 XTDI 0401 0000 1 2 0 60 0 00 V 1 00 0 2 2 3 4 XTDI lO Mode Title Tag name ON OFF OFF ON Dis ms r 3000 24V c n C4000 Safety Light Curtain Type 4 24V El 2 JE 36 MELSEC WS Connecting devices 4 1 Safety command devices and electro mechanical safety switches 4 1 1 Emergency stop pushbuttons e g SICK ES21 Table 14 Electrical connection Example from Setting and Monitoring Tool with Connection of WS0 XTIO i QU Single channel AN To o v Contact between 24 V and 11 pushbuttons without testing Single channel x2 wae 0 Uy Contact between X2 and I2 with testing Dual channel 24V A x Channel 1 Contact between 24 without testing codd ilis V and I3 Channel 2 Contact between 24 V and l4 Dual channel xi m x Channel 1 Contact between X1 with testing Re E and I5 Channel 2 Contact between X2 and I6 The dual channel emergency stop pushbuttons preconfigured in the Setting and Monitoring Tool have equivalent switching contacts Corresponding elements for implementing dual channel antivalent switching contacts are available in the element window under the group of floating contacts Table 15 Function Notes Functions of emergency Testing Possible siop pusnounone Series connection Max number of emergency stop pushbuttons connected in cascading series Take the max line resis
46. LIC INEA SR d o o SERBIA Technologick 374 6 zletnicka 10 CZ 708 00 Ostrava Pustkovec SER 113000 Smederevo Phone 420 595 691 150 Phone 381 0 26 617 163 Fax 4 420 595 691 199 Fax 381 0 26 617 163 B ELECTRIC s r o CZECH REPUBLIC AutoCont Control s r o SLOVAKIA Mladoboleslavska 812 Radlinsk ho 47 Z 197 00 Praha 19 Kbely SK 02601 Dolny Kubin Phone 420 286 850 848 420 724 317 975 Phone 4 421 0 43 5868210 Fax 420 286 850 850 Fax 421 0 43 5868210 Beijer Electronics A S DENMARK CS MTrade Slovensko s r o SLOVAKIA Lykkeg rdsvej 17 Vajanskeho 58 DK 4000 Roskilde SK 92101 Piestany Phone 45 0 46 75 76 66 Phone 421 0 33 7742 760 Fax 4 45 0 46 75 56 26 Fax 421 0 33 7735 144 Beijer Electronics Eesti OU ESTONIA INEA d o o SLOVENIA P rnu mnt 160i Stegne 11 EE 11317 Tallinn 51 1000 Ljubljana Phone 372 0 6 518140 Phone 4 386 0 1 513 8100 Fax 372 0 6 518149 Fax 386 0 1 513 8170 Beijer Electronics OY FINLAND Beijer Electronics AB SWEDEN Peltoie 37 Box 426 FIN 28400 Ulvila SE 20124 Malm Phone 358 0 207 463 540 Phone 4 46 0 40 35 86 00 Fax 4 358 0 207 463 541 Fax 46 0 40 93 23 01 UTECO A B E E GREECE Omni Ray AG SWITZERLAND 5 Mavrogenous Str m Sch rli 5 GR 18542 Piraeus CH 8600 D bendorf Phone 30 211 1206 900 Phone 41 0 44 802 28 80 Fax 30 211 1206 999 Fax 41 0 44 802 28 28 MELTRADE Ltd HUNGARY GTS TURKEY Fert utca 14 Bayraktar Bulvari Nutuk
47. O WSO XTIO WSO XTDI Reset switch and start switch or the like single channel NO contact Connect a stop switch with single channel NC contact for direct operation and a reset switch or a start switch with single channel NO contact between the I1 to I8 input terminals and the A1 24 V terminal Stop switch or the like single channel NC contact Reset switch and start switch or the like single channel NO contact Annex Figure 27 Wiring example of safety switches MELSEC WS 2 Wiring of safety switches Connect a safety switch to the MELSEC WS safety controller as shown below Safety switch dual channel equivalent switching contacts Connect a safety switch with dual channel equivalent Switching contacts for direct operation between the 11 to l8 input terminals and the X1 and X2 test output terminals WS0 CPUO WS0 XTIO WSO XTDI Connect a safety switch with interlock with dual channel equivalent switching contacts for direct operation between the I1 to 18 input terminals and the X1 and X8 output terminals Door switch with spring lock dual channel equivalent switching contacts Open Use the following terminal combinations for dual channel input wiring WSO XTIO I1 and X1 I2 and X2 I3 and X1 I4 and X2 I5 and X1 I6 and X2 I7 and X1 18 and X2 WSO X
48. Sok No 5 i HU 1107 Budapest TR 34775 Yukar Dudullu Umraniye ISTANBUL Phone 36 0 1 431 9726 Phone 90 0 216 526 39 90 Fax 36 0 1 431 9727 Fax 90 0 216 526 3995 Beijer Electronics SIA LATVIA CSC Automation Ltd UKRAINE Ritausmas iela 23 4 B M Raskovoyi St 1V 1058 Riga UA 02660 Kiev Phone 371 0 784 2280 Phone 4 380 0 44 494 33 55 Fax 371 0 784 2281 Fax 380 0 44 494 33 66 Beijer Electronics UAB LITHUANIA Savanoriu Pr 187 LT 02300 Vilnius Phone 370 0 5 232 3101 Fax 370 0 5 232 2980 Mitsubishi Electric Europe B V FA European Business Group Gothaer Stra e 8 D 40880 Ratingen Germany FACTORY AUTOMATION Tel 49 0 2102 4860 Fax 49 0 2102 4861120 info mitsubishi automation com www mitsubishi automation com
49. TCP PROFINET IO PROFIBUS DP DeviceNet and CANopen 2 EFI interfaces at the WSO CPU1 see Section 3 5 For the acquisition of Setting and Monitoring Tool please contact your local Mitsubishi representative Product description MELSEC WS 3 2 System configuration A MELSEC WS safety controller consists of the following modules a WS0 MPL memory plug aWSO0 CPUO or WSO CPU1 module up to 2 different network modules upto 12 additional WSO XTIO and WSO XTDI safety I O modules in addition up to 4 WSO 4RO safety relay output modules Figure 2 Examples for the minimum configuration of a MELSEC WS LE safety controller with X1 X2 A1 A2 CPUO and XTDI or CPU1 and XTIO n p BM A1 A2 X1 X2 X3 X4 A1 A2 MITSUBISHI H PBs MITSUBISHI MS MS MS cv cv CPU1 EFI1 6 6 7 B EFI2 1 EFI 2 PCED CEP CEP CI A BIIA B Q1 Q2 Q3 I5 6 I7 I8 I5 6 I7 I8 1 EFI 2 X5 X6 X7 X8 AB A B Q1 Q2 Q3 Q4 0000 Figure 3 Maximum configuration zu of the MELSEC WS Eas EE EE Ea BER BER EE ERE EE Hara EE EE safety controller without safety relay output module nor Ethernet interface module 22 MELSEC WS Table 2 Overview of the modules 23 Note Note Product description Type Kind Ppor gue Logic Max blocks occurrence WS0 CPUO CPU module i 255 1 WS0 CPU1 4 WS0 XTIO Safety I O combined module i T i 12 WSO XTDI Safety input module 8 WS0 4RO Safety relay output i 2 i mod
50. TDI I1 and X1 I2 and X2 I3 and X3 I4 and X4 to I7 and X7 18 and X8 82 MELSEC WS Figure 28 Wiring example of light curtain and laser scanner 83 Annex 3 Wiring of light curtains and laser scanners Connect a light curtain and a laser scanner to the MELSEC WS safety controller as shown below Sender Light curtain 24 V DC Synchronization Receiver WSO0 CPUO WSO0 XTIO WSO0 XTDI Synchronization Connect the OSSD1 and OSSD2 control outputs of the light curtain to the I1 to I8 input terminals Connect the OSSD1 and OSSD2 control outputs of the laser scanner to the 11 to 18 input terminals Laser scanner The light curtain is connected to the WSO XTIO and the laser scanner is connected to the WSO XTDI in the above example Both elements can be connected to either module Annex MELSEC WS 4 Wiring of contactors Connect a contactor to the MELSEC WS safety controller as shown below Figure 29 Wiring example of 24 V DC contactor WSO XTIO WSO0 CPUO Connect the NC contact of the contactor between the 11 to 18 input terminals and the X1 and X2 test output terminals Contactor Connect the positive terminal of the contactor to the Q1 to Q4 output terminals and the negative terminal of the conta
51. able country specific waste disposal regulations e g European Waste Code 16 02 14 CONDITIONS OF USE FOR THE PRODUCT e 1 Although MELCO has obtained the certification for Product s compliance to the international safety standards IEC61508 EN954 1 15013849 1 from TUV Rheinland this fact does not guarantee that Product will be free from any malfunction or failure The user of this Product shall comply with any and all applicable safety standard regulation or law and take appropriate safety measures for the system in which the Product is installed or used and shall take the second or third safety measures other than the Product MELCO is not liable for damages that could have been prevented by compliance with any applicable safety standard regulation or law 2 MELCO prohibits the use of Products with or in any application involving and MELCO shall not be liable for a default a liability for defect warranty a quality assurance negligence or other tort and a product liability in these applications 1 power plants 2 trains railway systems airplanes airline operations other transportation systems 3 hospitals medical care dialysis and life support facilities or equipment 4 amusement equipments 6 handling of nuclear or hazardous materials or chemicals 5 incineration and fuel devices 7 mining and drilling 8 and other applications where the level of risk to human life health or property
52. ades per module with max 30 mA each are possible The total current of the MELSEC WS safety controllers is limited to a maximum of 1 28 A This corresponds to e g 32 inputs of testable sensors with 30 mA each and 64 inputs of WSO XTIO or WSO0 XTDI modules Test pulse rate 1 Hz to 25 Hz configurable Test pulse duration 1 ms to 100 ms configurable Load capacity 1 uF for test pulse duration 2 4 ms 0 5 uF for test pulse duration 1 ms Cable resistance lt 100 0 Safety outputs Q1 to Q4 Number of outputs 4 Output type PNP semiconductor short circuit protected cross circuit monitoring Output voltage 24 V DC 16 V DC to 30 V DC Output current 2A Total current lsum Max 3 2A Test pulse width 0 65ms Test pulse rate Typ 0 8 Hz Load capacity lt 0 5 uF Cable length 100 m 1 5 mm Response time Depending on the logic configuration for details see Table 41 Data interface Internal bus FLEXBUS backplane bus 72 MELSEC WS Table 45 Data sheet WSO XTDI 73 Technical data 12 2 3 WS0 XTDI safety input module Category Category 4 EN ISO 13849 1 Category 4 EN 954 1 Safety Integrity Level SIL3 IEC 61508 Performance Level PL e EN ISO 13849 1 PFHd 0 4E 09 1 h TM service life Ambient temperature in operation 20 years 25 C to 55 C Storage temperature 25 C to 70 C Humidity
53. afe communication interface between SICK devices With it information from the sensor equipment can be read out as well as commands transferred to the sensor equipment 5 1 2 Properties Up to 4 SICK devices are possible per EFI line in as far as the EFl compatible devices support this number Connection of the devices using a 2 wire cable Various device combination possibilities Sensor with sensor within the same product family Sensor with safety controllers and network modules Transferring of status information between SICK devices using an EFI interface Activation utilisation of sensor functions 50 MELSEC WS 51 Special functions 5 1 3 Functions In addition to the product specific functions of the respective EFI compatible devices the following functions are available General functions Status information of the sensors are available in the MELSEC WS safety controller and at the sensor Diagnostics information of all the EFI nodes is available in the MELSEC WS safety controller Transfer of configuration information Special functions Simultaneous protective field evaluation Protective field switching Function changeover Operating mode selection Signal routing Decentralized diagnostics information via Ethernet Information on the location of the protective field interruption at host guest applications Evaluation of signals and forwarding of the results 5 1 4 Benefits Reduction of the i
54. apter describes the mounting of the modules of the MELSEC WS safety controller 6 1 Steps for mounting the modules The MELSEC WS safety controller is only suitable for mounting in a control cabinet with at least IP 54 degree of protection While supply voltage is applied modules must not be plugged to nor be removed from the MELSEC WS safety controller To ensure full electromagnetic compatibility EMC the DIN mounting rail must be connected to functional earth FE n a MELSEC WS safety controller the WSO CPUO or WSO CPU1 module is positioned at the extreme left The two optional network modules follow directly to the right of the CPU module Connect further MELSEC WS safety I O modules e g WSO XTIO or WSO XTDI onto the right side of the network modules and any additional safety relay output modules WSO 4RO to the extreme right of the entire MELSEC WS safety controller Ensure that suitable ESD protective measures are also taken during mounting Otherwise the FLEXBUS backplane bus may be damaged The connection between the modules is effected by means of the plug connection integrated in the housing Take into account that when replacing a module the MELSEC WS modules have to be pushed approx 10 mm apart before the corresponding module can be removed from the DIN rail Take suitable measures to ensure that foreign matter does not penetrate the connector openings in particular that of the memory plug
55. ating Manual and the logic editor in the Setting and Monitoring Tool so that it is ensured that the MELSEC WS safety controller can detect the switching of the sensors The minimum switch off time of sensors is usually specified in the technical data of the sensors Connecting devices MELSEC WS Note If an odd numbered test output is used odd numbered inputs have to be used If an even numbered test output is used even numbered inputs have to be used You have to use the test outputs of the module to which the device to be tested is connected After the configuration you obtain the following documentations in the Setting and Monitoring Tool under Report logic report Parts list Information on wiring Figure 11 Example extract of the documentation in the Setting and Monitoring Tool Module Type Code Address CPU1 WS0 CPU1 0 xrio WSO XTIO 1 XTDI WSU XTDI 2 2 3 WVO Module 2 3 1 XTIO General Information Type Code Serialnumber Version Hardware Firmware Address version version WS0 XTIO 0401 0000 1 2 0 60 0 00 v 1 00 0 1 2 3 2 XTIO 10 Test outputs Period value ms Gap value ms Long gap value ms xi 200 1 x2 200 1 Mode Title Tag name ON OFF OFF ON Dis ms 24V ai Ai XTIO 1 Power Supply ov A2 xi za now E Stop ES21 Dual Channel 3000 x2 plc 24V M w Reset Single Channel Es 9 ai e Lamp Singie Channel D Q3 Motor Contactor Dual Channel te aut 2 3 3 XTD
56. ats and switching Period value of the test rails output b Testable sensors Type 4 Period value of the test e g L41 output C All other sensors only when 12 ms gap value of the the gap value of the test test output output 1 ms Logic Total E1 Total A1 Occurrence EFI message transmitter EFI message receiver If EFI functions are used via Response time of the EFI Response time of the message EFI compatible devices data source as a rule a receiver e g scanner with protective sensor for external field switching via EFI OSSDs via EFI Constant EFI cycle time of the EFI receiver a Scanner e g S300 3000 3 5 ms b Light grid e g C4000 Constant a Scanner e g S300 3000 24 ms b Light grid e g C4000 M4000 2 5 M4000 1 5 ms ms Total E2 Total A2 Occurrence Data from the network Data to the network General Response time field bus Response time field bus receiver sender General 2 x cycle time field bus 2 x cycle time field bus General 2 x update rate for data 2 x update rate for data to the from the network Logic network If 1 network module 3 ms 0 ms If 2 network modules 7 ms 4ms If WSO GETH 8ms 8ms Total E3 Total A3 Evaluation Response time of the considered input in the signal path E1 or E2 or E3 from above table Response time of logic 2 x logic execution time Delay through logic application e g On
57. ay elements and terminal description Y1Y3 Y14Y24 13233343 24 B1 B2Y2Y4 intemal 14243444 Product description MELSEC WS Figure 10 WS0 4RO display element 13 23 33 43 Y14 Y1 Y24 Y3 PWR D K4 2 B Y1 i 5 kt pf Y2 14 24 ron K3 4 gj va 33 43 LNT U ee Y4 3 4 YA 4RO B1 Y2 B2 Y4 14 24 34 44 Table 12 Display Meaning WS0 4RO displays PWR green Supply voltage via safety bus is applied K1 2 green K3 4 green Relay K1 K2 safety contacts closed Relay K3 K4 safety contacts closed Table 13 Assignment Description WS0 4RO terminals B1 Circuiting relay K1 K2 B2 Circuiting relay K3 K4 13 14 and 23 24 Safety contacts for switch off circuit outputs K1 K2 33 34 and 43 44 Safety contacts for switch off circuit outputs K3 K4 Y1 Y2 Feedback EDM K1 K2 NC contact Y3 Y4 Y14 Feedback EDM K3 K4 NC contact NO contact safety contact K1 K2 current limited see Chapter 12 Y24 NO contact safety contact K3 K4 current limited see Chapter 12 34 MELSEC WS Connecting devices 4 Connecting devices 35 ATTENTION This chapter describes the connection of safety sensors and actuators to the MELSEC WS safety controller and provides configuration information for the selected functions The MELSEC WS safety controller supports applications up to Performance Level PL e in accordance with
58. ccordance with EN 954 1 EN ISO 13849 1 and in accordance with SIL3 to EN 62061 and conform to the required safety level in accordance with EN 954 1 EN 62061 or EN ISO 13849 1 For further information refer to Chapter 12 Ensure that all the modules of the MELSEC WS safety controller the connected protective devices as well as the voltage supply ies are connected with the same earth GND The GND of the RS 232 interface is connected internally to the GND of the supply of the CPU module A2 If the RS 232 interface at the CPU module is used as an alternative to a network module observe the limitation of the cable length max 3 m In addition the line at least has to be connected to the CPU module and earthed in the control cabinet in which the CPU module is connected Route the lines outside the control cabinet in such a manner that cross circuiting between these lines can be excluded e g in separate sheathed cables or in protected areas In order to protect the safety outputs and to increase the service life the external loads have to be equipped with for example varistors or RC elements Take into account that the response times may increase depending on the type of protective circuiting The safety outputs and the contactor monitoring EDM have to be wired inside the control cabinet If a module is replaced the terminal assignment has to be guaranteed for example by labelling or corresponding cable routing Electrical installat
59. ces It is imperative that the safety distance between the light beam and hazardous point be observed at access protection 4 In the future EN ISO 13855 MELSEC WS D 1 S peer 7 te ys mu R D fos 22 j S Sender R Receiver D Distance between sender and receiver 1 Limit to hazardous area 2 Reflective surface 3 Direction of access to hazardous area 4 Optical axis a Minimum distance from reflective surfaces 46 MELSEC WS Figure 13 Minimum distance a as a factor of the distance D for testable single beam photoelectric safety switches with a field of view of 10 e g SICK Wx12 18 24 27 Vx18 Note Figure 14 Mounting to avoid mutual optical influence 47 Connecting devices a mm 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 260 D m Diagrams for L21 and L41 are available in the respective manuals Avoiding mutual influence at single beam photoelectric safety switches and between cascades f several single beam photoelectric safety switch pairs are used the field of view of the sensors has to be observed in order to prevent mutual influence Ifthe senders are only mounted on one side the light beams may not overlap on the receiver side so that the light beam of one sender does not reach two receivers Ifthe senders and receivers
60. communication errors caused by failure such as a poor contact Create an interlock program using a reset button to prevent the MELSEC WS safety controller from restarting automatically after the safety function is activated and the safety controller turns off the outputs N CAUTION Ensure that an entire system using the MELSEC WS safety controller meets the requirements for the corresponding safety category The life of safety relays in the safety relay output module depends on the switching condition and or load Configure a system satisfying the number of switching times of the safety relays in the module Do not install the communication cables together with the main circuit lines or power cables Keep a distance of 100 mm or more between them Failure to do so may result in malfunction due to noise Observe the protective notes and measures Observe the following items in order to ensure proper use of the MELSEC WS safety controller e When mounting installing and using the MELSEC WS safety controller observe the standards and directives applicable in your country e The national international rules and regulations apply to the installation use and periodic technical inspection of the MELSEC WS safety controller in particular Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Provision and Use of Work Equipment Directive 89 655 EC Low Voltage Directive 2006 95 EC The work safety regulations
61. crease the EMC resistance of the bus communication it is important to connect the EFI cable screen on one or both sides to functional earth Connect this screen to the same DIN rail to which the functional earth FE of the MELSEC WS safety controller is connected in order to minimize interferences on the EFI cable The connection of the screen to FE should be close to the cable inlet of the control cabinet The FE terminal of the MELSEC WS safety controller is located at the bottom of the housing and connects automatically to the DIN rail when the module is mounted To avoid further interferences the functional earth of the SICK sensors e g M4000 S3000 must be connected to the EFI screen as well f other cables are present within the same cable duct where the EFI cable is routed and these cables emit a high degree of EMC interference drives or motor related this can lead to availability problems in the application In this case it is recommended to install the EFI cable in a separate duct Special functions MELSEC WS 5 Special functions 5 1 Enhanced Function Interface EFI The WSO CPU1 module has 2 EFI interfaces This chapter describes the properties the functions and the benefits of these interfaces The general EFI function description and the possibilities for combining SICK products with regard to EFI are available in the corresponding manuals of SICK products 5 1 4 Definition An EFI interface is a s
62. ctor switch Note Untested variant operating mode selector switches can be used that allow selections between 2 and 8 operating modes test variant switches between 2 and 4 When wiring the tested operating mode selector switches it should be noted that odd numbered inputs 11 13 15 I7 have to be used if an odd numbered test output X1 X3 X5 X7 is used and even numbered inputs I2 14 16 18 have to be used if an even numbered test output X2 X4 X6 X8 is used Further information is available in the manual of the operating mode selector Switch 4 1 7 Floating contacts The Setting and Monitoring Tool makes a series of floating contacts available for free configuration of contact elements This allows different NC NO contact combinations with and without testing to be implemented In addition elements are available for the start and stop button reset button and external device monitoring EDM Table 26 Function Notes Functions of floating Testing Possible contacts Series connection Possible Discrepancy time See the Safety Controller Setting and Monitoring Tool Operating Manual 41 Connecting devices MELSEC WS Table 27 Connection of magnetic safety switches with equivalent inputs Table 28 Connection of magnetic safety switches with complementary inputs Table 29 Functions of magnetic safety switches Note 4 2 Non contact safety sensors 4 2 1 Magnetic sa
63. ctor to the A2 0 V terminal 84 MELSEC WS Annex 5 Wiring of contactors Category 3 4 The system meets the requirements of Category 3 even when the output of WSO0 XTIO Q1 to Q4 is a single channel structure When the output is a dual channel structure the system meets the requirements of Category 4 Properly connect the wires so that two wires will not simultaneously short out or break Figure 30 24V DC Wiring example of 4 contactor Category 3 4 L E pe Tie aj at 02 ean 2 WS0 CPU0 WSO XTIO Connect the NC contact of the contactor between the 11 to I8 input terminals and the X1 and X2 test output terminals 6 6 Connect the positive terminal of the contactor to the Q1 to Q4 output terminals and the negative terminal of the contactor to the A2 0 V terminal Contactor 85 Annex MELSEC WS Application example Simultaneous protection from danger Use of a laser scanner Figure 31 Application example Function Two independent robots are protected with one laser scanner S3000 An operator can access the dangerous area through the protective area or the side gates When the operater opens the side gate or crossing the laser protected area the robots stop their operation Both robots stop when any one of the emergency stop switches is activated Reset the safety device after act
64. d have been instructed by the responsible machine operator in the operation of the machine and the current valid safety guidelines and have access to the MELSEC WS manuals and have read and familiarised themselves with them and have access to the manuals for the protective devices e g light curtain connected to the safety controller and have read and familiarised themselves with them 2 2 Applications of the device MELSEC WS safety controller is a configurable controller for safety applications It can be used in accordance with EN 61508 to SIL3 in accordance with EN 62061 to SILCL3 in accordance with EN ISO 13849 1 up to Performance Level e in accordance with EN954 1 up to Category 4 The degree of safety actually attained depends on the external circuit the realization of the wiring the parameter configuration the choice of the pick ups and their location at the machine Opto electronic and tactile safety sensors e g light curtains laser scanners safety Switches sensors emergency stop pushbuttons are connected to the safety controller and are linked logically The corresponding actuators of the machines or systems can be switched off safely via the switching outputs of the safety controller 17 On safety ATTENTION MELSEC WS 2 3 Correct use The MELSEC WS safety controller may only be used within specific operating limits voltage temperature etc refer to the technical data in
65. data MELSEC WS 12 Technical data Figure 20 Response times within a MELSEC WS safety controller Note 12 1 Response times of the MELSEC WS safety controller In order to calculate the response times of a MELSEC WS safety controller all paths have to be taken into consideration Digital Digital Inputs Outputs Flex Bus Flex Bus Network je ata Sender EFI Data Sender Fieldbus Fieldbus Receiver Fast Shut Off The Fast Shut Off function can be realised on a single WSO XTIO module A response time of 8 ms can be reached this way The Fast Shut Off function has only an effect on the inputs and outputs of the same WSO XTIO module The Fast Shut Off function can not be combined with additional function blocks For more information see the Safety Controller Setting and Monitoring Tool Operating Manual 66 Technical data MELSEC WS Calculation of the response times The following table can be used to calculate the response times of corresponding paths within the MELSEC WS safety controller Table 40 Calculation of the response times of the MELSEC WS safety controller in ms Occurrence Digital inputs Digital outputs General Response time of the Response time of the actuator sensor General Input processing time 6 5ms Output processing time 4 5ms When On Off filter 8 0 ms When X1 to X8 is connected at the test output a Safety m
66. e a 4 I3 Channel 2 Contact between 24 V and l4 Coil at Q1 Dual channel x 9 Mo NC Channel 1 Contact between X1 and 11 with testing ic z e Channel 2 Contact between X2 and I2 p Coil at Q1 Function Notes Testing Possible Series connection Cascading The max number of series connected safety switches is determined by the max line resistance of 100 Q see Chapter 12 Discrepancy times See the Safety Controller Setting and Monitoring Tool Operating Manual Further information is available in the manuals of the electro mechanical safety switches or in the manuals of devices used 38 MELSEC WS Table 19 Connection of enabling switches Table 20 Functions of enabling switches Note 39 4 1 3 Enabling switch e g SICK E100 Connecting devices Electrical connection Example from Setting and Monitoring Tool with WSO0 XTIO 2 positions without testing a Y n I2 NC 2 Channel 1 V and I1 Channel 2 V and I2 Contact E31 between 24 Contact E41 between 24 2 positions with testing x1 Y x2 I3 4 W Channel 1 and I3 Channel 2 and l4 Contact E31 between X1 Contact E41 between X2 3 positions without testing xv Y 24V Y 24V uds Channel 1 V and I5 Channel 2 V and l6 Channel 3 V and I7 Channel 4 V and l8 Contact E13 between 24 Contact E23 between 24 Contact E31 between 24 Contact E41 between 24
67. e IIIC At Type IIIC two pairs of antivalent inputs NO NC contact pairs of the two two hand buttons are monitored A valid input signal is only generated if the ON state H L level exists at both inputs within a period of 0 5 s synchronous change both two hand buttons pressed and if both were in the OFF state L H level beforehand Further information is available in the manual of the two hand control 4 1 5 Safety mats Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Pressure sensitive x1 g oc Channel 1 Contact between X1 baa o RM ML short circuiting and I1 switching mats in 4 wire Channel 2 Contact between X2 technology with testing and I2 Function Notes Testing Possible Series connection Possible Further information is available in the manual of the safety mats 40 MELSEC WS Connecting devices 4 1 6 Operating mode selector switch Table 24 Electrical connection Example from Setting and Monitoring Tool with Connection of operating WS0 XTIO mode ele ctor eh Operating mode 24v F H wo Channel 1 Contact between 24 V selector switch 1 of 2 wo g uv and 11 without testing Channel 2 Contact between 24 V and I2 Operating mode x1 3 wo Channel 1 Contact between X1 selector switch 1 of 2 oe Bue and 11 with testing Channel 2 Contact between X1 and I3 Table 25 l Function Notes Function of operating Testing Possible mode sele
68. ection data Single core or finely stranded 1 x 0 14 mm to 2 5 mm or 2x0 14 mm to 0 75 mm Finely stranded with ferrules to EN 46228 1 x0 25 mm to 2 5 mm or 2x0 25 mm to 0 5 mm Stripped length 8 mm Maximum break away torque 0 6 Nm Functional safety in accordance with Category 4 EN 954 1 Functional safety in accordance with Category 4 EN ISO 13849 1 Functional safety in accordance with SIL3 EN 61508 Safety specific characteristics All these data are based on an ambient temperature of 55 C PFD 1 6 x 10 PFH 1x10 n SFF 99 696 DC 9996 76 Technical data MELSEC WS 12 3 Dimensional drawings 12 3 1 WS0 CPU0 CPU1 module with memory plug Figure 23 Dimensional drawing 114 4 ii WSO0 CPUO 1 mm esc MITSUBISHI 7 uw c om 8 amp 8 QR LILILILT 4 Y PE 7 22 5 93 7 a le 120 8 Unit mm 12 3 2 WS0 XTIO module WS0 XTDI module and WS0 4RO module Figure 24 Dimensional drawing WS0 XTIO WSO XTDI WS0 4RO mm Unit mm 77 Ordering information 13 Ordering information 13 1 Available modules and accessories MELSEC WS Table 47 Device type Device types of MELSEC WS modules Part WSO0 MPLO00201 Memory plug WS0 CPU000200 CPU module Two tier spring terminals WS0 CPU1
69. ennen 79 14 3 Wiring examples ete dte i dett 80 14 4 Troubleshooting etu e ee G 89 14 4 1 Basics of troubleshooting sssesee 89 14 4 2 Troubleshooting flowchart for CPU module sssss 90 14 4 3 Troubleshooting flowchart for safety I O module 96 14 5 SIGK cont act e Apne tee eee iad ie ees 104 GENERIC TERMS AND ABBREVIATIONS Generic term abbreviation Description WSO0 MPL Abbreviation for the WSO0 MPL00201 MELSEC WS safety controller memory plug WS0 CPUO Abbreviation for the WS0 CPU000200 MELSEC WS safety controller CPU module WS0 CPU1 Abbreviation for the WS0 CPU130202 MELSEC WS safety controller CPU module WSO XTIO WSO XTDI Abbreviation for the WS0 XTIO84202 MELSEC WS safety controller safety I O combined module Abbreviation for the WSO XTDI80202 MELSEC WS safety controller safety input module WS0 4RO Abbreviation for the WS0 4RO4002 MELSEC WS safety controller safety relay output module WS0 GETH WS0 GCC1 Abbreviation for the WS0 GETH00200 MELSEC WS safety controller Ethernet interface module Abbreviation for the WS0 GCC100202 MELSEC WS safety controller CC Link interface module CPU module Generic term for the WSO CPUO and WSO CPU1 Safety I O module Generic term for the WSO XTIO and WSO XTDI Network module Generic term for the WSO GETH and WS0 GCC1
70. equipment e g light curtains External device monitoring Enhanced Function Interface Probability of dangerous failure per hour Output signal switching device Safety Integrity Level safety class Safety Integrity Level Claim 1 6 Symbols used Recommendations are designed to give you some assistance in your decision making process with respect to a certain function or a technical measure Notes provide special information on the device LED symbols describe the state of a diagnostics LED Examples Red The red LED is illuminated constantly ORed The red LED is flashing Green The green LED is off Instructions for taking action are shown by an arrow Read carefully and follow the instructions for action Warning An ATTENTION indicates an actual or potential risk or health hazard They are designed to help you to prevent accidents Read carefully and follow the attention notices 16 MELSEC WS On safety 2 On safety This chapter deals with your own safety and the safety of the equipment operators Please read this chapter carefully before working with the MELSEC WS safety controller or with the machine protected by the MELSEC WS safety controller 2 1 Qualified safety personnel The MELSEC WS safety controller may only be installed commissioned and serviced by qualified safety personnel Qualified safety personnel are defined as persons who have undergone the appropriate technical training an
71. er Setting and Monitoring Tool Operating Manual The simultaneous use of several WSO XTDI modules is possible see Section 3 2 Voltage supply is effected via the FLEXBUS backplane bus A WSO XTDI has two test signal generators One test signal generator is responsible for the odd numbered test outputs X1 X3 X5 and X7 the other for the even numbered test outputs X2 X4 X6 and X8 Take the following points into account for the wiring The WSO XTDI recognises short circuits between odd numbered X1 X3 X5 XT and even numbered X2 X4 X6 X8 test outputs Short circuits under the odd numbered X1 X3 X5 X7 or under the even numbered X2 X4 X6 X8 test outputs are not recognised 3 7 2 Display elements and terminal description The displays of the MS LED as well as the input LEDs 11 to l8 are identical with those of the WSO XTIO see Section 3 6 2 LED MS Module Status 8 input LEDs Product description Table 11 Terminal assignment WSO0 XTDI Figure 8 Example of the inclusion of a relay output module in the MELSEC WS safety controller Note MELSEC WS Terminal X1 X3 Test output 1 X2 X4 Test output 2 11 to 14 Inputs 1 to 4 I5 to 18 Inputs 5 to 8 X5 X7 Test output 1 X6 X8 Test output 2 3 8 WS0 4RO safety relay output module 3 8 1 Description The WSO 4RO safety relay output module makes dual channel contact based outputs with positively driven
72. er applications where the level of risk to human life health or property are elevated d MELCO SHALL NOT BE LIABLE FOR SPECIAL INCIDENTAL CONSEQUENTIAL INDIRECT OR PUNITIVE DAMAGES FOR LOSS OF PROFITS SALES OR REVENUE FOR INCREASED LABOR OR OVERHEAD COSTS FOR DOWNTIME OR LOSS OF PRODUCTION FOR COST OVERRUNS OR FOR ENVIRONMENTAL OR POLLUTION DAMAGES OR CLEAN UP COSTS WHETHER THE LOSS IS BASED ON CLAIMS FOR BREACH OF CONTRACT OR WARRANTY VIOLATION OF STATUTE NEGLIGENCE OR OTHER TORT STRICT LIABILITY OR OTHERWISE e In the event that any damages which are asserted against MELCO arising out of or relating to the Products or defects in them consist of personal injury wrongful death and or physical property damages as well as damages of a pecuniary nature the disclaimers and limitations contained in these terms shall apply to all three types of damages to the fullest extent permitted by law If however the personal injury wrongful death and or physical property damages cannot be disclaimed or limited by law or public policy to the extent provided by these terms then in any such event the disclaimer of and limitations on pecuniary or economic consequential and incidental damages shall nevertheless be enforceable to the fullest extent allowed by law f In no event shall any cause of action arising out of breach of warranty or otherwise concerning the Products be brought by Customer more than one year after the cause of ac
73. er level controllers Check the correct data transfer from and to the MELSEC WS safety controller Check the logic program of the safety controller Perform a complete validation of the safety functions of the system in each operating mode and an error simulation Observe the response times of the individual applications in particular UUU Completely document the configuration of the system the individual devices and the result of the safety check n order to prevent unintentional overwriting of the configuration activate the write protection of the configuration parameters of the MELSEC WS safety controller Modifications are only possible if the write protection has been deactivated 60 MELSEC WS 61 Commissioning 9 2 Tests before the initial commissioning A report that provides the configuration can be created with the Setting and Monitoring Tool The purpose of the initial commissioning tests is to confirm the safety requirements specified in the national international rules and regulations especially in the Machine and Work Equipment Directive EC Conformity Check the effectiveness of the protective device at the machine using all the selectable operating modes and functions Ensure that the operating personnel of the machine fitted with the MELSEC WS safety controller become instructed by the qualified safety personnel of the machine owner before beginning work Arranging the instruction is the respo
74. f the MELSEC WS safety controller at hand so that network operation can be re established as fast as possible Safety measures for replacing devices Observe the following safety measures when replacing the MELSEC WS modules Do not try to dismantle or repair the MELSEC WS safety controller modules Not only does Mitsubishi accept no claims for liability but it is also dangerous because checking of the original safety functions is not possible in this case Reset the device into a state in which safety is ensured Carry out replacement only when the voltage supply is switched off in order to avoid an electric shock or unexpected device behaviour In order to continue using the system configuration check Whether the new module is of the same type same material number and whether there is no error at the new module after the replacement and That the new module is plugged at the same position as the replaced module Otherwise you have to completely reconfigure and commission the new system including all the necessary tests see Chapter 9 EFI compatible devices have to be reconfigured after the replacement After the replacement ensure that no errors arise with the new MELSEC WS modules Always carry out a function test before commissioning a replacement module If you send in modules for repair enclose a brief detailed description of the problem with the device and send the modules to your local Mitsubishi representative Technical
75. fety switches e g SICK RE Magnetic safety switches with equivalent inputs e g SICK RE13 RE27 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO With testing x1 pu n ney Channel 1 Contact between X1 x2 2 2E and 1 Channel 2 Contact between X2 and I2 Magnetic safety switches with complementary inputs e g SICK RE11 RE21 RE31 RE300 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO With testing xi pa Bo Nemo NC contact between X1 and 11 M 4 77 NO contact between X2 and I2 Function Notes Testing Possible Series connection Possible observe max line resistance of 100 O and correct Cascading setting of the test impulse time Discrepancy time See the Safety Controller Setting and Monitoring Tool Operating Manual Further information is available in the manuals of the SICK magnetic safety switches or in the manuals of devices used 42 MELSEC WS Table 30 Connection of inductive safety switches Table 31 Functions of inductive safety switches Note Table 32 Connection of transponders Table 33 Functions of transponders Note 43 Connecting devices 4 2 2 Inductive safety switches e g SICK IN4000 IN40 Direct Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO IN4000 x1 a n c Test input TE IN4000 at X1 Output A IN4000 at I1 IN40
76. her improper environment or 11 damaged or malfunctioning due to Acts of God fires acts of vandals criminals or terrorists communication or power failures or any other cause or failure that results from circumstances beyond MELCO s control f All Product information and specifications contained g on MELCO s website and in catalogs manuals or technical information materials provided by MELCO are subject to change without prior notice The Product information and statements contained on MELCO s website and in catalogs manuals technical bulletins or other materials provided by MELCO are provided as a guide for Customer s use They do not constitute warranties and are not incorporated in the contract of sale for the Products h These terms and conditions constitute the entire agreement between Customer and MELCO with respect to warranties remedies and damages and supersede any other understandings whether written or oral between the parties Customer expressly acknowledges that any representations or statements made by MELCO or others concerning the Products outside these terms are not part of the basis of the bargain between the parties and are not factored into the pricing of the Products i THEWARRANTIES AND REMEDIES SET FORTH IN THESE TERMS ARE THE EXCLUSIVE AND ONLY WARRANTIES AND REMEDIES THAT APPLY TO THE PRODUCTS j MELCO DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
77. iguration stored in the memory plug The outputs of the system are switched as a result of the processing whereby the FLEXBUS backplane bus serves as the data interface The CPU module furthermore has an RS 232 interface with the following functions Transferring the configuration from the Setting and Monitoring Tool to the memory plug Uploading the configuration from the memory plug to the Setting and Monitoring Tool Diagnostics of the MELSEC WS safety controller with the Setting and Monitoring Tool The maximum permissible cable length is 3 m The screen has to be shielded and connected at suitable points to the FE Avoid ground loops between the GND of the RS 232 interface and the connection A2 of the CPU module e g by using optocouplers When the memory plug is not plugged in ensure that no debris can enter the corresponding opening 3 4 2 Display elements and terminal description Memory plug LED MS Module Status FERAS mierace LED CV Configuration Verified Pin Assignment A1 24 V voltage supply for all the modules with the exception of the outputs A2 GND of the voltage supply 24 MELSEC WS Table 4 Displays of the MS LED 25 Product description MS LED Meaning Notes O Supply voltage lies outside range Switch on the supply voltage and check it at the terminals A1 and A2 Red green 1 Hz Green 1 Hz A self test is being ca
78. ime of the overall system For switching off outputs only 8 ms have to be added to the response times of the devices connected to the inputs and outputs The response time on the FLEXBUS backplane bus as well as the logic execution time is irrelevant in this case See also Section 12 1 The WSO XTIO module cannot be used alone and always requires a WSO CPU1 or WSO0 CPU 1 module See the Safety Controller Setting and Monitoring Tool Operating Manual The simultaneous use of several WSO XTIO modules is possible see Section 3 2 Voltage supply is effected via the FLEXBUS backplane bus Voltage supply of the outputs Q1 to Q4 is affected directly at the WSO XTIO module 28 MELSEC WS Figure 6 Display elements WSO0 XTIO Table 8 Terminal assignment WSO XTIO Table 9 Displays of the MS LED 29 Product description 3 6 2 Display elements and terminal description iaaa nene PAUR LED MS Module Status 8 input LEDs 4 output LEDs Terminal Assignment X1 X2 Test output 1 test output 2 11 to 14 Inputs 1 to 4 A1 24 V A2 GND I5 to 18 Inputs 5 to 8 Q1 to Q4 Outputs 1 to 4 MS LED Meaning Notes O Supply voltage is outside Check the supply voltage at terminals A1 Red green of tolerance Configuration required and A2 system 1Hz Green Module is ready for Start the application in the Setting and 1 Hz operation Monitoring Tool Green Application
79. ion MELSEC WS ATTENTION Note Mount the reset button so that it cannot be actuated by a person located in the hazardous area When operating the control device of the reset button the operator must have full visual command of the hazardous area Between the supply circuit and output circuit and between the input circuit and output circuit in the WSO A4RO module are isolated On the other hand those in the safety I O module are not isolated Limited short circuit recognition A WSO XTDI module has two test signal generators One test signal generator is responsible for the odd numbered test outputs X1 X3 X5 and X7 the other for the even numbered test outputs X2 X4 X6 and X8 This means that short circuits between odd numbered and even numbered test outputs are recognised when the test gaps 4 ms If the test gaps 4 ms the short circuits are not always recognised in every case Similarly short circuits amongst the even numbered test outputs and odd numbered test outputs are not recognised Take this into consideration during the wiring e g separate routing sheathed cables 58 MELSEC WS Configuration 8 Configuration 59 ATTENTION Note Check the configuration for the protective device before commissioning and after every change If you change the configuration you must check the effectiveness of the protective device Please observe the test notes in the manual of the connected protective device
80. ions are not evaluated by UL The approval is ccomplished according to UL508 general use applications The MELSEC WS safety controller fulfils the requirements of Class A industrial applications in accordance with the Interference emission basic specifications The MELSEC WS safety controller is therefore only suitable for use in an industrial environment and not for private use 18 MELSEC WS 19 ATTENTION On safety 2 4 General protective notes and protective measures Observe the protective notes and measures Please observe the following items in order to ensure proper use of the MELSEC WS safety controller When mounting installing and using the MELSEC WS safety controller observe the standards and directives applicable in your country The national international rules and regulations apply to the installation use and periodic technical inspection of the MELSEC WS safety controller in particular Machinery Directive 2006 42 EC EMC Directive 2004 108 EC Provision and Use of Work Equipment Directive 89 655 EC Low Voltage Directive 2006 95 EC The work safety regulations safety rules Manufacturers and owners of the machine on which a MELSEC WS safety controller is used are responsible for obtaining and observing all applicable safety regulations and rules The notices in particular the test notices see Chapter 9 of this manual e g on use mounting installation or integration into the exis
81. it tester On green or off How is the MS LED Is the power supply voltage within specifications Supply power within the rated voltage Flashing red On green or flashing green Flashing red How is the MS LED y Please consult your local Mitsubishi service center or representative explaining a detailed description of the problem Completed Replace the safety I O module Le IH 99 Annex Figure 44 Flowchart when the MS LED is flashing red and green MELSEC WS 5 When the MS LED is flashing red and green Refer to the following flowchart when the MS LED of the safety I O module is flashing red and green at power on or during operation of the MELSEC WS safety controller MS LED of the safety I O module is flashing red and green The configuration of the safety 1 O module whose MS LED is flashing red and green is invalid The configuration needs to be re examined using Setting and Monitoring Tool Are there any other safety I O modules whose MS LED is flashing red and green Completed 100 MELSEC WS Figure 45 Troubleshooting flowchart for safety output relay module 101 Annex WS0 4RO 1 Troubleshooting flowchart The following shows the error description according to the types of events Error description Y PWR LED has turned off When the PWR LED has turned off K1 2 or K3
82. ivalent switching pushbuttons contacts for direct operation between the 11 to 18 input terminals and the X1 and X2 test pulse output terminals mm a Rx Dll i HAH A1 ME X2 A1 A2 X1 x2 x3 x4 Emergency a i2si3s ada i is stop pushbutton dual channel equivalent switching contacts WSO CPUO WSO0 XTIO WSO0 XTDI Connect an emergency stop pushbutton with dual channel equivalent switching contacts for direct operation between the 11 to 18 input terminals and the X1 and X2 test pulse output terminals I5 16 I7 18 15 16 I7 I8 Q1 JQ2 Q3 QA4 X5 X6 X7 X8 GU Emergency stop pushbutton dual channel equivalent switching contacts E Use the following terminal combinations for dual channel input wiring WSO0 XTIO I1 and X1 I2 and X2 3 and X1 I4 and X2 I5 and X1 I6 and X2 I7 and X1 I8 and X2 WSO XTDI I1 and X1 I2 and X2 I3 and X3 I4 and X4 to I7 and X7 18 and X8 80 MELSEC WS Figure 26 Wiring example of start Switches stop switches and reset switches 81 Annex b Single channel wiring without test pulse outputs Connect start switches stop switches and reset switches to the MELSEC WS safety controller as shown below 24 V DC Stop switch or the like single channel NC contact G eaae iee 13 12 WS0 CPU
83. ivation Safety This system meets the performance level d in accordance with EN ISO13849 1 86 MELSEC WS Annex 1 Wiring Figure 32 Wiring of an application Sms MD 7 2 amp ai qt ea X P s N BR E N a x o E BR R O 0 9 Q9 9 EC Cy Q a Q9 Q9 OVDC The WSO A4RO cannot be used alone The WSO A4RO performs the ON OFF control via the WSO XTIO Connect the output terminals Q1 to Q4 of the WSO XTIO to the input terminals B1 and B2 87 Annex Figure 33 Hardware configuration of an application example Figure 34 Logic of an application example 2 Configuration in the Setting and Monitoring Tool a Hardware configuration MELSEC WS A1 A2 MITSUBISHI mugg a ea nop 3n X1 X2 A1 A2 nBK MS 5 6 7 B Qi Q2 Q3 Q4 0000 13 73 33 43 606000 Y14 Y1 Y24 Y3 13 Y14 23 33 43 Y1 Y24 Y3 88 MELSEC WS Annex 14 4 Troubleshooting This section describes errors that may occur during system operation how to locate the errors and measures against the errors Note Check the LEDs of the module during troubleshooting 14 4 1 Basics of troubleshooting In order to increase the reliability of the system resuming the system operation promptly after correcting a problem is one of the important factors as well as using reliable devices To promptly start up the sys
84. lectric safety switches Note Table 35 Functions of testable Type 2 single beam photoelectric safety switches Note MELSEC WS 4 3 Testable single beam photoelectric safety switches 4 3 1 Testable Type 2 single beam photoelectric safety switches e g SICK Wx12 18 24 27 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Wx12 18 24 27 x no ncy Test input TE transmitter at X1 Vx18 Output Q receiver at 11 L21 27 28 X2 g pw Test input TE transmitter at X2 Output Q receiver at I2 Route the transmitter and receiver lines outside the control cabinet in such a manner that cross circuiting between these lines can be excluded for example in separate sheathed cables or in protected areas Function Notes Testing Possible Series connection Cascading Wx12 18 24 27 Vx18 max 5 pairs per input can be cascaded L21 max 35 pairs per input can be cascaded L27 28 max 4 pairs per input can be cascaded Max power up delay of the cascade 12 ms otherwise the test gap will lead to switching off Take the max line resistance of 100 Q into account For further information refer to the manual of the testable Type 2 single beam photoelectric safety switches 44 MELSEC WS Table 36 Connection of testable Type 4 single beam photoelectric safety switches Note Table 37 Functions of testable Type 4 single beam
85. ned on red NO MS LED is flashing red or flashing red and green NO Unable to communicate with Setting YES When the CPU module cannot communicate and Monitoring Tool with the Setting and Monitoring Tool When the MS LED has turned on red When the MS LED is flashing red or flashing red and green 90 MELSEC WS Figure 36 Flowchart when the MS LED has turned off 91 2 When the MS LED has turned off Annex Refer to the following flowchart when the MS LED of the CPU module has turned off at power on or during operation of the MELSEC WS safety controller MS LED of the CPU module has turned off NO Supply power Is power supplied On or flashing How is the MS LED of the CPU module s the power supply voltage Supply power within within specifications the rated voltage On or flashing How is the MS LED of the CPU module ls the memory plug properly Properly plug the memory plugged into the CPU module plug into the CPU module On or flashing Configure the system only with the CPU module and the memory plug The memory plug or the CPU module has been failed The module needs to be replaced How is the MS LED of the CPU module On or flashing Mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Completed Mit
86. nsibility of the machine owner Diagnostics MELSEC WS 10 Diagnostics ATTENTION Note 10 1 In the event of faults or errors Cease operation if the cause of the malfunction has not been clearly identified Stop the machine if you cannot clearly identify or allocate the error and if you cannot safely remedy the malfunction Complete functional test after remedying malfunction Carry out a full functional test after a malfunction has been remedied ERROR operating mode With certain malfunctions or a faulty configuration the MELSEC WS safety controller enters the safe status The MS and CV LEDs of the individual modules of the safety controller indicate the corresponding type of error To place the device back in operation gt Rectify the cause of the malfunction in accordance with the display of the MS and CV LEDs Switch the voltage supply of the safety controller off and back on again The MELSEC WS safety controller may restart when it detects a recoverable error caused by noise The MELSEC WS safety controller is ready for operation again if the error cause has been eliminated after the restart Create an interlock program using a reset button to prevent the MELSEC WS safety controller from restarting automatically after the safety function is activated and the safety controller turns off the outputs 10 2 Mitsubishi support If you cannot remedy a malfunction using the information in this chapter please
87. nstallation work only 2 wires when signals from several sensors are used Reduction of the required material through possibility of saving function blocks and I Os High availability through provision of the diagnostics information with high information contents for rapid and correct handling options Special functions Table 39 Selection of the SICK optical muting sensors 5 2 Muting 5 2 1 General description MELSEC WS Muting is the automatic temporary bypassing of all the safety oriented functions of the control system or of the safety device Muting is used when certain objects such as pallets with material may be moved into the hazardous area During this transportation through electro sensitive protective equipment ESPE such as a safety light curtain the muting function suppresses monitoring by the ESPE Observe the information in the Safety Controller Setting and Monitoring Tool Operating Manual for the further procedure 5 2 2 SICK muting sensors Sensor Type Switching output Q Photoelectric proximity switch WT24 Light switching WT27 2 WT260 Light switching Photoelectric reflex switch WL23 Dark switching WL27 WL260 Dark switching WL12 Dark switching WL14 Dark switching WL18 2 Dark switching Through beam photoelectric WS24 WE24 Dark switching switch WS27 WE27 WS260 WE260 52 MELSEC WS Mounting Dismantling 6 Mounting Dismantling 53 ATTENTION This ch
88. onnel documents physical evidence and records concerning the warranty problem and allow MEL CO to examine and test the Products in question offsite or at the premises where they are installed or used and 3 If MELCO requests Customer shall remove Products it claims are defective and ship them to MEL CO or MELCO s authorized representative for examination and if found defective for repair or replacement The costs of removal shipment to and from MELCO s designated examination point and reinstallation of repaired or replaced Products shall be at Customer s expense 4 If Customer requests and MELCO agrees to effect repairs onsite at any domestic or overseas location the Customer will pay for the costs of sending repair personnel and shipping parts MELCO is not responsible for any re commissioning maintenance or testing on site that involves repairs or replacing of the Products Repairs of Products located outside of Japan are accepted by MELCO s local authorized service facility centers FA Centers Terms and conditions on which each FA Center offers repair services for Products that are out of warranty or not covered by MELCO s limited warranty may vary Subject to availability of spare parts MELCO will offer Product repair services for 4 years after each Product model or line is discontinued at MELCO s or its FA Centers rates and charges and standard terms in effect at the time of repair MELCO usually produces and
89. ontrollers The User s Manuals for each network module describe important information on the configuration of the network modules The User s Manuals Hardware are enclosed with each MELSEC WS module They inform on the basic technical specifications of the modules and contain simple mounting instructions Use the User s Manuals Hardware when mounting the MELSEC WS safety controller 13 About this document MELSEC WS The following shows the relevant manuals Title Number WS CPU U E Safety Controller User s Manual 139232 WS ET U E Safety Controller Ethernet Interface Module User s Manual 134233 WS CC U E Safety Controller CC Link Interface Module User s Manual 139245 Safety Controller Setting and Monitoring Tool Operating SW1DNN WSOADR B O E Manual 13JU67 WS CPU U HW Safety Controller CPU Module User s Manual Hardware 13200 Safety Controller Safety I O Module User s Manual WS IO U HW Hardware 13201 Safety Controller Safety Relay Output Module User s WS SR U HW Manual Hardware 134202 Safety Controller Ethernet Interface Module User s Manual WS ET U HW Hardware 13203 Safety Controller CC Link Interface Module User s Manual WS CC U HW Hardware 13209 1 2 Target group This manual is addressed to the planning engineers designers and operators of systems which are to be protected by a MELSEC WS safety controller It also addresses people who integrate the MELS
90. out regard to conflicts of laws To the extent any action or dispute is not arbitrated the parties consent to the exclusive jurisdiction and venue of the federal and state courts located in the Southern District of the State of New York Any judgment there obtained may be enforced in any court of competent jurisdiction 6 Arbitration Any controversy or claim arising out of or relating to or in connection with the Products their sale or use or these terms shall be settled by arbitration conducted in accordance with the Center for Public Resources CPR Rules for Non Administered Arbitration of International Disputes by a sole arbitrator chosen from the CPR s panels of distinguished neutrals Judgment upon the award rendered by the Arbitrator shall be final and binding and may be entered by any court having jurisdiction thereof The place of the arbitration shall be New York City New York The language of the arbitration shall be English The neutral organization designated to perform the functions specified in Rule 6 and Rules 7 7 b 7 8 and 7 9 shall be the CPR Microsoft Windows Windows NT and Windows Vista are registered trademarks of Microsoft Corporation in the United States and other countries Pentium is a trademark of Intel Corporation in the United States and other countries Ethernet is a trademark of Xerox Corporation All other company names and product names used in this manual are trademarks or registered trademarks
91. reen at power on or during operation of the MELSEC WS safety controller Figure 38 Flowchart when the MS LED is flashing red or flashing red and green MS LED of the CPU module is flashing red or flashing red and green The configuration of the module whose Are there any modules whose MS LED is flashing red and green is MS LED is flashing red and green incorrect The configuration or system configuration needs to be reexamined Execute the system diagnostics using the Setting and Monitoring Tool and perform troubleshooting according to the diagnostics result 93 Annex MELSEC WS 5 When the CPU module cannot communicate with Setting and Monitoring Tool Refer to the following flowchart when communication with a peripheral device is disabled when connecting the CPU module with Setting and Monitoring Tool Figure 39 Flowchart when the The CPU module cannot communicate CPU module cannot with Setting and Monitoring Tool communicate with Setting and Monitoring Tool Connect the connection cable properly Is the connection cable properly connected Can the CPU module ommunicate with Setting and Monitoring Tool YES Can the CPU module communicate with Setting and Monitoring Tool after replacing the connection cable Can the CPU module Communicate with Setting and Monitoring Tool after replacing with another CPU module To
92. relay contacts available The WSO 4RO safety relay output module cannot be used independently but are switched via a WSO XTIO module To this purpose a control output of the WSO0 XTIO module Q1 to Q4 has to be jumpered to a control input of the relay output module B1 B2 see the following figure NENNEN Eeee The relay output modules are not nodes on the FLEXBUS backplane bus Control signals cannot therefore be received from the CPU module A max of 4 WSO 4RO safety relay output modules can be connected to a MELSEC WS safety controller i e a maximum of 16 safe relay outputs are available 32 MELSEC WS 33 Figure 9 Internal configuration WS0 4RO Product description The WSO 4RO has two control inputs B1 B2 These control two times two internal relays that form two independently redundant switch off paths Control input B1 controls two internal relays and forms a redundant switch off path consisting of two safe enabling circuits 13 14 23 24 dual channel and floating a signaling circuit Y14 dual channel and non isolated afeedback EDM Y1 Y2 dual channel and floating Control input B2 controls two internal relays and forms a redundant switch off path consisting of two safe enabling circuits 33 34 43 44 dual channel and floating a signaling circuit Y24 dual channel and non isolated a feedback EDM Y3 Y4 dual channel and floating 3 8 2 Displ
93. rried out or the system is being initialized System is ready for Please wait In order to start the application press the operation Start button in the Setting and Monitoring Tool Green Application is being carried out Red 1 Hz Correctable error either Check the module type and version of the in the CPU module or CPU module and safety I O modules one of the safety I O whose MS LED flashes red green modules If appropriate adapt the configuration using the Setting and Monitoring Tool For detailed diagnostics information refer to the Setting and Monitoring Tool Red 2 Hz Module has caused Switch the supply voltage off and on internal system error again If appropriate adapt the configuration using the Setting and Monitoring Tool For detailed diagnostics information refer to the Setting and Monitoring Tool e Red Critical error in the Switch the supply voltage off and on system again If the error is not eliminated after multiple repetitions replace the module In order to narrow down the respective module use the diagnostics display in the Setting and Monitoring Tool Product description MELSEC WS Table 5 CV LED Meaning Note Displays of the CV LED O Configuration required Yellow 2Hz Storing of Supply voltage may not be interrupted until configuration data in the storage process has been completed the memory plug Yellow
94. safety rules e Manufacturers and owners of the machine on which a MELSEC WS safety controller is used are responsible for obtaining and observing all applicable safety regulations and rules e The notices in particular the test notices of this manual e g on use mounting installation or integration into the existing machine controller must be observed e The test must be carried out by specialised personnel or specially qualified and authorized personnel and must be recorded and documented and retraced at any time by third parties e The external voltage supply of the device must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204 e The modules of the MELSEC WS safety controller conform to Class A Group 1 in accordance with EN 55011 Group 1 encompasses all the ISM devices in which intentionally generated and or used conductor bound RF energy that is required for the inner function of the device itself occurs The MELSEC WS safety controller fulfils the requirements of Class A industrial applications in accordance with the Interference emission basic specifications The MELSEC WS safety controller is therefore only suitable for use in an industrial environment and not for private use Installation Precautions NWARNING Do not use the MELSEC WS safety controller in flammable gas atmosphere or explosive gas atmosphere Doing so may result in a fire or explosion due
95. spection intervals specified in the national rules and regulations This procedure ensures that any changes on the machine or manipulations of the protective device are detected before use re use Each safety application must be checked at an interval specified by you The effectiveness of the protective device must be checked by authorised commissioned persons gt lf any modifications have been made to the machine or the protective device or if the MELSEC WS safety controller has been changed or repaired the system must be checked again as specified in the checklist in the annex gt Carry out regular or daily inspections in order to keep the MELSEC WS safety controller modules in an optimal operating mode gt Check whether the implementation of the MELSEC WS safety controller modules fulfills all the technical data of the device Check the mounting conditions and whether the wiring of the MELSEC WS safety controller modules has been carried out correctly gt Regularly verify that the safety functions fulfill the requirements of the application as well as all the regulations and standards e g regular checking in order to ensure the reliability of the safety functions 64 MELSEC WS 65 Note Maintenance 11 2 Device replacement A fault in the MELSEC WS safety controller modules impairs the complete network Devices that have faults must therefore be repaired or replaced rapidly We recommend keeping spare devices o
96. ssible Commissioning MELSEC WS 9 Commissioning Do not commission without a check by qualified safety personnel Before initial commissioning of a system using a MELSEC WS safety controller it ATTENTION must be checked and released by qualified safety personnel Check the hazardous area Ensure that no one is located in the hazardous area before commissioning ATTENTION Check the hazardous area and secure it against being entered by people e g set up warning signs attach blocking ropes or similar Observe the relevant laws and local regulations 9 1 Full approval of the application System commission may only be carried out if full approval was successful Full approval may only be performed by professionals trained accordingly The full approval includes the following items to be checked gt Check whether the attachment of components to the connections corresponds to the required Safety Integrity Level in accordance with EN 954 1 or EN 62061 and or EN ISO 13849 1 Check the devices connected to the safety controller in accordance with the test notes from the accompanying manual Clearly mark all the connection cables and plugs at the safety controller in order to avoid confusion Since the MELSEC WS safety controller has several connections of the same design ensure that loosened connection cables are not connected back to the wrong connection Check the signal paths and the correct inclusion in high
97. ssseeeeen een 17 2 2 Applications of the device ssssssssssssseeeeemmeen 17 2 3 COITect USE triedia is rae eae ern aie ugred eed 18 2 4 General protective notes and protective measures 19 2 5 Environmental protection 20 2 5 1 Disposals rone oett tei cete e een 20 2 5 2 Material separation sssssssssssssssseeeeen eee 20 3 Product descriptlon eei etre eee hc e e v ee ia ans 21 3 1 System propertles 2 dn ertet va tutt ego rtc eb cire ig tea techs 21 3 2 System configuration aridis aniani i aaas ideare aai Ris ed iaeia 22 3 3 Memory plug WSO MPL ssssse eene emen nnns 23 3 4 CPU module WSO CPUJO ssssssssssssssseenerenenenenmerenet nnne 24 3 4 1 DDeSCriptiori i i ith e ae eee RU E ettet 24 3 4 2 Display elements and terminal description ssssssssse 24 3 5 CPU module WS0 CPU1 ieia eani a aaa aei eaaa a aa aaa 26 3 5 1 Description en arn eea a eea ea bert Hee tenth aa e a a 26 3 5 2 Display elements and terminal description ssssssssse 27 3 6 WSO XTIO safety I O combined module ssseeees 28 3 6 1 Description iei o netu e aui 28 3 6 2 Display elements and terminal description ssssssssse 29 3 7 WSO XTDI safety input module sssem 31 3 7 1 BI Cre gere 31 3 7 2 Display elements and terminal description
98. stem could start up unexpectedly while you are connecting the devices N CAUTION Ground the FG and LG terminals to the protective ground conductor dedicated to the MELSEC WS safety controller Failure to do so may result in electric shock or malfunction Check the rated voltage and terminal layout before wiring to the module and connect the cables correctly Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or failure Tighten the terminal screw within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction Prevent foreign matter such as dust or wire chips from entering the module Such foreign matter can cause a fire failure or malfunction Mitsubishi MELSEC WS safety controllers must be installed in control cabinets Connect the main power supply to the MELSEC WS safety controller through a relay terminal block Wiring and replacement of an external power supply must be performed by maintenance personnel who is familiar with protection against electric shock For wiring methods refer to Chapter 7 Place the cables in a duct or clamp them If not dangling cable may swing or inadvertently be pulled resulting in damage to the module or cables or malfunction due to poor contact Startup and Maintenance Precautions
99. stems or production lines into which the Products may be incorporated including any safety fail safe and shut down systems using the Products MELCO is not responsible for determining the suitability of the Products for their intended purpose and use including determining if the Products provide appropriate safety margins and redundancies for the applications equipment or systems into which they are incorporated c Customer acknowledges that qualified and experienced personnel are required to determine the suitability application design construction and proper installation and integration of the Products MELCO does not supply such personnel promptly and in no event later than thirty 30 days d MELCO is not responsible for designing and after the Customer knows or has reason to believe conducting tests to determine that the Product that Products are not as warranted and iv in any functions appropriately and meets application event the notice must given within the warranty standards and requirements as installed or period incorporated into the end user s equipment 2 Customer shall cooperate with MELCO and production lines or systems MELCO s representatives in MELCO s investigation e MELCO does not warrant any Product of the warranty claim including preserving evidence ofthe claim and its causes meaningfully responding to MELCO s questions and investigation of the problem grant MELCO access to witnesses pers
100. subishi service center or representative explaining a detailed description of the problem Annex MELSEC WS 3 When the MS LED has turned on red Refer to the following flowchart when the MS LED of the CPU module has turned on red at power on or during operation of the MELSEC WS safety controller Figure 37 Flowchart when the MS LED has turned on MS LED of the CPU module red has turned on red Power off the MELSEC WS safety controller and then on How is the MS LED of the CPU module Other than on red On red Can the CPU module YES Execute the system diagnostics communicate with the Setting and Monitoring Tool and perform troubleshooting according to the diagnostics result NO Configure the system only with the CPU module and the memory plug On red The memory plug or the CPU How Is tne MS LED Di module has been failed the CPU module The module needs to be replaced Other than on red Mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Mitsubishi service center or representative explaining a detailed description of the problem 92 MELSEC WS Annex 4 When the MS LED is flashing red or flashing red and green Refer to the following flowchart when the MS LED of the CPU module is flashing red or flashing red and g
101. tance of 100 Q in account see Chapter 12 Discrepancy times See the Safety Controller Setting and Monitoring Tool Operating Manual Note Further information is available in the manual of the emergency stop pushbutton SICK ES21 or in the manuals for devices used 37 Connecting devices Table 16 Connection of electro mechanical safety switches Table 17 Connection of interlocks Table 18 Functions of electro mechanical safety switches and interlocks Note 4 1 2 MELSEC WS Electro mechanical safety switches with and without interlock e g SICK 110 1100 and 11000 Electrical connection Example from Setting and Monitoring Tool with WS0 XTIO Single channel aa 4 e Contact between 24 V and I1 without testing Single channel x2 4 0 uu Contact between X1 and 11 with testing Dual channel 24V 4 e DN Channel 1 Contact between 24 V and without testing ae ose lie Channel 2 Contact between 24 V and l4 Dual channel x1 5 ey Channel 1 Contact between X1 and I5 with testing im S Channel 2 Contact between X2 and l6 Electrical connection Example from Setting and Monitoring Tool with WSO0 XTIO Single channel nud Y s wg Contact between 24 V and I1 without testing E prar Coil at Q1 Single channel m E no y Contact between X2 and I2 with testing Coil at Q2 Dual channel av og Mo nc Channel 1 Contact between 24 V and without testing ov
102. tem the trouble cause must be located and eliminated correctly The basic three points to be followed in the troubleshooting are as follows 1 Visual inspection Visually check the following 1 Behavior of the safety controller and other connected devices 2 Applicability of the power supply 3 States of input and output devices 4 Installation states of the CPU module and safety I O modules 5 Wiring Power cable and l O lines 6 Display status of all indicators such as MS LED and CV LED After checking 1 through 6 connect the Setting and Monitoring Tool and monitor the operating status and logic processing of the MELSEC WS safety controller 2 Error checking Check how the error status changes by operating the following to the safety controller 1 Turn on or off the power supplied to the memory plug 3 Narrowing down the scope for identifying trouble cause Estimate the troubled part based on the check results of the items 1 and 2 above 1 MELSEC WS safety controller or external devices 2 CPU module or others 3 Configuration 89 Annex MELSEC WS 14 4 2 Troubleshooting flowchart for CPU module This section describes how to identify errors and measures to eliminate the errors 1 Troubleshooting flowchart The following shows the error description according to the types of events Figure 35 Troubleshooting module When the MS LED has turned off MS LED has turned off NO MS LED has tur
103. the PCB Send the separated components to the corresponding recycling centers see the following table Component Disposal Product Housing Plastic recycling PCBs cables plugs and electrical Electronics recycling connection pieces Packagin pu Paper cardboard recycling Cardboard paper 20 MELSEC WS 21 Product description 3 Product description Figure 1 MELSEC WS safety controller This chapter provides information on the features and properties of the MELSEC WS safety controller and describes the structure and operating principle 3 4 System properties SN SN yoo SSSSNN SS DS ATA ATA ATA CS M si a d pi 5 A A E E E E E E E E E E aaa aa ou VAS S NS SASISCSSES SESS SES coos The MELSEC WS safety controller is characterised by the following system properties Modular structure 1 CPU module up to 12 safety I O modules up to 4 safety relay output modules and up to 2 different network modules each with 22 5 mm compact width 8 to 96 inputs and 4 to 48 outputs Programmable Use of up to 255 standard and application specific logic blocks Standard logic blocks e g AND OR NOT XNOR XOR Application specific logic blocks e g emergency stop two hand muting pressing operating mode selector switch reset restart Integration in different networks via network modules possible EtherNet IP Modbus
104. the next page Is the USB to RS 232 conversion cable used Is the USB driver installed into the PC Install the USB driver into the PC Can the CPU module communicate with Setting and Monitoring Tool Please consult your local Mitsubishi service center or representative Completed explaining a detailed description of the problem 94 MELSEC WS Annex From the previous page Reconnect Setting and Monitoring Tool to the old CPU module and check that the CPU module runs normally How is the MS LED Flashing red See the flowchart When the MS LED is flashing red See the flowchart When the MS LED has turned on red See the flowchart When the MS LED has turned off Can the CPU module communicate with Setting and Monitoring Tool Configure the system only with the CPU module and the memory plug Then mount the modules other than the CPU module one by one and check their operation For the module that does not operate normally please consult your local Mitsubishi service center or representative explaining a detailed description of the problem Completed 95 Annex Figure 40 Troubleshooting flowchart for safety I O module 14 4 3 Troubleshooting flowchart for safety I O module MELSEC WS This section describes how to identify errors and measures to eliminate the errors WSO XTIO WSO XT
105. through logic application Response time of the considered output in Path 2 A2 44 5 ms Total response time 66 0 ms 69 Technical data Table 43 Data sheet WS0 CPUO and WSO CPU1 12 2 Data sheet MELSEC WS 12 2 1 WS0 CPU0 and WS0 CPU1 modules WS0 CPUO WS0 CPU1 Category Category 4 EN ISO 13849 1 Category 4 EN 954 1 Safety Integrity Level SIL3 IEC 61508 SILCL3 EN 62061 Performance Level PL e EN ISO 13849 1 PFHd 1 07E 09 1 h 1 69E 09 1 h TM service life 20 years Ambient temperature in operation 25 C to 55 C Storage temperature 25 C to 70 C Humidity Climatic conditions 10 to 95 non condensing To EN 61131 2 55 C 95 rel Humidity No corrosive gases Rigidity 5 Hz to 500 Hz tested to EN 61131 2 Enclosure rating to EN IEC 60529 Terminals IP 20 Housing IP 40 Electromagnetic compatibility Protection class EN 61000 6 2 EN 55011 Class A Il Number of EFI interfaces Data interface 0 2 Internal bus FLEXBUS backplane bus Configuration interface RS 232 Cross circuit of connecting wires Single core or finely stranded 1 x 0 14 to 2 5 mm or 2 x 0 14 to 0 75 mm Finely stranded with ferrules to EN 46228 1 x 0 25 to 2 5 mm or 2 x 0 25 to 0 5 mm EFI connection method Two tier spring terminals Dimensions W x H x D Weight 22 5 x 96 5 x 120
106. ting machine controller must be observed The tests must be carried out by specialised personnel or specially qualified and authorised personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time by third parties This manual must be made available to the user of the machine where the MELSEC WS safety controller is used The machine operator is to be instructed in the use of the device by qualified safety personnel and must be instructed to read the manual 1 WSO 4RO only On safety ATTENTION Table 1 Overview of disposal by component MELSEC WS 2 5 Environmental protection The MELSEC WS safety controller has been designed to minimise environmental impact It uses only a minimum of power and natural resources At work always act in an environmentally responsible manner 2 5 4 Disposal Disposal of unusable or irreparable devices should always occur in accordance with the applicable country specific waste disposal regulations e g European Waste Code 16 02 14 2 5 2 Material separation Material separation may only be performed by qualified safety personnel Exercise care when disassembling the devices The danger of injury is present Before you can turn over the devices for environmental friendly recycling you must separate the different materials of the MELSEC WS module from one another Separate the housing from the remaining components especially
107. tion accrues g Each of the limitations on remedies and damages set forth in these terms is separate and independently enforceable notwithstanding the unenforceability or failure of essential purpose of any warranty undertaking damage limitation other provision of these terms or other terms comprising the contract of sale between Customer and MELCO 4 Delivery Force Majeure a Any delivery date for the Products acknowledged by MELCO is an estimated and not a promised date MELCO will make all reasonable efforts to meet the delivery schedule set forth in Customer s order or the purchase contract but shall not be liable for failure to do so b Products stored atthe request of Customer or because Customer refuses or delays shipment shall be at the risk and expense of Customer c MELCO shall not be liable for any damage to or loss of the Products or any delay in or failure to deliver service repair or replace the Products arising from shortage of raw materials failure of suppliers to make timely delivery labor difficulties of any kind earthquake fire windstorm flood theft criminal or terrorist acts war embargoes governmental acts or rulings loss or damage or delays in carriage acts of God vandals or any other circumstances reasonably beyond MELCO s control 5 Choice of Law Jurisdiction These terms and any agreement or contract between Customer and MELCO shall be governed by the laws of the State of New York with
108. ule WS0 GETH Ethernet interface module i i WS0 GCC1 CC Link interface module l i 1 EFI terminals 2 Single channel 3 3 Memory plug WS0 MPL The system configuration of the complete MELSEC WS safety controller is only stored in the memory plug This offers the advantage when terminal modules are replaced that the MELSEC WS safety controller does not have to be reconfigured Connected EFl compatible devices have to be configured again when they are replaced The data stored in the memory plug are retained when the voltage supply is interrupted The CPU module and the inputs of the system are supplied with electricity exclusively through the memory plug The outputs on the other hand are supplied separately The current of the power supply unit that supplies the CPU module has to be limited to a maximum of 4 A either by the power supply unit itself or by a fuse If modules are replaced ensure that the memory plug is plugged into the suitable CPU module Uniquely mark all the connection cables and connectors at the MELSEC WS safety controller in order to avoid confusion Product description MELSEC WS Figure 4 Display elements WSO CPUO Table 3 Memory plug pin assignment Note Note 3 4 CPU module WS0 CPUO 3 4 1 Description The WSO CPUO module is the central process unit of the entire system in which all the signals are monitored and processed logically in accordance with the conf
109. wired single channeled In order to maintain the respective Safety Integrity Level the lines have to be routed in such a manner that Cross circuits to other live signals can be excluded for example by routing them within protected areas such as in a control cabinet or in separate sheathed cables 48 MELSEC WS 49 Note Note Connecting devices 4 6 EFI devices If shielding is required for example for EMC reasons when connecting the EFI devices use an earth terminal that is placed in the control cabinet near the CPU module for this purpose Connect this earth terminal with the shielding No termination is required for unused EFI connections on the CPU The CPU and the connected EFI devices should be powered by the same voltage supply to ensure a simultaneous start up of all devices You will find information on connecting EFI devices incl pin assignments in the manuals for the corresponding devices 4 6 1 EFI communication and EMC Cables Mitsubishi offers a 5 wire cable and a 12 wire cable for the connection of EFI devices The 5 wire cable has a high EMC rating and can be used up to a length of 100 m The 5 wires are typically used for the EFI1 EFI2 24 V DC 0 V DC contacts and for the functional earth If more wires are required to exchange additional signals between sensor and controller 12 wire cables are available These can be used up to a length of 50m Connecting the EFI cable to FE To in

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